GE Industrial Solutions CPS6000-M2 User Manual

CPS6000-M2 Frame-Mounted Battery Plant

Model H5694720

Product Manual Select Code 167-793-112 Comcode CC848802595 Issue 8 January 2008

Notice:

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

CPS6000-M2 Installation Guide H5694720

1 Introduction.................................................................................................................... 5

Document Objectives...................................................................................................... 5

Additional Product Documentation ................................................................................ 5

Customer Service Contacts............................................................................................. 6

2 Product Description....................................................................................................... 7

Architecture..................................................................................................................... 8

Millennium II Controller................................................................................................. 9

Rectifier Shelves ........................................................................................................... 10

QS-Series Rectifiers...................................................................................................... 12

QS-Series Ringers......................................................................................................... 12

AC Input........................................................................................................................ 14

Battery Options and Monitoring Features..................................................................... 14

DC Distribution and Battery Termination .................................................................... 15

Specifications................................................................................................................ 16

3 Safety............................................................................................................................. 21

Safety Statements.......................................................................................................... 21

Warning Statements and Safety Symbols..................................................................... 23

Precautions.................................................................................................................... 24

Handling Batteries ........................................................................................................ 25

Special Installation Notes ............................................................................................. 26

4 Installation.................................................................................................................... 28

Preparation .................................................................................................................... 28

Anchoring Frame .......................................................................................................... 31

Connecting Frame Ground............................................................................................ 32

Connecting Central Office Ground (COG)................................................................... 33

Connecting AC Utility .................................................................................................. 34

Installing Batteries ........................................................................................................ 35

Installing and Wiring DC Loads................................................................................... 40

Installing QS-Series Rectifiers...................................................................................... 44

Installing QS-Series Ringers......................................................................................... 46

Controller Connections ................................................................................................. 48

Installing Optional Circuit Packs.................................................................................. 55

5 Controller User Interface............................................................................................ 63

Controller Display Menu Maps .................................................................................... 70

Minimum Controller Configuration.............................................................................. 74

Controller Defaults........................................................................................................ 79

Web Interface................................................................................................................ 84

6 Acceptance Testing ...................................................................................................... 89

7 Troubleshooting ........................................................................................................... 92

Troubleshooting Controller Circuit Pack...................................................................... 99

Modem and Data Switch Cards .................................................................................... 99

Controller Alarm Descriptions.................................................................................... 100

Clear Events................................................................................................................ 104

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Uninstall Devices........................................................................................................ 105

Troubleshooting QS-Series Rectifiers ........................................................................ 105

Troubleshooting QS-Series Ringers ........................................................................... 107

Troubleshooting VT-Probes........................................................................................ 109

8 Ordering Information and Spare Parts .................................................................. 110

9 Product Warranty...................................................................................................... 118

Appendix A: Battery Functions................................................................................... 120

Appendix B: EasyView for Windows®........................................................................ 127

Appendix C: Upgrading Software Through Network Connection Or Craft Port.. 130

Revision History............................................................................................................ 134

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CPS6000-M2 Installation Guide H5694720

1 Introduction

Document Objectives

This manual provides installation and maintenance information for the Lineage Power CPS6000-M2 power system:

• Product Description

• Safety Information

• Installation Procedures

• Test and Acceptance

• Troubleshooting

• Controller and Rectifier Operations

• Product Warranty

Audience

Equipment Installers – Instructions for installation, test, and acceptance. Equipment Users – Plant basics and troubleshooting.

CAUTION: This unit must be installed, serviced, and operated only by skilled and qualified personnel who have the necessary knowledge and practical experience with electrical equipment and who understand the hazards that can arise when working on this type of equipment.

Applications

The 48V CPS6000-M2 is ideally suited for small central office (CO) applications and high end huts and vaults.

Additional Product Documentation

For additional specification, engineering and installation information, refer to the following

drawings as needed. These drawings may be accessed on our web site at

http://lineagepower.com/. Click on Energy Systems Products/CPS6000 Plants.

Drawing Description

H5694720 Ordering Guide 167-790-063 Remote Peripheral Monitoring (RPM) 157-010-202 210E Thermal Probe Multiplexer Module 167-792-182 Advanced Features User Guide For The

Millennium II

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CPS6000-M2 Installation Guide H5694720

Customer Service Contacts

Customer Service, Technical Support, Product Repair and Return, and Warranty Service

For customers in the United States, Canada, Puerto Rico, and the US Virgin Islands, call 1-800THE-1PWR (1-800-843-1797). This number is staffed from 7:00 am to 5:00 pm Central Time (zone 6), Monday through Friday, on normal business days. At other times this number is still available, for emergencies only. Services provided through this contact include initiating the spare parts procurement process, ordering documents, product warranty administration, and providing other product and service information.

For other customers worldwide the 800 number may be accessed after first dialing the AT&T Direct country code for the country where the call is originating, or you may contact your local field support center or your sales representative to discuss your specific needs.

Customer Training

Lineage Power offers customer training on many Power Systems products. For information call

1-972-284-2163. This number is answered from 8:00 a.m. until 4:30 p.m., Central Time Zone (Zone 6), Monday through Friday.

Downloads and Software

To download the latest product information, product software and software upgrades, visit our web site at

http://lineagepower.com/

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CPS6000-M2 Installation Guide H5694720

2 Product Description

The 48V CPS6000-M2 Power Plant is a 23 inch wide, front access, frame mounted battery plant. The system integrates QS series vertical airflow rectifiers and ringers, dc distribution options, battery connections and the Galaxy Millennium II controller in 500A and 1000A capacity systems. System dimensions are 25.5 inches wide, 15 inches deep and 29.8 inches tall (500A system) or 38.5 inches tall (1000A system). This allows the system to be mounted in either a 42 inch (1/2 height) frame for mounting on a battery stand or Unigy battery stack or in a 7 foot (full height) framework with battery trays.

The system operates directly from commercial power in 208/220/240Vac single phase @ 50/60Hz. 110Vac operation is also available with some rectifiers. AC connects to a terminal block panel at the top of the system.

48V CPS6000-M2 DC Power System Configuration

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CPS6000-M2 Installation Guide H5694720

Architecture

The plant architecture is shown in the diagram below. The CPS6000-M2 System rectifiers accept alternating current (ac) power and produce a regulated dc -48V nominal voltage distributed to float the batteries, power the controller and power the loads through distribution circuit breakers or fuses. Batteries are used to provide backup dc power when the ac is lost. They are connected in parallel with the rectifiers through either optional battery breakers or a low voltage disconnect (LVD). AC power is distributed to each rectifier through ac terminal blocks located in the ac termination panel at the top of the frame. The Millennium II system controller monitors and controls system operation.

CPS6000-M2 Block Diagram

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Millennium II Controller

The Millennium II controller is located on the door of the dc distribution. It uses an RS485 bus to serially monitor and control rectifiers, ringers and peripheral modules called RPM’s. It can also monitor and control external power equipment, including standby generators, converter plants, and inverters.

Local viewing and setting of system parameters and various alarm thresholds, user-definable alarm inputs and relays can be accessed either by a LCD graphics display with intuitive navigation mounted on the front door of the system or by the local RS-232 port connected to a notebook computer.

Remote access is available through a 10/100 Base-T network connection to the world wide web (internet) or your enterprise network (intranet) using standard browsers such as Microsoft Internet Explorer® or Netscape® Navigator. There is also an optional BSM5 56k bps modem available.

The controller performs various battery management functions to ensure peak performance and protection from thermal issues. In addition to monitoring for open battery breakers, measuring current from the battery shunt and monitoring and control of a optional low voltage battery disconnect contactor, the controller also measures battery string temperature and voltage with either traditional analog thermistor based temperature probes or digital QS873 Voltage/Thermal Probes (VT Probes) for slope thermal compensation. The VT probes connect in a daisy-chain fashion with one probe mounted to the negative post of each mid-string battery using the serial 1Wire® bus.

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Rectifier Shelves

Rectifier shelves are equipped in either two shelf (500A system) or four shelf (1000A system) arrangements. DC output from each rectifier is bused up the back to the distribution and protected by clear lexan covers. Individual AC feeds from terminal blocks in the ac box route down the ac duct to a connector on each shelf. Serial communication cables daisy-chain from QS845A interface boards on the left side of each shelf and up to the controller.

The system is designed to allow field upgrades from two shelf to four shelf systems. This can be safely accomplished on working systems because the new shelves are first installed and then bus and cable links added.

DC Bussing to Rectifier Shelves (Rear View)

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QS845A Rectifier Interface Board Access

Rectifier Communication Connections

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QS-Series Rectifiers

These constant power rectifiers are hot pluggable for quick installation. All interconnections (AC input, DC output, and control) are made automatically during insertion. The rectifiers communicate with the controller via a digital RS-485 serial cable allowing all rectifier settings to be made automatically by the controller. Load-share circuits allow all rectifiers to apportion the plant load equally, reducing the stress on individual units. The rectifier uses temperature dependent variable speed fans to provide vertical flow cooling. QS-series of rectifiers are available in 15A and 25A operating from 85VAC to 275VA and 20A, 30A, 40A, and 50A operating from 150VAC to 275VAC.

QS-Series Rectifier

QS-Series Ringers

QS820A Ringers convert -48Vdc to a 100VA ringing power output with configurable ac voltage, ac frequency, and dc offset. A ringer chassis may be installed in the two rightmost positions of any rectifier shelf. Each ringer chassis includes two vertical airflow fans, accepts up to two QS820A ringers, a primary and a spare, and provides a single ringing output. Install one ringer for non-redundant (simplex) operation and two ringers for redundant (duplex) operation. Should the primary ringer fail or be removed, the ringer output is provided by the spare ringer. The controller provides ringer output voltage and frequency settings, status and alarm communication. If communication is lost, the ringers continue to operate with the last received configuration.

QS820A Ringers and QS820M Chassis

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Types of Ringing

QS820 Ringers can be configured to provide one of three types of ringing: Battery Backed, Ground Backed, and Ground Backed-no dc. Ringing type is selected with jumper J12 on the chassis and by enabling or disabling dc Offset in the controller

Ground

(VBUS+)

Ring Return

tied to VBUS+

Voltage

(Tip wire)

Ring

(Ring wire)

-48Vdc

(VBUS-)

Ground

(VBUS+)

-48Vdc

(VBUS-)

Voltage

Ring

(Ring wire)

Battery Backed (Common in USA)

Ring

(Ring wire)

Ground

(VBUS+)

-48Vdc

(VBUS-)

Ring Return

tied to VBUS+

(Tip wire)

Voltage

Ground Backed

No dc

Ring Return

tied to -48Vdc

(Tip wire)

Ground Backed

Ring Signaling Types

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AC Input

• Connects to AC termination panel at the top of the system.

• One 1-inch conduit per shelf.

• Each rectifier fed individually by 10 gage wire protected with a 20A circuit breaker or fuse.

Battery Options and Monitoring Features

Battery Options

• Designed for operation with Flooded, VRLA, NiCad, and Lithium batteries (Nickel metal Hydride in the future).

• Half-height systems mount on Unigy II batteries, Full Height systems may be equipped with battery trays.

• Battery trays available for up to 170Ahr batteries with Anderson PowerPole® connectors or circuit breaker disconnects.

Battery Monitoring Features

• Open String (OS) Alarms

• Emergency Power Off (EPO) for

disconnecting batteries from the system

• Temperature/voltage probes (up to 16) used in Battery Management options

 Slope Thermal Compensation  Battery High Temp Disconnect

• Battery Discharge Test

• Battery Shunt

Low Voltage Battery Disconnect/Reconnect Contactor (LVBD)

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DC Distribution and Battery Termination

Group 660 Option

• Two 19 position bullet distribution panels each rated at 400A.

• 12 pair of battery landings for battery cables up to 350Kcmil. (6 pair with 750Kcmil cable) 3/8” studs on 1” centers

• 8 position center section for optional 800A Low Voltage Battery Disconnect (LVBD), GJ type circuit breakers with 25mV shunts or TPL-C fuse blocks with 1500A, 50mV shunts.

Group 661 Option

• One 19 position bullet distribution panel rated at 400A.

• One fuse panel rated at 600A equipped with 4 TPS fuses with 100A, 50mV shunt monitoring and 4 TPL-B fuses with 600A, 50mV shunt monitoring

• RPM shunt monitoring for fuse panel and up to 4 center TPL-C fuse blocks with 1500A, 50mV shunt monitoring

• 12 pair of battery landings for battery cables up to 350Kcmil. (6 pair with 750Kcmil cable) 3/8” studs on 1” centers

• 8 position center section for optional 800A Low Voltage Battery Disconnect (LVBD), GJ type circuit breakers with 25mV shunt or TPL-C fuse blocks with 1500A, 50mV shunt.

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Specifications

AC Input

Input Distribution

Wire Size 10 AWG minimum for individual feeds.

System Voltage -48V Maximum Output Current: Two Rectifier Shelves (G255) 450A charge, 500A discharge Four Rectifier Shelves (G256) 800A charge, 1000A discharge Maximum Recharge Current Installed rectifier capacity minus plant -48V load Low-Voltage Disconnect 39 to 50 Vdc Low-Voltage Reconnect 39 to 55 Vdc

Safety Agency Approvals

VDE licensed to VDE0805/EN60950

European Economic Community (EEC) Directives

Radiated and Conducted Emissions

Harmonics EN61000-3-2 (IEC61000-3-2) Voltage Fluctuations EN61000-3-3 (IEC61000-3-3) Electromagnetic Immunity Meets Telcordia GR-1089-CORE Electrostatic Discharge EN61000-4-2 Level 3 RF Immunity IEC61000-4-3 Level 3, 10 V/m EFT IEC61000-4-4 Level 3, No Error; Level 4, No Damage Surge IEC 61000-4-5 Level 3, No Error; Level 4, No Damage Conducted Immunity IEC 61000-4-6 Level 3, 10V Voltage Dips, Interruptions, and

Variations

Operating Ambient Temperature -20 to 45 °C Altitude -200 to 13,000 feet (-61 to 3962 meters)

Humidity 10% to 95% non-condensing Audible Noise < 60 dBA Earthquake Rating Zone 2 or Zone 4, upper floors, depending on battery configuration Note 1: For altitudes above 5000 feet, derate the temperature by 3.6 °F per 1000 feet. For altitudes above

1524 meters, derate the temperature by 0.656 degrees Celsius per 100 meters.

Terminal Blocks per rectifier fed from 20A breaker or fuse at the AC service panel.

System Output

Safety / Standards Compliance

Underwriters Laboratories (UL) Listed per Subject Letter 1801: Power Distribution Center for Communications Equipment, and cUL Certified (CSA 22.2 950): Safety of Information Technology Equipment

Rectifiers are individually UL Recognized (UL1950), cUL Certified (CSA 22.2 234) or evaluated to EN60950 by an EC Notified Body, as appropriate.

EMC Directive 89/336/EEC, Low Voltage Directive 73/23/EEC as amended by Marking Directive 93/68/EEC

FCC Part 15, Class A EN55022 (CISPR22), Class A

IEC 61000-4-11

Environmental

See Note 1

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Installation Category

CPS6000-M2 is suitable for connection to ac utility systems where the expected level of lightning surges complies with ANSI C62.41 Category B or IEC 60664-1 Overvoltage Category II.

A service entrance surge protector is required in applications where the installation categories can not be classified as being compliant to either ANSI C62.41 Category B or IEC 60664-1 Overvoltage Category II.

CPS6000-M2 rectifiers have been tested for repeated lightning surges typically found in an Overvoltage Category III installation; however, a service entrance surge protector is recommended in cabinet applications to bring the power feeds in compliance to the installation categories above. The service entrance protection should be coordinated with the protection provided in the power modules.

The power module provides common-mode protection via a 320V MOV in series with a 2500V gas-discharge device and differential-mode protection via a 320V MOV in series with a 3.5A fuse

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Millennium II Controller

General Specifications

Input Voltage Range -48 Vdc (Range: 18-60V) Maximum Input Power 36W depending upon options Display Graphic displayed arranged to

8-line by 40-character backlit LCD

Configuration Method Through front panel LCD display and menu keys

Through IBM compatible PC with RS-232 port Through LAN internet connection

Mounting Requirements Door mounted

Input/Outputs Specifications

Form C Alarm Output Contact Ratings 60VDC at 0.5A Plant Voltage Measurement

Accuracy

0 to 50 °C (±.05% of full scale + 1

count)

-40 to 85 °C (±0.1% of full scale + 1 count)

Resolution

Plant Current Measurement

Accuracy

Resolution

Temperature Measurement

Accuracy

Thermistor temperature

One-Wire Serial probes

Resolution

4-20mA Input Monitor

Accuracy Resolution

General (0-5V) Input

Accuracy

Resolution

48V Systems: ±40 mV 48V Systems: ±70 mV

0.01V

0 to +50 °C : ±0.5% of full scale

-40 to +85 °C: ±1.25% of full scale 1A

-5 to +55 °C: ±2°C

-40 to +85 °C: ±3°C

-5 to +55 °C: ±1°C

-40 to +85 °C: ±3°C

0.1°C

±100µA ±10.0µA

0 to +50 °C: ±0.5% of full scale

-40 to +85 °C: ±1.0% of full scale

0.01VDC

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Rectifiers

Item Specification

Nominal Output Voltage 48/52/54.5 Vdc Operating Output Voltage

42 to 58 Vdc

Ranges Boost Voltage 48 to 58 Vdc Output Current QS861A: 0 to 15A at 54.5V

QS862A: 0 to 30A at 54.5V

QS852A: 0 to 20A at 54.5V QS853A: 0 to 25A at 54.5V QS864A: 0 to 40A at 54.5V QS865A: 0 to 50A at 54.5V

Nominal Input Voltage QS861A: 100/120/208/240

Vac QS862A: 100/120/208/240 Vac

Input Voltage Ranges QS861A: 85 to 275 Vac

(Shutdown from 135 to 150V)

QS862A: 85 to 275 Vac

QS852A: 208/240 Vac QS853A: 208/240 Vac QS864A: 208/240 Vac QS865A: 208/240 Vac

QS852A: 150 to 275 Vac QS853A: 150 to 275 Vac QS864A: 150 to 275 Vac QS865A: 150 to 275 Vac

(Shutdown from 135 to

150V)

Input Current QS861A: 8A at 120 Vac

4.4A at 208 Vac

QS862A: 13A at 120 Vac

8.8A at 208 Vac

QS852A: 7.4A at 208 Vac QS853A: 7.4A at 208 Vac QS864A: 11.8A at 208 Vac QS865A: 14.5A at 208 Vac

Operating Frequency Range 45 to 66 Hz Operating Temperature -40 to +65 °C Output Voltage Regulation ±0.5% Output Noise, Ripple 250 millivolts peak to peak maximum, over the range dc to

100 MHz

Load Share Accuracy 1.5A maximum deviation between rectifiers Heat Dissipation at Full Load QS861A: 141W (480 BTU) per rectifier at 120 Vac operation

160W (546 BTU) per rectifier at 240 Vac operation QS862A: 177W (604 BTU) at 100 to 120 Vac operation

212W (724 BTU) at 200 to 240 Vac operation

QS852A: 133W (454 BTU) per rectifier at 240 Vac operation QS853A: 151W (515 BTU) per rectifier at 240 Vac operation QS864A: 240W (819 BTU) per rectifier at 240 Vac operation QS865A: 267W (911 BTU) per rectifier at 240 Vac operation

Selective High-Voltage

Above 58 Vdc

Shutdown Backup High-Voltage

Above 60 Vdc for 1 millisecond

Shutdown

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Ringers

Item Specification

Input Voltage -40 to -57 Vdc See Output VA Thermal Limiting. Nominal Input Voltage -48 Vdc Input Current 5 A max. Output

Voltage ac tolerance ± 5 Vac

Regulation ±5% ac component only dc Offset

dc Offset Tracking

Harmonic Distortion 5% THD Crest Factor 1.21 to 1.51 Output Frequency 15 to 50 Hz

Frequency tolerance ± 1 Hz

Output VA

Thermal Limiting Output VA may be reduced by reducing Vac when

Load Power Factor Operating: 0.5 Leading to 0.9 Lagging

Operating Temperature -40 to +75 °C See Output VA Thermal Limiting. Heat Dissipation 50 W (170 BTU / hr) Under Voltage Shutdown 50% of Output Vac Set Point

ac Component

Type of ringing Battery Backed Ground Backed Ground Backed no-dc

65 to 100 Vac Factory Default: 100Vac

• -40 to +57 Vdc Battery Backed

• +40 to +57 Vdc Ground Backed

• 0 Vdc Offset Disabled

• dc Offset tracks dc Input Voltage

• Factory Default: Enabled

• Battery or Ground Backed is selected by Ringer

Chassis jumper J12 or by external connection of Ring Rtn to Battery or to Ground. Factory Default: Battery Backed by Jumper

± 3 Vdc

Error

Factory Default: 20 Hz

100 VA

operating simultaneously above 50°C and less than

-50Vdc input. Vac is reduced only sufficiently to prevent damage to the ringer.

No Damage: 0 Leading to 0.7 Lagging

While shutdown due to external fault, restart will be performed at approximately 2 minute intervals.

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3 Safety

Safety Statements

Please read and follow all safety instructions and warnings before installing, maintaining, or repairing the CPS6000-M2 System:

• The CE Mark demonstrates compliance with the European Union Council Directives for

Low Voltage and EMC.

• The CPS6000-M2 platform is Underwriters Laboratories (UL) Listed per Subject Letter

1801, DC Power Distribution Centers for Telecommunications Equipment.

• CPS6000-M2 shelves equipped with QS820A ringers have hazardous secondary voltages

on the secondary bus output connectors.

• Install only in restricted access areas (dedicated equipment rooms, equipment closets, or the

like) in accordance with articles 110-16, 110-17, and 110-18 of the U.S. National Electric Code (NEC), ANSI/NFPA No. 70, and pursuant to applicable local codes.

• This equipment is to be used in controlled environments (an area where the humidity is

maintained at levels that cannot cause condensation on the equipment, the contaminating dust is controlled, and the steady-state ambient temperature is within the range specified).

• This equipment has been evaluated for continuous use in ambient temperature from -40°C

to 65°C.

• This equipment must not be installed over combustible surfaces.

• For installations in the United States, Listed compression connectors are to be used to

terminate Listed field-wired conductors where required. For all installations, the appropriate connector is to be applied only to the correct size conductor as specified by the connector manufacturer, using only the connector manufacturer's recommended tooling or tooling approved for that connector.

• If the proper connector for the country of installation is not provided, obtain appropriate

connectors and follow manufacturer’s and all local requirements for proper connections. All national and local rules and regulations should be followed when making field connections.

• The main output voltage (48V) meets SELV requirements.

• Insulation on field-wired conductors should be rated no less than 90° Celsius. Wire

conductor size should be sized per electrical codes for 75° Celsius wire, and based on the ampacity of the associated protection device. Wiring internal to enclosed equipment cabinets should be rated at 105° Celsius (minimum).

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• Torque electrical connections to the values specified on labels or in the product

documentation.

• Battery input cables must be dressed 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.

• Alarm contacts on the office alarm board are not fused; therefore, current limiting

protection for these contacts must be provided by external circuits. Maximum ratings for alarm connections are 60Vdc and 0.5 amperes. Exceeding these maximum ratings could result in fire or damage to the unit.

• Fuse and/or circuit breaker loads must not exceed 80% of the fuse and/or circuit breaker

current rating. Distribute loads across the panel.

• The short circuit current capability of the battery input to the distribution panel must not

exceed 10,000A.

• AC branch circuits to this equipment must be protected with either fuses or circuit breakers

sized as required by the National Electric Code (NEC) and/or local codes. The maximum size of the over-current protector is based on the type of shelf. Refer to the equipment ratings to assure rating of equipment will not exceed 80% of the value of the protector chosen.

• High leakage currents are possible due to contribution from simultaneous multiple AC

input connections. Earth ground connection is essential before connecting the ac source to the shelf. This connection must be achieved by ensuring that the C.O. grounding stud is connected as shown in the Installation Section, or quality service personnel shall ensure that the rack system is bonded per the provision below.

• An accessible ac disconnect/protection device to remove power from the equipment in the

event of an emergency must be provided. Disconnect all AC branch circuits prior to making AC connections.

• Installing fuses or circuit breakers not specified for use in these distribution modules may

result in injury to service personnel or equipment damage. Use only replacement parts listed in this manual and on the equipment drawings.

• The telecom-type (e.g., GMT type) fuses can produce sparks during interruption or clearing

of a fault on a high energy circuit. Use only fuses provided with safety caps for this type of circuit. Installing telecom-type fuses not equipped with safety caps may result in injury to service personnel.

• While installing batteries, follow all safety precautions outlined in the appropriate battery

product manuals.

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Warning Statements and Safety Symbols

The symbols may sometimes be accompanied by some type of statement; e.g., “Hazardous voltage/energy inside. Risk of injury. This unit must be accessed only by qualified personnel.” Signal words as described below may also be used to indicate the level of hazard.

Indicates the presence of a hazard that will cause death or severe personal

DANGER

WARNING

CAUTION

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.

One of these two symbols (or equivalent) may be used to identify the presence of rectifier and battery voltages. The symbol may sometimes be accompanied by some type of statement, for example: “Battery voltage present. Risk of injury due to high current. Avoid contacting conductors with non-insulated metal objects. Follow safety precautions.”

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:

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“Fuses can cause arcing and sparks. Risk of eye injury. Always wear safety glasses.”

CPS6000-M2 Installation Guide H5694720

Precautions

When working on or using this type of equipment, the following precautions should be noted:

• This unit must be installed, serviced, and operated only by skilled and qualified personnel

who have the necessary knowledge and practical experience with electrical equipment and who understand the hazards that can arise when working on this type of equipment.

• The equipment could 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.

• High leakage currents may be possible on this type of equipment. Make sure the equipment

is properly safety earth grounded before connecting power.

• 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.

• Hazardous energy and voltages are present in the unit and on the interface cables that can

shock or cause serious injury. Follow all safety warnings and practices when servicing this equipment. When equipped with ringer modules, hazardous voltages will be present on the ringer output connectors.

In addition to proper job training and safety procedures, the following are some basic precautions that should always be used:

• 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.

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Handling Batteries

• To direct attention to the possible source of danger from battery gases, post one or more

warning signs, lettered in large characters, in a conspicuous location near the battery. For example:

• Fully brief anyone who is permitted access to battery areas on the hazards of handling lead-

acid batteries. Make it clear to anyone handling, unpacking, or installing lead-acid batteries that they contain electrolyte (sulfuric acid and water). Everyone must wear protective equipment such as rubber gloves, rubber aprons, full face mask, and splash-proof goggles when performing any activity involving handling of batteries or cells containing electrolyte.

• A storage battery gives no indication by its appearance of the potential energy stored in it.

All lead-acid storage cells/batteries have enormous short circuit capability which can result in serious burns. Use extreme care to avoid shorting out cell and/or battery terminals. Shorting a cell or battery with a non insulated tool can vaporize or throw the tool.

• All lead-acid batteries generate hydrogen gas, even under open circuit conditions. If not

permitted to escape, this gas can build up to explosive concentrations. NEVER tamper with or block the vent caps of the 12IR125 battery modules. A damaged gas vent cap could become clogged, resulting in an explosion due to internal pressure. Such an explosion could short circuit other battery modules and result in a fire. ALWAYS place batteries in a wellventilated area. NEVER place battery modules in a sealed environment.

• In case of electrolyte contact with the skin, remove the electrolyte immediately by flushing

the affected area with large amounts of plain tap water. In case of electrolyte in the eye, pour water into the inner corner of the eye and allow at least one quart of water to run over the eye and under the eyelid. Eye injuries should be treated by a physician immediately.

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Special Installation Notes

Deutsch

• Installationsanleitung

• Eingangsspannung ( Voltage ) : 120/200-240VAC , DC 54VDC

Eingangsstrom ( Current ) : <15A per rectifier, DC 15A-1000A Eingangsleistung ( Watts ) : Nennfrequenz ( Frequency ) : 50 / 60 Hz

• Seriennummer ( Assembly No. ): J5694720

• Modellnummer (Modell No. ) : H5694720

• Abmessungen sind nur zur Referenz : 978mm x 648mm x 381mm

( Dimensions are for reference only )

• Max. Umgebungstemperatur : max. 45 deg. C ( Max. Operation temperatur )

• Achtung: Für kontinuierlichen Feuerschutz sollte die Sicherung nur mit einer des gleichen Types ersetzt werden. Sicherungswert : ( Warning : For continued protection against fire replace with same type and rating of fuse )

• Das System ist ein Gerät der Schutzklasse I / Überspannungs Kategorie II ( Power Supply is a Class I equipment / overvlotage category II )

• Ausgangsspannungen und -stöme: DC 58 V / SELV ( Output Voltage and Current )

• --Das Gerät darf nur in Räumen mit beschränktem Zutritt aufgestellt werden. ( Nur ausgebildetes Personal )

• --Nur für Aufstellung auf Boden oder einer anderen brennbaren Oberfläche geeignet.

• --Das Gerät hat keinen eigenen Ausschalter, es muß daher mit einem Ein- und Ausschalter im Versorgungskreis versehen sein.

• --Das Gerät ist für den Einbau in IT- Geräte in einem Rahmen bestimmt (siehe weitere Anleitung)

• --Beim Einbau des Gerätes ist daraf zu achten das alle Anforderungen gemäß EN60950 eingehalten werden.

ACHTUNG: HOHER ABLEITSTROM VOR ANSCHLUSS AN DEN VERSORGUNGSSTROMKREIS UNBEDINGT ERDUNGSVERBINDUNG HERSTELLEN

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Espanol

Notas especiales para instalaciones en países de habla hispana

• Instrucciones de instalación (Installation Instructions)

• Voltaje (Voltage): 120/200-240VAC

• Corriente (Current): <15A per rectifier

Frecuencia (Frequency): 50/60Hz

• Voltaje y corriente de salida (Output Voltage and Current): 54VDC, 15A-1000A Temperatura máxima de operación (Maximum Operation Temperature): 45°C (113°F)

• Sin cabina contra incendios, suelo no combustible (No fire enclosure, non-combustible floor)

• Evaluado en EN60950 (Evaluated to EN60950)

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4 Installation

This section describes the following installation sequence for the CPS6000-M2 power system.

1. Preparations

2. Anchoring frame

3. Connecting frame ground

4. Connecting CO ground

5. Connecting ac utility

6. Installing batteries

7. Wiring dc loads and installing fuses/circuit breakers

8. Installing rectifiers and converters

9. Controller Connections

10. Starting Up System

Preparation

Safety

Please review all safety warnings in Section 3 before beginning the installation process. Observe all warnings and labels on the equipment.

WARNING: Due to the possibility of working on energized circuits during these procedures, all tools and test equipment must be insulated in an approved manner. Proper ESD protection is required in order to prevent ESD damage to the equipment.

WARNING: Only qualified personnel should install and service the power system and plug-in modules. Hazardous energy and voltages are present in the unit and on the interface cables and will shock or cause serious injury or death if safety precautions are ignored. Follow all safety warnings and practices when servicing this equipment.

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Wiring Guidelines

• All electrical connections should be made using the proper crimping tools and dies and should be torqued to values specified.

• All building wiring should comply with the NEC and other applicable local codes.

• The temperature rating of the wire must be 90°C minimum.. Wire gauge must be sized based

on 75°C wire and the ampacity of the associated branch-circuit protection.

• Wiring internal to enclosed equipment cabinets must be rated no less than 105° Celsius.

Packaging

• All packages should be opened with a box cutter with the blade minimally exposed so that only the sealing tape is cut.

• Save all packaging material until the system has been powered up and all parts are operating within specifications.

Installation Tools

You will need the following tools to install and test the CPS6000-M2 System.

• Wire cutters and strippers

• Heat shrink gun

• 5/16-inch (8 mm) hex driver

• Digital meter with an accuracy of

±0.02%

• Screw drivers (flat-blade and Phillips)

• ESD wrist strap

• 48V test load

• Calibrated clamp-on dc current meter

(0.1 ADC sensitivity)

• Torque wrench

• Socket wrenches:

− 7/16” and 9/16” for load and

battery connections;

− 19 mm for anchor bolts;

− 12" extension for socket

• Masonry drill kit as required

• Compression for installation of various

compression lugs

• Protective canvas

• Insulating rubber mat

• Standard insulated installation tools,

screwdrivers, etc.

• Windows-based personal computer laptop (PC) and cable to connect the PC communications port to the local port of the controller OR a CAT5 LAN cable.

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Accounting for Ship Loose Materials

QTY H5694720 Group COMCODE DESCRIPTION

60 660, 661 802841635 Flat Washer, 3/8

60 660, 661 801829607 Lock Washer, 3/8

60 660, 661 841064777 Nut Hex, 3/8

40 660, 661 230707-1 Amp Barrel Terminal

144 660, 661 901352617 Nut ¼ - 20

3 441, 451, 471 406954222 Cable ties for securing battery cables

1 441, 451, 471 CC848809104 2 gauge battery cable

2 440-471 901281444 Phillips flat head screws 10-32 x 3/8

3 440-471 848466884 Battery separators

1 440, 441, 451, 471 CC848768201 Front battery bracket

1 441, 451, 471 CC848770248 Clear cover for battery breaker

2 441, 451, 471 845143858 Screw 6-32 x ¼

2 101-104 CC408575947 ¼-20 x ¾-inch HH bolt

2 101-104 801829557 ¼-inch lockwasher

2 101-104 CC408576012 ¼-inch flat washer

1 104 CC848795385 Drill template

Torque Requirements

Torque (in-lb) Connection

10 AC terminal block screws 35 10-32 screw for dc rear covers and ac duct 35 12-24 frame-mounting screws

65 1/4-20 nuts for bullet panel loads 135 M8 bolts for large breaker and fuse kits and LVBD connections 240 3/8-16 nuts for large breaker and fuse load leads and all battery leads

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Anchoring Frame

Floor Mounted Frames

Using the 847135688 Floor Anchor Kit (recommended):

Anchor Type (Hilti) Wrench Hole Size Torque

(4) 12 mm Cap Bolts 19 mm

Note: For systems with tray mounted batteries at sites requiring Seismic Zone 4 rating, (2)

847135688 kits are required to provide (8) floor anchors.

Note: If using Equivalent Floor Anchors, make sure the floor anchors are rated for this application.

18mm 100mm deep

Step Action

Mark floor anchor locations, using the provided Floor Template.

720 in·lbs 60 ft·lbs

81.6 N·m

G103 7ft Standard Frames

G104 7ft Heavy Duty Frames

Drill anchor holes.

Caution: Follow safe floor drilling procedures to prevent possible asbestos exposure.

Place frame and install floor anchors according to manufacturer requirements.

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Battery or Battery Stand Mounted Half-Height Frames:

Step Action

Place and secure frame to battery or battery stand per instructions provided with the battery stand or adapter.

Connecting Frame Ground

Select a Frame Ground landing on the top of the frame and clean.

Step Action

Secure Frame Ground connection with provided hardware: (2) 801256165 ¼-20 x 3/4" HH bolt (2) 801829557 ¼-inch lockwasher (2) 802841577 ¼-inch flat washer

If required by local code or practice, treat with an oxidation inhibitor such as NO-OX.

Use 7/16” socket. Torque to 65 in·lbs.

Note: Landings are compatible with lugs

with 5/8” hole spacing for ¼” or 6mm hardware.

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Battery or Battery Stand Mounted Frames:

If required by local code or practice, battery or battery stand mounted frames may be grounded to the frame or chassis of the other equipment. Select a Frame Ground landing at the side of the frame and clean.

Step Action

Secure Frame Ground connection with provided hardware: (2) 801256165 ¼-20 x 3/4" HH bolt (2) 801829557 ¼-inch lockwasher (2) 802841577 ¼-inch flat washer

If required by local code or practice, treat with an oxidation inhibitor such as NO-OX.

Use 7/16” socket. Torque to 65 in·lbs.

Note: Landings are compatible with lugs

with 5/8” hole spacing for ¼” or 6mm hardware.

Connecting Central Office Ground (COG)

Action

• COG lead landing is as shown.

• If required by local code or practice,

treat with an oxidation inhibitor such as NO-OX.

• Secure COG connection with provided hardware: (2) 841064777 3/8-16 nut (2) 801829607 3/8-inch lockwasher (2) 814251898 3/8-inch flat washer

• Use 9/16” socket. Torque to 240 in·lbs.

Note: Landings are compatible with lugs with

1” hole spacing for 3/8” hardware.

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Connecting AC Utility

WARNING: Disconnect all AC branch circuits prior to making AC connections to the CPS6000 Plant System. When connecting to utility source, ensure compliance to all local and national wiring rules.

Step Action

• AC is connected to terminal blocks located at the top of the equipment frame.

• Route and attach conduit or other commercial fitting. A 1-inch conduit is required per

rectifier shelf.

• Pull and terminate AC wire.

• Terminal blocks are provided for up to twenty rectifiers (four shelves).

• Each rectifier must be fed by 10 gauge wire protected by a 20A circuit breaker or fuse.

• Terminate ground connection on terminal blocks or optional lugs.

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Installing Batteries

Installing Battery Trays

Optional battery trays are suitable for use with general trade VRLA batteries. VRLA batteries come in two jar widths; approximately 4.25” width, typically used in 19” frame applications and approximately 5” width, typically used in 23” frame applications. These battery trays accommodate both types.

Step Action

Position the battery tray in the frame as shown. Secure with provided (Comcode

901078717) rack screws.

Installing Tray Mounted Batteries

The system can be configured with battery trays sized for various batteries and may include optional factory installed battery disconnect or battery mid-string voltage and temperature monitoring units.

WARNING: All batteries contain hazardous electrical energy. Lead-acid batteries contain sulfuric acid and explosive hydrogen gas. Follow all precautions noted in the literature accompanying the batteries. Use only insulated tools.

CAUTION: Equipment frame anchoring, load rating, and seismic zone rating should be verified before field installing trays and batteries.

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Typical Battery Installation on Trays with Battery Disconnect

Step Action

Ensure disconnect switch is in the OFF position (downward) prior to making any connections.

Remove the two 6/32 screws to remove the plastic cover.

Does system have larger batteries?

Yes – Proceed to Step 2. No – Go to Step 3.

Reposition the battery disconnect switch to the outside of the battery tray as shown using (2) provided

901281444 Flathead 10-32 x 3/8” Phillip screws.

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Step Action

Place front bracket on battery tray. Batteries sit on flange of bracket holding it in place.

Note: For systems with larger

batteries the front bracket is mounted to extend beyond the front of the tray.

Connect one end of the 2 gage cable to the input bus of the disconnect switch. Secure with

1/4-20 hex nuts (901352617) provided.

Torque to 65 in-lb. Re-attach clear plastic cover to

disconnect switch and secure

with 6-32 screws.

Place four batteries on each battery tray.

Position three Battery Spacers between the batteries.

Interconnect three inter-cell bus bars to configure one 48V battery string per the battery

manufacturer’s instructions.

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Step Action

Attach the battery securing top rail. Secure with provided

(Comcode 901078717) rack screws

Connect the 2 gage cable between the V- post of the leftmost battery and the input bus

of the disconnect switch. Torque to battery manufacturer’s specification.

Is the system equipped with a factory installed QS873 VT thermal probe?

Note: The Millennium II can support up to 16 QS873VT 1-Wire probes. It also has the capability of directly monitoring up to (4) analog temperature probes. Temperature measurements are also available through the use of Remote Peripheral Modules (RPM’s).

Connect the QS873 VT thermal probe to the inter-cell busbar at the V- post in the middle of the battery string.

Cable-tie to front bracket along

with the battery cable.

See “Installing Thermal Probes” later in this chapter if field installing Thermal Probes

No – Proceed to Step 11. Yes – Proceed to Step 10.

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Step

Action

Connect the factory-wired battery cable to the V+ post of the rightmost battery. Torque to battery manufacturer’s specification.

Battery installation is complete.

Attaching Battery Cables to CPS6000-M2 Busses

• Battery Cable landings are as shown. If required by local code or practice, treat with an oxidation inhibitor such as NO-OX.

• Secure Battery Cable connections with provided hardware (per cable): (2) 841064777 3/8-16 nut (2) 801829607 3/8-inch lockwasher (2) 814251898 3/8-inch flat washer

• Use 9/16” socket. Torque to 240 in·lbs.

Action

Note: Landings are compatible with lugs with

1” hole spacing for 3/8” hardware.

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Installing and Wiring DC Loads

Installing DC Bullet Style Distribution

Bullet Terminal distribution panels accept Bullet Terminal Circuit Breakers, TPS Fuse Holders, and GMT Fuse Modules.

CAUTION: Ensure Circuit Breakers are in the OFF position prior to installation. Ensure Fuse Holders are empty prior to installation.

• CAUTION: In order to meet UL Listing temperature limits, GMT Fuses on the bullet fuse module must meet these layout restrictions:

• All 12A rated fuses must have an unused position to at least one side.

• All 15A rated fuses must not be installed next to another fuse. Leave empty position.

• CAUTION: In order to meet UL Listing temperature limits, bullet distribution panels

must meet the following layout restrictions

• Panel is rated 400A but derates to 350A if Large Breakers or Fuses are installed in the Center Section of distribution.

• bullet circuit breakers rated 80A, 90A and 100A require one adjacent position be left unoccupied.

Step Action

Loosen screws and swing hinged retainer cover clear of the distribution devices (if present).

Vertical distribution panel

Insert distribution devices into the panel load busses as shown in the figure above.

Connect loads.

Note: To allow for future growth start from the top most position and work down the panel. This will allow orderly and managed cable dressing as loads are added.

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Step Action

Secure GMT Module Return bus bars to the distribution panel Return bus bar with

provided (901352617) 1/4-20 nuts. Secure the hinged retainer cover if removed in step 1 above.

Single- and Two-Pole, Breakers and TPS Fuses:

Secure Two-Pole adapter busses to the distribution Load and Return busses with

provided (901352617) 1/4-20 nuts. Secure Load and Return Cable connections with provided (901352617) 1/4-20 nuts.

Use 7/16” socket. Torque to 65 in·lbs. Verify (using a voltmeter) polarity of the voltage between the Return bus and the

distribution input bus. Verify wiring polarity at the input of the load equipment.

Leave breaker switches in the OFF position and do not install load fuses until the load equipment is ready to be energized.

• WARNING: Do not install load fuses until the load equipment is ready to be energized.

Three-Pole Breakers:

Secure Three-Pole adapter busses to the distribution Load and Return busses with

provided (901352617) 1/4-20 nuts. Use 7/16” socket. Torque to 65 in·lbs.

Secure Load Cable connections with provided hardware (per cable): (2) 841064777 3/8-16 nut

(2) 801829607 3/8-inch lockwasher (2) 814251898 3/8-inch flat washer Use 9/16” socket. Torque to 240 in·lbs.

Using a voltmeter, verify polarity of the voltage between the Return bus and the distribution input bus.

Verify wiring polarity at the input of the load equipment. Leave breaker switches in the OFF position until the load equipment is ready to be

energized.

• WARNING: Do not install circuit breakers until the load equipment is ready to be energized.

GMT Bullet Fuse Modules:

Issue 8 January 2008 41

Strip load wire 3/8” and secure in the GMT module terminal block. Use #1 slot screwdriver. Torque to 13 in·lbs.

Dress and wire tie with service loop to provide strain relief. Using a voltmeter, verify polarity of the voltage between the RTN and distribution input

bus. Verify wiring polarity at the input of the load equipment.

• WARNING: Do not install load fuses until the load equipment is ready to be energized.

CPS6000-M2 Installation Guide H5694720

Installing TPL-C Fuse Holders and Panels

TPL-C Fuse holders can either be factory or field installed per kit CC109129129128. The following figure shows the installation of this kit and corresponding fuse installation. Note that the fuse snaps into the fuse handle which is then pushed into the holder.

Step Action

Ensure Fuse Holders are empty prior to making any connections.

Secure Load Cable connections with provided hardware (per cable): (2) 841064777 3/8-16 nut (2) 801829607 3/8-inch lockwasher

(2) 814251898 3/8-inch flat washer Use 9/16” socket. Torque to 240 in·lbs.

WARNING: Do not install load fuses until the load equipment is ready to be energized.

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Installing Large Circuit Breakers

KS22012 Circuit Breakers can either be factory installed or field installed per the following kits:

• CC109127635 150A Single Pole Breaker

• CC109127627 250A Single Pole Breaker

• CC109127486 Two Pole Breaker

Step Action

Ensure Circuit Breakers are in the OFF (down) position prior to making any connections.

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Installing QS-Series Rectifiers

Action

Rectifiers are installed or removed with the rectifier handle in the open position as shown.

Use the above rectifier installation procedure as needed in the following steps:

Step Action

Turn on ac service circuit breakers to apply power to the system rectifier positions.

Install a rectifier in an available rectifier position.

Wait until the rectifier establishes communications with the controller (the red Fail

LED stops flashing). Verify green Norm LED is lit.

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Step Action

Apply 10 amperes of load to the system.

If equipped, verify the contactor closes and connects the battery strings.

If an audible alarm is present, press the ENTER key to MUTE the audible alarm.

Verify all LEDs are green on the controller and the display is visible with the proper

voltage shown. Increase the plant load current to 20 amperes.

Install rectifier in the next position. Wait until the rectifier establishes communications with the controller (the red Fail

LED stops flashing). Verify green Norm LED is lit. Verify the two rectifiers are present and verify the rectifier output currents by using the

front panel:

MENU > STATUS > RECTIFIERS > RECTIFIER CURRENTS.

Increase the plant load current to 50 amperes. Continue to add rectifiers until the system is fully equipped or has a maximum of 20

rectifiers. Verify the rectifiers share the load and the voltage regulation is correct. Rectifiers

should load share after 2 minutes to within 2% of the total average output. Verify front panel display voltage is within 0.5% of the Float Set-point. Remove a rectifier and ignore the request to remove missing equipment. Verify the controller identifies the rectifier as missing to verify that the Minor

Communication Fail alarm is operational.

For more information on QS Rectifiers, see the Troubleshooting section.

Re-install the rectifier and verify that the alarm clears.

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Installing QS-Series Ringers

Step Action

• Up to two Ringer Chassis’s may be installed per rectifier shelf, one in each of the two right-most power slots. Each Ringer chassis accepts up to two ringer modules, a primary and a spare.

• For redundant ringing, install both Primary and Spare Ringers in each Ringer Chassis.

WARNING: Consider the Ring signal as hazardous voltage. When

rectifiers and/or battery power is present, all installed QS820M ringer chassis and QS820A ringer modules will be powered.

• Note: Ringer output connections are made after ringers are seated in the Ringer chassis.

• Note: The primary and spare Ringer modules install facing opposite directions. No rectifiers may be installed to the right of a Ringer Chassis. Slots dedicated to Ringers do not require an ac input circuit in the AC Termination Panel

• Slide the ringer chassis into the power slot.

• Press firmly until the connector on the rear of the ringer chassis engages with the connector at the back of the power slot on the shelf.

• Verify the hook under the front left of the ringer chassis

hooks under the shelf.

• Press down on the faceplate latch and open the faceplate.

• Secure the ringer chassis to the shelf using one #4 screw, hand tight to approximately 5 in-lbs.

• Repeat if a second ringer chassis is required.

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Step Action

• Locate connector on rear of ringer module and the mating connector on the inside rear of the ringer chassis.

• Align the ringer module connector with the ringer chassis connector. Place the ringer module in the guides

and slide the ringer in until it fully engages with the connector at the back of the ringer chassis.

• Note: The Ringer modules install facing opposite directions

• Repeat until all Ringer modules are installed.

• Use Tip Jumper J12 to set the Ringer output type.

• Note: Ringer output type is determined by connecting Ring Return (Tip) to Battery or

Ground. External connection of Ring Return (TIP) to Battery or Ground may be used with J12 in EXTERNAL position. Ringer output is disabled if Ring Return is not connected to Battery or to ground.

Ringing Type

Ground Backed 1. TIP BAT Battery Backed 2. TIP GND

Ground Backed – no-dc 2. TIP GND

Externally Selected 3. EXTERNAL

Tip Jumper

J12 Position

Comments

Also requires Controller configuration of dc Offset: Disabled

Requires external connection of Tip to Battery or Ground.

Repeat until all Ringer modules are installed

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Step Action

• Connect Ringer loads using Molex 39-01-4031 connector, Socket Terminal to the HDR13 plug located inside the Ringer Chassis at the bottom-front

WARNING: Consider the Ring signal as hazardous voltage.

Controller Connections

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The MCR1/MCR1B control board contains the connections for all the input and outputs. The following table provides a list of the connections with their respective reference designators and brief description of the particular connection.

Interface

Reference Description

P1 P2 P3 P6

P8 P9

P13 P14

P15 P201 P202 P205

TB1

TB2

J10

Connectorized interface for large parallel format 8x40 LCD assembly 10/100 Base-T LAN/Ethernet interface Connectorized interface for 10K/30K thermistor probe options or 210E Connectorized input for input power, monitoring of two shunts, plant sense voltage, and Major Fuse alarm (Same connection as on the Millennium) RJ45 receptacle for ground referenced Auxiliary RS485 circuit and One-Wire monitoring devices BSL1-4 circuit pack Interface connector for Input/Output to controller RJ45 receptacle for isolated RS485 system component monitoring and control of rectifiers, converters, low voltage disconnect contactors, and bay level alarm inputs (Serial Rectifier bus) Factory test connector (not used in the field) Connectorized interface for future smaller serial format LCD Connectorized interface for future smaller serial format LCD Connectorized interface for optional Modem Ground referenced DB-9 for local RS232 serial port Option board connector Terminal block interface for RS232/RS485 Auxiliary port and Remote Peripheral Module (RPM) connections Terminal block interface for three additional 10K thermistor probe or 210E connection options USB interface (reserved for future use)

Fuses

Two Fuses, located on the MCR1/MCR1B board, provide protection for the controller input power and Alarm Battery Supply (ABS). ABS is used to power alarm panels or other devices requiring the power system voltage at no more than 1.3A.

Fuse Description Fuse Size

F1 Controller Input Power 3A F2 Alarm Battery Supply (ABS) 1.3A

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Network (LAN) Connections

Step Action

Note

The LAN port P2 is an IEEE 802.3 compliant 10/100Base-T Ethernet interface. This port can be used for remote monitoring or configured as local Craft port. Factory default is to be a DHCP client where the network will serve the controller and IP address.

Since the cable length required to connect to the network is variable, this cable must be supplied by the user.

At the controller, connect one end of the network interface cable to P2. This connector is located at the bottom center of the MCR1 board, and immediately below the MCR2 board.

Connect the other end to an IEEE 802.3 compatible network. Configure the network parameters by contacting the customer’s network

administrator.

BSL Alarm Outputs and Control Inputs

The following tables provide the input/output signal assignments for the BSL alarm interface board. Use 18-26 gage wire for alarm board terminations. Form-C Alarm contact ratings are 60VDC, 0.3A

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BSL Alarm Outputs

Signal Name Pin

Power Critical

Alarm -Audio

Power Critical

Alarm -Visual

Power Critical

Alarm-External

Power Major Alarm-Audio

Power Major

Alarm –External

Power Major

Alarm–Visual

Power Minor Alarm-Audio

Power Minor

Alarm –Visual

Power Minor

Alarm –External

Major Fuse Alarm

Number

1 PCRAO 34 MNFR 2 PCRAC 35 MNFC 3 PCRAR 4 PCRVR 37 BDO 5 PCRVC 38 BDC 6 PCRVO 7 PCREO 40 ACFR 8 PCREC 41 ACFC

9 PCRER 10 PMJAR 43 RFAO 11 PMJAC 44 RFAC 12 PMJAO 13 PMJEO 46 HVR 14 PMJEC 47 HVC 15 PMJER 16 PMJVR 49 UR1O 17 PMJVC 50 UR1C 18 PMJVO 19 PMNAO 52 CTLRR 20 PMNAC 53 CTLRC 21 PMNAR 22 PMNVR 55 UR2O 23 PMNVC 56 UR2C 24 PMNVO 28 PMNER 58 VLVR 29 PMNEC 59 VLVC 30 PMNEO 31 MJFO 32 MJFC 33 MJFR

Signal

Reference

Signal Name Pin Number Signal

Minor Fuse Alarm

36 MNFO

Battery On

Discharge Alarm

AC Fail Alarm

Rectifier Fail

Alarm

High Voltage

Alarm

User Relay 1

Controller Fail

Alarm

User Relay 2

Very Low Voltage

39 BDR

42 ACFO

45 RFAR

48 HVO

51 UR1R

54 CTLRO

57 UR2R

60 VLVO

Reference

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BSL Alarm and Control Inputs

Alarm Pin

Number

61 LVD2 Low Voltage 2 Disconnect State Detect

62 LVD2R Fuse Alarm Major 63 FAJ Fuse Alarm Minor 65 FAN Auxiliary Alarm Major 64 AMJ Auxiliary Alarm Minor 66 AMN Timer Float Control 67 TFLT Timer Boost Control 68 TBST Timer Control Return 69 TRTN

Plant Battery Test

Open String Detect 72 OS Transfer Rectifier 1 73 TR1 General Purpose Input 4 74 IN-4 (previously TEQ) General Purpose Input -5 (Previously Engine Transfer)

Reserve Operation

Transfer Rectifier 2 79 TR2 Transfer Rectifier 4 80 TR4 Reserve Battery-Emergency Power Off 81 RBRPO General Purpose Input 1 82 IN-1 BTP or General Purpose Input 2 83 IN-2/BTP Low Voltage 1 Disconnect State Detect 84 LVD1 Transfer Rectifier 3 85 TR3 General Purpose 4-20mA Measuring Circuit General Purpose 4-20mA Measuring Circuit-RTN BTPFLT or Generic Input 3 89 IN-3/ BTPFLT Low Voltage 3 Disconnect State Detect Also Battery Thermal Protect Major General Purpose 0-5Vdc Measuring Circuit General Purpose 0-5Vdc Measuring Circuit-RTN

70 PBTR

71 PBT

75 IN-5 (Previously ETR)

77 RO

78 ROR

87 4-20mA

88 4-20mAR

90 LVD3/ BTMJ

91 0-5V

92 0-5VR

Signal Name

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Following are additional details concerning the alarm and control input signals.

BSL-63 FAJ: Fuse Alarm Major

An optional “battery” or non-grounded potential input, must use an external 1K ohm 2W current limiting resistor at the source. A Fuse Alarm Major is generated when battery potential is received.

BSL-65 FAN: Fuse Alarm Minor

An optional “battery” or non-grounded potential input, must use an external 1K ohm 2W current limiting resistor at the source. A Fuse Alarm Minor is generated when battery potential is received.

BSL-72 OS: Open String Alarm

An optional “battery” or non-grounded potential input, must use an external 1K ohm 2W current limiting resistor at the source. This circuit is used to signal the controller that a battery string protective device or switch is in the open position. An Open String Alarm is generated when battery potential is received.

BSL-64 AMJ: Aux Major

An optional “battery” or non-grounded potential input, must use an external 1K ohm 2W current limiting resistor at the source. This circuit is used to allow the controller to monitor another power device and provide alarms for it. An Aux Major Alarm is generated when battery potential is received.

BSL-66 AMN: Aux Minor

An optional “battery” or non-grounded potential input, must use an external 1K ohm 2W current limiting resistor at the source. This circuit is used to allow the controller to monitor another power device and provide alarms for it. An Aux Minor Alarm is generated when battery potential is received.

LVD1: BSL-84 Low Voltage Disconnect Active

An optional “battery” or non-grounded potential input, must use an external 1K ohm 2W current limiting resistor at the source if not using standard controller. This circuit is used to inform the controller that the monitoring circuit of a Low Voltage Disconnect device has failed.

LVD2/LVD2R: BSL-61/62 Low Voltage Disconnect Active

A closure between these points or a ground signal into LVD2/ BSL-61 is used to inform the controller that a Low Voltage Disconnect device has opened.

External Boost Option

A variety of external devices may be used to initiate boost in the controller. Wiring is required from positions 67/68/69 on the BSL board for operation of this feature. Providing a contact closure between TBST and TRTN initiates the boost feature. A contact closure between TFLT and TRTN returns the plant to float.

Rectifier Sequence Option

The controller is capable of sequencing rectifiers on line after detecting AC is being provided by emergency generator. Internal Rectifier Sequencing requires external wiring to ETR/ETRR on BSL pin numbers 75/76, and optionally RO/ROR on BSL pin numbers 77/78, in order to

Lineage Power LVD circuit boards or

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function. The controller can also accept ground signals onto TR1 to TR4 on BSL 73/79/ 85/80 from an external device to control the sequencing of plant rectifiers in groups as follows:

TR leads and Associated Rectifiers

Signal

TR1 G01, G02, G09, G10, G17, G18, G25, G26, G33, G34, G41, G42, G49, G50, G57,

G58

TR2 G03, G04, G11, G12, G19, G20, G27, G28, G35, G36, G43, G44, G51, G52, G59,

G60

TR3 G05, G06, G13, G14, G21, G22, G29, G30, G37, G38, G45, G46, G53, G54, G61,

G62

TR4 G07, G08, G15, G16, G23, G24, G31, G32, G39, G40, G47, G48, G55, G56, G63,

G64

Rectifiers Affected

Alarm Battery Supply Outputs on BSL Board

ABS Pin Numbers

Signal

Name

ABS 93 ABS 94

DG 95 DG 96

BSL-93, 94 ABS: Alarm Battery Supply

This is an alternate plant voltage source for user alarm systems. This power is fused with a 1-1/3 ampere ABS fuse labeled F2 on the controller.

BSL-95, 96 DG: Discharge Ground

Plant ground/return source for user alarm systems.

Pin No.

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Installing Optional Circuit Packs

Field-Installable Circuit Packs

BSM5 Modem Card

Step Action

Note

Installation or replacement of this pack can be done “hot”; power removal is not necessary.

Remove the controller plastic front cover.

Place insulator under BSM5 modem and install to the door using four 407882141

standoffs. Wrap insulator around modem and secure with four 845143866 screws. Connect 848091798 cable assembly between the BSM5 J100 plug and P201 on the

MCR1 board.

Note: This step may be performed at a later time

Connect a telephone cable to the RJ11 connector at the top of the BSM5 board

Connect Tip/Ring conductors to TB1 at the top of the board. NOTE: Tip is TB1 pin 1 (Pin closest to the RJ11 connector) and Ring is Pin 3. Pin 2

is not used. Operate the controller reset switch on the MCR1 board in the lower left corner of the

MCR1 board. The Password Reset button is to the LEFT of the serial port connector (Not present on

the MCR1B must use the front panel), and the Controller Reset is to the right of the serial connector.

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BSW Data Switch Card

Step Action

Note

Installation or replacement of this pack can be done “hot”; power removal is not necessary.

Install two 407882133 standoffs on the MCR1 located just below TB1 connector in the

upper left hand corner. Place BSW pack inside the 847950938 insulator.

Plug BSW pack into the P205 connector on the MCR1 board

Secure the BSW board to the standoffs with two 900562208 screws.

To install the Data Switch Extension board, please see the Basic Installation And User’s Guide For The Millennium II Controller (167-792-181).

BSL Alarm Termination Board

An insulation displacement (punch down) type alarm terminal board (BSL3, 848741711) is provided with the system. For a wire wrap type terminal board, order BSL4 (848749507) and perform the following steps:

Step Action

In the upper right hand corner of the MCR1 board, find the alarm board already

installed. Remove the two screws holding the board at the top.

Holding the board on both sides, slowly, but firmly, remove the alarm board from the

P8 connector. Connect the new alarm board to P8 and press down firmly, until the board is seated.

Secure the alarm board at the top using the two screws removed earlier.

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Remote Peripheral Monitoring (RPM)

Monitoring modules available consist of:

• 221F -50-150mV Shunt monitors (6 channels + 1 temperature channel)

• 221J 0-100mV DC Voltage transducer monitors (6 channels + 1 temperature channel)

• 221A 0-3V DC Voltage monitors (6 channels + 1 temperature channel)

• 221B 0-16V DC Voltage monitors (6 channels + 1 temperature channel)

• 221C 0-70V DC Voltage monitors (6 channels + 1 temperature channel)

• 221D 0-200V DC Voltage monitors (6 channels + 1 temperature channel)

• 222A Binary Input monitor (6 channels + 1 temperature channel)

• 223T Temperature monitor (7 Channels)

• 214A Control Relay module (3 sets of programmable form C relay outputs)

The user may connect a maximum of 95 of any combination of these modules serially.

Step Action

NOTE:

This section only describes a single module connection to the controller. Modules MUST BE PROGRAMMED after they have been installed or they may not function properly. Detailed connection and configuration information may be found in the RPM Product Manual 167-790-063.

Using RPM bus cable (comcode 407377704), wrap the cable through the EMI inductor bead twice. Place the bead approximately 3 inches from the controller. Connect the bus cable to TB-1 on Millennium and TB101 on the RPM

TB-1 Pin

Assignments

6 *6 Blue or White Power/Communications 8 *8 Blue or White Power/Communications

9 or 10 FGND Bare wire Shield

*connections of the bus wire are NOT polarity sensitive.

TB-1 Pin

Descriptions

RPM

Conductor

Color

RPM Conductor

Description

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Step Action

Note

Secure the module connection unit and route the wires through the open-faced bottom of the connection unit.

Make the connections to TB2 on the connection unit:

TB-2 Pin RPM Conductor

Color

IN Blue or White Power/Communications

OUT Blue or White Power/Communications

SHIELD Bare wire Shield

*connections of the bus wire are NOT polarity sensitive. * there are 2 IN, and 2 OUT connections. Either one may be used.

Locate the control unit. This is the half with circuitry on it. Each RPM must have a unique switch address to be recognized by the controller. In

the lower right hand side of the control unit (inside), are two rotary switches. Set SW-1 (LO) to 1. The module will be recognized as 01 by the controller. Other modules added cannot have the same address or 00 for the address.

Carefully attach the control unit to the connection unit using the ribbon connector. This connector/cable is not keyed, so be careful to line up the pins properly. After approximately 1 minute, the green LED on the front of the module will blink

once approximately every 5 seconds.

RPM Conductor

Description

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Thermal

Without thermal probes, many of the controller’s battery management features will not function, or will produce erroneous results. Some features requiring thermal inputs are:

• Slope Thermal Compensation

• Reserve Time Prediction

• High Temperature Alarm

• High Temperature Disconnect

The controller supports both analog and digital thermal probe inputs. Analog signal probes connect to the controller at the P3 temperature probe connector or TB2 terminal block. The first thermal probe connects to P3 and three more probes may be connected to TB2 by cutting of the connector. If more than four thermal probes are required, a 210E Thermal Probe Multiplexer can be connected to the P3 connector for an additional 8 probes. The 210E monitors the probe temperatures and reports the highest temperature to the controller. See Section 8 for thermal probes and cable options. See Product Manual 157-010-202 (Thermal Probe Multiplexer) for ordering and installation of a 210E and associated cables.

Probes

TB2 Pin Description

1 Probe 2 2 Probe 2 RTN 3 Probe 3 4 Probe 3 RTN 5 Probe 4 6 Probe 4 RTN

There are also QS873 VT 1-Wire thermal probes that use the P7 1-Wire connector on the controller.

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Analog Thermal Probe Cables

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Installing QS873 VT Battery Probes

Step Action

Insert the RJ-45 end of the CC848817024 wireset into the P7 1-wire connector on the

controller. Cut the brown voltage sense wire on the CC848817024 at the 3-pin connector.

QS873 probe provides 2-pin and 3-pin receptacles and a 1/4inch ring terminal.

Insert the 3-pin connector end into the receptacle on the closest VT-Probe.

Snap the cover closed on the VT-probe.

Place the first probe to the battery post (as in the battery string picture above).

Verify the number of probes (1) registered with the controller with command:

MENU →STATUS → BATTERIES → NUM TEMP PROBES.

Connect either the 848719803 (5-ft) or the 848719811 (10-ft) cable to the 2-position

receptacle of the first probe and to the 3-position receptacle of another probe. Verify the number of probes (2) registered with the controller with command:

MENU → STATUS → BATTERIES →NUM TEMP PROBES.

Repeat Steps 7-8 for each probe until all probes are installed.

When all probes are installed, verify they are connected and operating with command:

MENU → STATUS → BATTERIES → NUM TEMP PROBES.

The controller is now set to make thermal measurements in performing slope thermal compensation. Additional parameters may be set on the controller to customize this feature.

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5 Controller User Interface

The Millennium II controller monitors and controls system components rectifiers, converters, distribution modules, and Remote Peripheral Modules (RPMs) via a digital communications bus. It can also monitor and control external power equipment, including standby generators, converter plants, and inverters.

System parameters, various alarm thresholds, user-definable alarm inputs and relays can be viewed and configured from the controller display, or from a laptop computer connected to a local RS-232 or Ethernet port, or by remote access is through a network connection to the world wide web (internet) or your enterprise network (intranet). An optional 56k modem is also available.

NOTE: A complete list of Controller Alarm Descriptions and Troubleshooting instructions can be found in Section 7.

Millennium II Front Panel Main Display

Menu Navigation Buttons

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Display Contrast

Millennium II Main Display and Menus

Parameter Change

Direction Buttons

Enter Button

Menu Button

ESC Button

Help Button

Lamp Test

In the Main Display, the ▲▼ buttons increase or decrease the display contrast. When changing a system parameter, the ▲▼ buttons increase or decrease the value of the parameter. In the Menus, the ◄▲▼► direction buttons navigate to make a selection

Enters a sub-menu or confirms a parameter change. From the Home Page only, goes to the top level Main menu. Goes to the top level Main menu.

Goes up one menu level or exits a parameter change without saving. Shows a Help screen.

Initiates a Lamp Test operation.

Main Display

The Main Display is the normal controller display. The display will return to the Main Display after a period of inactivity.

Top Level Menu

Information Menus

Control / Operations Menu

The Main menu allows you to view your equipment status in detail, history, and to view and edit a variety of parameters.

These Information menus give detailed information regarding the status and history of your plant.

The Control / Operations menu allows you to perform common operations on your plant. Operations that are required to turn up and verify your plant are detailed in the Installation and Test and Verification sections of this manual.

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Configuration Menu

CAUTION: Incorrect plant settings can result in hazardous conditions and

equipment damage or injury. Make sure all plant settings are suitable for your application, batteries, and other equipment.

The Configuration menu allows you to access and modify all user accessible plant parameters. Configuration tasks that are required to turn up and verify your plant are detailed in the Installation and Test and Verification sections of this manual. NOTE: An Hourglass may appear in the lower left hand corner of the screen. This indicates that a configuration change is being saved to non-volatile memory.

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Millennium II Controller Status and Alarms

Alarm Status LEDs

Status Function Condition

Note: Which conditions are indicated as Critical, Major, and Minor Alarms may be configured by

the user.

Normal

Critical Alarm

Major Alarm

Minor Alarm

Battery on Discharge

Remote Access [LAN/Modem]

Normal operation, no alarms, inputs and outputs are in their normal range.

Power to load equipment is at immediate and high risk. Power to load equipment is at immediate risk. A problem requiring attention exists, but power to load

equipment is not at immediate risk. Batteries are discharging and delivering current to the

load.

Blinks to indicate traffic on an attached LAN or Modem.

Equipment Status LEDs

Status Function Condition

AC System

Battery

Controller

Rectifier/Converter

Distribution

Remote Modules

Remote Access [LAN/Modem]

AC input to one or more rectifiers is out of range. The batteries are not in a normal operating state. The system controller has detected an internal

problem. A rectifier or converter power unit in the system has

failed The output distribution is not in a normal operating

state. There is a problem with a Remote Peripheral

Module (RPM) Blinks to indicate traffic on an attached LAN or

Modem.

Audible Alarm

The controller assembly is equipped with a user configurable alarm buzzer.

Voltage Test Jacks

Voltage Test Jacks allow you to measure the main plant output voltage with a hand-held meter.

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Local and Remote Access Ports

Local Access

Remote Access

Examples of Frequently Used Menu Features:

This section contains a small number of menu navigation examples to help you get familiar with the menu.

The examples below use shorthand to describe the navigation process. For example, “MENU →

CONTROL / OPERATIONS → START LAMP TEST” means:

Step Action

Connect a laptop PC to a RS-232 port or Ethernet port and access the controller with EasyView or Web Pages.

An RJ-45 Ethernet connector is provided for 10/100 Base-T network connection to the world wide web (internet) or your enterprise network (intranet) using Microsoft Internet Explorer®, Mozilla Firefox®, or other web browser. An optional 56k modem is also available.

Press to go to the top level Menu.

Press navigation buttons to select Control / Operations.

Press to select and enter Control / Operations.

Press navigation buttons to select Start Lamp Test.

Press to execute the Start Lamp Test command.

Lamp Test: MENU > CONTROL / OPERATIONS > START LAMP TEST

Lamp Test allows you to make sure all LEDs and displays in your system are working. This test lights up all of the LEDs and displays in the system for about ten seconds. Multicolor LEDs light up multiple colors in sequence, and should be lit for the entire length of the test.

Control / Operations

Start Lamp Test

Restart Devices

Clear Events

Using the Lamp Test feature is a quick and easy way to see if a system component is communicating with the system controller. If it responds to Lamp Test, then it is receiving commands from the controller.

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Clear Events: MENU > CONTROL / OPERATIONS > CLEAR EVENTS

Latched events may be cleared using this feature. Latched events remain active after their cause is removed (retired) until manually cleared.

Control / Operations

Start Lamp Test

Restart Devices

Clear Events

If the Alarm is a Latched Event and does not retire after performing this operation, the alarm condition most likely still exists.

Uninstall Devices: MENU > CONTROL / OPERATIONS > UNINSTALL EQUIPMENT

This command can be used to clear a COMMUNICATION Fail alarm that has been caused by removing installed equipment (rectifiers, converters, distribution monitors, thermal probes, batteries monitors).

Control / Operations

Start Lamp Test

Restart Devices

Clear Events

Uninstall Equipment

Alarm Cutoff

This feature is used to silence local audible alarms. Any subsequent Power Critical, Power Major, or Power Minor alarm will again sound the audible alarm.

When the alarm occurs, the “CUT OFF AUDIBLE ALARM” appears. Press ENTER to turn off alarms. Then “TURN ON AUDIBLE ALARM” message appears to turn audible alarms back on.

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View Rectifier Current: Menu→ Status→ Rectifiers→ Rectifier Currents

This command is used to view rectifier currents.

Status

Rectifiers

Alarm Thresholds

Rectifier

Currents

View IP Address: Menu→ Status→ Network Settings→ (Port #)→ IP Address

This command is used to view the controller’s network IP address.

Status

Rectifiers

Network Settings

Port 1 or 2

IP Address

Restart Rectifiers: Menu → Control / Operations → Restart Rectifiers

This command is used to restart rectifiers.

Control /

Start Lamp Test

Restart Devices

Clear Events

Restart

Rectifiers

This is a non-invasive procedure: rectifiers and converters that are operating normally ignore this command.

Alarm History: Menu → History → Alarm History

This command is used to view alarm history.

History

Alarm History

Rectifier History

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Controller Display Menu Maps

Configuration Menu Map

*Note: The QS series of constant power rectifiers do not utilize the current limit threshold setting (30-110%) under Rectifier configuration. QS series rectifiers are designed to provide 100% their nameplate power rating at any given normal output condition and will ignore this configuration.

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Control and Operations Menu Map

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Status Menu Map

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History Menu Map

Statistics Menu Map

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Minimum Controller Configuration

The Millennium II controller’s primary user interface is the front panel, which includes a backlit LCD, and an array of pushbutton controls. SW202-8 must be set to ENABLED for changes to be made from the front panel. This section covers the basic operations that must be performed so that the controller is minimally configured.

Step Configuration

Attribute to Change

DATE/TIME

Menu Path/Action

Format This field allows you to select one of the following date

formats: MM/DD/YY, DD/MM/YY, YY/MM/DD, MM/DD/YYYY, DD/MM/YYYY, YYYY/MM/DD. Use the <+> or <-> key to select the desired format and press <ENTER> to save the change.

Month Use this field to change the month; the possible value is from 1

to 12.

Day Use this field to change the day of the month; the possible

value is from 1 to 31.

Year Use this field to change the year; the possible value is from

1992 and up.

Note Please note that the system will validate the entries before the system date is

modified. TIME

Format This field allows you to select one of the following time

display formats: 12 or 24 hour. Use the <+> or <-> key to select the desired format and press <ENTER> to save the

change. Time Allows you to change/set the time. Daylight Enables or Disables Daylight Savings per the new standards

created by the Energy Policy Act of 2005. Starts in 2007.

SYSTEM SHUNT

Type CPS6000-M2 is factory configured with a battery shunt. The

battery shunt is a 1500A, 50mV device located in the V- (hot)

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Step Configuration

Attribute to Change

mV Factory configured to 50 I Factory configured to 1500A

ALARM

THRESHOLDS

High Voltage When the plant voltage exceeds this threshold, the plant High

High Voltage Float When the plant voltage exceeds this threshold, the plant High

Battery on Discharge If the plant voltage is less than the threshold value, the Battery

Very Low Voltage This alarm threshold is used to indicate that the system voltage

5 Rectifiers

Menu Path/Action

bus.

Voltage Alarm (HVA) is turned ON, and the controller will

send a signal to the rectifiers to shut down in an orderly and

timely fashion. This will also light the Major (MJ) LED, and

activate the PMJ relay (assuming there is no alarm with

CRITICAL severity level active). Move the cursor to the fields

and use the <+> or <-> key to adjust the High Voltage shut

down alarm for FLOAT mode to the desired level. Press

<ENTER> to save the change.

Float Voltage Alarm (HFV) is turned ON, and this will also

light the Minor LED, activate the PMN contact closure

(assuming there is no alarm with CRITICAL or MAJOR

severity level active). The purpose of this alarm is to indicate

that the plant voltage is high probably due to an adjustment in

the plant rather than due to a failure. This alarm allows the

High Voltage (HV) shutdown threshold to be raised slightly,

thus reducing the number of nuisance shutdowns without

decreasing the plant reliability. Move the cursor to the fields

and use the <+> or <-> key to adjust the High Voltage shut

down alarm for FLOAT mode to the desired level (normally

less than the HV threshold). Press <ENTER> to save the

change.

Discharge alarm is turned ON, this in turn activates the PMJ

and BD relays, and lights the MAJ and BD LEDs. Move the

cursor to the fields, and use the <+> or <-> key to adjust the

threshold to the desired level. Press <ENTER> to save the

change.

is very low, and that the batteries have discharged to a

dangerously low depth. When the plant voltage falls below this

level, the Very Low Voltage (VLV) and Power Critical alarm

will be generated. Move the cursor to the field and use the <+>

or <-> key to adjust the threshold value. Press <ENTER> to

save the change.

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Step Configuration

Attribute to Change

Set-point This value sets the system voltage for all serial rectifiers.

HVSD The configuration of this field sets the internal high voltage

Batteries

Model The configuration of this field selects the installed battery type

Strings The configuration of this field selects the number of battery

Cells/String The configuration of this field selects the number of installed

Type The configuration of this field selects the battery type, Flooded

Thermal Comp

Menu Path/Action

Move the cursor to the field and use the <+> or <-> key to

adjust the threshold value. Press <ENTER> to save the change.

shutdown value of all serial rectifiers. Move the cursor to the

field and use the <+> or <-> key to adjust the threshold value.

Press <ENTER> to save the change.

from a list of pre-defined battery types used in reserve time

prediction and enhanced battery test features. Move the cursor

to the field and use the <+> or <-> key to adjust the threshold

value. Press <ENTER> to save the change.

strings in the system. This parameter is used in reserve time

prediction and enhanced battery test features. Move the cursor

to the field and use the <+> or <-> key to adjust the threshold

value. Press <ENTER> to save the change.

cells in the battery strings. This parameter is used in reserve

time prediction and enhanced battery test features. Move the

cursor to the field and use the <+> or <-> key to adjust the

threshold value. Press <ENTER> to save the change.

or Valve Regulated (sealed). This parameter is used in reserve

time prediction and enhanced battery test features. Move the

cursor to the field and use the <+> or <-> key to adjust the

threshold value. Press <ENTER> to save the change.

This feature allows dynamic control of sealed cell battery

voltage as a function of temperature. Enabled Enables or Disables the Thermal Compensation Feature. Move

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Step Configuration

Attribute to Change

High Temp Comp

Volt Step Down

High Comp Limit Decrease

Nominal Temp

Low Temp Comp This feature allows the system to compensate for low

Low T Comp

Low Comp Limit Increase

Recharge Current

Limit

Menu Path/Action

the cursor to the field and use the <+> or <-> key to Enable or

Disable. Press <ENTER> to save the change.

This feature allows the system to compensate for high

temperatures.

Battery step temperature can be set from 113-185F. At this

temperature, the system voltage is reduced by 0.17 X # of

cells/string.

This sets the maximum temperature for which thermal

compensation is active.

This sets the slope (mV/degC) for high temperature

compensation.

This field set the temperature at which no compensation is

required. The system voltage is at the set-point float mode.

temperatures.

This enables or disables the low temperature compensation

feature.

This sets the minimum temperature for which thermal

compensation is active.

This sets the slope (mV/degC) for low temperature

compensation.

This feature sets the total amount of current that will be

allowed to recharge the batteries.

Limit

Limit to

The configuration of this field enables or disables the feature.

This programmable value sets the maximum amount of

recharge current (in Amps) that will be allowed for recharging

the batteries. The range is from 10 – 1000A.

Contactors

Up to three optional LVD devices can be connected to a

Millennium and configured from this screen.

Contactor 1-3

Type

This setting identifies the type of contactor, BATTERY,

LOAD or NONE that has been installed in the plant. Be sure

that the wiring for the contactor being configured matches the

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Step Configuration

Attribute to Change

Disconnect

Reconnect

Menu Path/Action

type chosen here. To toggle between the various contactor

types, move the cursor to one of the fields and use the <+> or

<-> key to select the desired type. Press <ENTER> to save the

change.

This setting configures the plant voltage at which the contactor

will disconnect from the bus. Use the <+> or <-> key to adjust

the voltage to the desired level. Press <ENTER> to save the

change.

This setting configures the plant voltage at which the contactor

will reconnect to the bus. To prevent the contactor from re-

operating when battery voltage increases due to load removal,

a voltage several volts higher than the disconnect voltage is

recommended. Use the <+> or <-> key to adjust the voltage to

the desired level. Press <ENTER> to save the change.

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Controller Defaults

Dip Switch Settings

The Millennium II has 8 dip switch (SW202) positions that may be configured. SW202 is located on the MCR1 board, above the MCR2 board.

Millennium II Controller Dip Switch Settings

Switch

Position SW202-8 SW202-7

SW202-6

SW202-5 SW202-4 SW202-3 SW202-2 SW202-1

Default Description Closed

(1)

1 Front Panel Configuration ENABLED DISABLED 1 Modem/Aux/Local/Network/ Port

Setting Configuration (Remote Access)

0 Enhanced Security Mode (See Table

5-I, for features affected 1 Auxiliary Port Configuration RS-232 RS-485 0 Remote Rectifier in Standby ENABLED DISABLED 0 Boost Mode ENABLED DISABLED 1 Reserved for Future Use ENABLED DISABLED 1 Reserved for Future Use ENABLED DISABLED

ENABLED DISABLED

Open

(0)

Modem/Aux/Local/Network/ Port Setting Configuration (Remote Access)

The modem and auxiliary ports can be configured for full access or read-only access by properly configuring DIP switch 202-7. Full access with Read/Write capability is achieved by closing SW202-7 (Set to a “1”).

Enhanced Security Mode

Restricted access is also available. When Enabled, the controller prevents remote configuration changes via the modem, network, and auxiliary ports that will affect the state of the plant, even when logged in as a Super-User or Administrator. This enhanced remote security is enabled and disabled with DIP switch SW202-6. The functions and parameters restricted with the enhanced remote security feature are listed below.

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Enhanced Remote Security Features

Restricted Configuration Items

Enable or disable Rectifier Restart feature Change All Rectifier On Threshold Change Timed Manual Boost Duration Change Boost Current Threshold Change Rectifier Status to “Standby”/ “Vacant” status is prohibited. The change to “On”status is allowed. Change Rectifier Shunt Voltage configuration Change Rectifier Float High Voltage Shutdown Threshold Change Rectifier Boost High Voltage Shutdown Threshold Change Rectifier Float Set Point Change Rectifier Boost Set Point Change Rectifier Boost Current Limit (Setting has no affect on QS Series rectifiers) Change Converter Voltage Set-Point Change Converter Low Voltage Disconnect Threshold Change Converter Low Voltage Reconnect Threshold Enable or disable Converter Low Voltage Disconnect feature Change Converter Status to “Standby”/ “Vacant” status is prohibited. The change to “On”status is allowed. Change Battery High Temperature Threshold Enable or disable Battery Current Limit Change Battery Limit Threshold Change Battery Contactor Status to “Open” status is prohibited. The change to “Close” status is allowed. Change Battery Disconnect Threshold Change Battery Reconnect Threshold Change Very Low Voltage Alarm Threshold and Severity Change Multiple Rectifier Fail Alarm Threshold and Severity Change Limited Recharge Current Alarm Threshold and Severity Change Excess Rectifier Drain Alarm Threshold and Severity Change Engine Transfer Timeout Alarm Threshold and Severity Change Reserve Time Low Alarm Threshold and Severity Change Multiple Converter Fail Alarm Threshold and Severity Change Battery On Discharge Alarm Threshold and Severity

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Voltage Threshold Ranges and Default Values

The following table provides the ranges and factory default settings of key configurable voltage thresholds in the Millennium II.

Voltage Threshold Ranges and Default Values

Low High Default

Very Low Voltage (VLV)

24V 20.00 25.50 23.00 48V 40.00 51.00 46.00

Battery on Discharge (BD)

24V Float 23.00 28.00 25.00 24V Boost 23.00 28.00 25.00 48V Float 46.00 55.00 51.00 48V Boost 46.00 55.00 51.00

High Float Voltage (HFV)

24V Float 24.75 29.75 26.50 24V Boost 25.75 31.75 26.50 48V Float 50.00 60.00 53.00 48V Boost 52.00 60.00 53.00

High Voltage Shutdown Alarm (HV)

24V Float 24.75 29.75 26.8 24V Boost 25.75 31.75 26.8 48V Float 50.00 60.00 53.6 48V Boost 52.00 60.00 53.6

Rectifier On Threshold (ROT)

24V 20.00 25.00 22.00 48V 40.00 51.00 44.00

Controller Alarm Severity, LED and Relay Default Values

The following tables provide the various controller alarms and their associated default severity and LED assignments as well as rectifier specific alarms. These items may be reconfigured through remote means.

Controller Alarm Severity, LED and Relay Default Values

Symbol Default Designation Default

Severity

AAC

ABS

AMJ

AMN

ATA

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ACO Active RO None None Alarm Battery Supply Fuse Major CTLR CTLR Auxiliary Major Major None None Auxiliary Minor Minor None None Alarm Test Active RO None None

Default LED Default Relay

CPS6000-M2 Installation Guide H5694720

Symbol Default Designation Default

Severity

ATB

ATF

BBL

BCA

BDA

BFA

BID

BTA

BTJ

BTN

CCH

CDFA

CDID

CFA

CLC

CMA

CMFA

CNF1

CNF2

CNF3

CNO1

CNO2

CNO3

COF

COR

CPA

CRA

DID

EMD

EPD

EPO

EPR

ETO

EXL

FAJ

FAN

HCL

HFV

HVA

LMR

Alarm Test Aborted RO None None Alarm Test Failed Warning None None Memory Backup Battery Low Warning None None Battery Type Conflict Warning None None Battery on Discharge Major BD BD Battery Test Failed Minor BAT None Bay Interface ID Conflict Major CTLR CTLR Battery Test Active RO BD BD Battery Thermal Major Major BAT None Battery Thermal Minor Minor BAT None Configuration Changed RO None None Converter Distribution Fuse Major RECT MJF Converter ID Conflict Major RECT None Converter Fail Minor RECT None Clock Changed RO None None Minor Communications Failure Minor CTLR None Multiple Converter Fail Major RECT None Contactor 1 Failed Major BAT None Contactor 2 Failed Major BAT None Contactor 3 Failed Major BAT None Contactor 1 Open Major BAT None Contactor 2 Open Major BAT None Contactor 3 Open Major BAT None Queue Overflow Warning None None Number Did Not Respond Warning None None Circuit Pack Fail Major CTLR CTLR Controller Fail Major CTLR CTLR Rectifier ID Conflict Major RECT None Energy Management Disabled Warning None None Excess Plant Drain Minor RECT None Emergency Power Off Critical BATT None External Password Reset Warning None None Engine Transfer Timeout Minor AC None Excessive Login Attempts Warning None None External Fuse Major Major DIST MJF External Fuse Minor Minor DIST MNF History Cleared RO None None High Float Voltage Minor RECT None High Voltage Major RECT HV Limited Recharge Minor RECT None

Default LED Default Relay

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Symbol Default Designation Default

Severity

LVD

LVDA

MCM

MDF

MOR

MTC

NNC

OSA

PFD

PGI

PHT

POR

RLS1

RPI

RTL

SNC

STF

TPA

URC

VLA

VSF

ZID

Low Voltage Disconnect Minor BAT None Low Voltage Disconnect Fail Minor BAT None Major Communication Fail Minor CTLR None Module Failure Minor RM None Measurement Out Of Range Minor RM None Module Type Conflict Warning None None Number Not Configured Warning None None Open String Minor BAT None Password At Default Warning None None Program Line Invalid Major None None Processor Halt RO None None Number Did Not Respond Warning None None Redundancy Loss Minor RECT None Rectifier/Plant Inconsistency Warning None None Reserve Time Low Minor BAT None Shunt Not Configured Warning None None Self Test Failed Minor CTLR CTLR Thermal Probe Failure Minor CTLR CTLR User Relay Conflict Warning None None Very Low Voltage Critical BAT UR3 Sense/Control Fuse Major CTLR CTLR ID Not Configured Major RECT None

Rectifier Alarm Defaults

Symbol Default Designation Default

Severity

ACF

CLM

ERD

ETS

HPA

LCA

LSF

MACF

MAN

MFA

MMAN

PHA

Rectifier Current Limit RO None None

Excess Rectifier Drain Minor RECT None

External Transfer Shutdown Minor RECT None

Multiple Rectifier Fail Major RECT RFA

Multiple MAN Alarm Major RECT None Phase Or Low Output Minor AC None

AC Fail Minor AC ACF

Half Power Minor RECT None

Low Current Alarm Minor RECT None

Load Share Fuse Minor RECT None

Multiple AC Fail Major AC ACF

Manual Off Minor RECT None

Default LED Default Relay

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Symbol Default Designation Default

Severity

RIC

RFA

Rectifier Incomplete Config Warning None None

Rectifier Fail Minor RECT RFA

Default LED Default Relay

Web Interface

The Millennium II with its 10/100Base-T port supports standard protocols like SNMP, TCP/IP, FTP and Telnet. It also has an integrated web server that serves up web pages to remote PCs using standard web browsers. Simply typing the IP address assigned to the controller in the browser will serve up the log-in screen. The web pages support the majority of the functionality supported by EasyView and the T1.317 interface. The best way to learn the operation and content of the screens is through use. Following are few sample screens. Note: web pages are updated for functionally and aesthetics. Thus, some of the screens shown may be slightly different than those served up by your Millennium II.

Craft Port

The web interface can be accessed remotely over the LAN or with a direct connection from a local PC. Once logged in the interface is the same. The following describes configuring the port as a local Craft port. . This mode of operation allows a user to connect an external craft PC directly to the port and use the PC’s standard Web browser to locally access the system. This Craft port is supported by the Millennium II operating in DHCP (Dynamic Host Configuration Protocol) server mode. While the Craft port is operating as a DHCP server, it should never be plugged into the building or surrounding LAN.

To access the system using the Craft Port follow the following basic procedure:

Step Action

Find and take note of the controller’s Working IP (WIP) on the front panel display by

going to MenuÎStatusÎNetwork SettingsÎ Port 1

Note: If the Port is not configured as a Server it will not have the correct IP address. To use the Ethernet port locally as a Craft port it needs to be configured as a DHCP Server. DHCP Server operation can be validated at MenuÎStatusÎNetwork Settings. Scroll down to view the port’s present configuration.

If it is not in DHCP Server mode, make sure the Craft port is not plugged into a LAN connection and re-configure the DHCP setting from the front panel to be Server. This is parameter is found in MenuÎConfigurationÎCommunication PortsÎNetwork SettingsÎDHCP.

Note: the controller should automatically reboot to accept the new Ethernet port configuration. This process takes approximately two minutes. Validate the change to server mode at MenuÎStatusÎNetwork Settings

Attach the LAN cable between the RJ45 (P2) on the main board to the appropriate

Ethernet port on the Craft PC.

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Open the PC’s browser and enter the controller’s WIP as the destination address. This

address should be should begin to return appropriate system representative web pages.

Using a standard browser, a login page similar to that depicted below should be served

up by the Millennium II controller. There are three levels of access through the port; Read-Only, Read/Write, and Read/Write with password management privileges. Passwords defaults for the Craft port as well as other remote access means default as follows:

Access Default Password

User (Read-Only) lineage Super-User (Read/Write) super-user Administrator (Read/Write/Password Administration) administrator

These password defaults can be changed by a user of administrator privileges.

http://192.168.2.1. The Millennium II has HTTP capabilities and

After the controller has granted access through the port, the controller serves up a Home page similar to that shown below. Front panel access and capabilities are a super-set of the functions and features available through the Craft port. Configuration of individual parameters and features can be performed by using the items located in the Settings tab or a general quick configuration of the system can be performed through the Installation tab. The Home Page has tabs that are partitioned as the following:

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Home

Main login page that shows representative graphic of the plant. The graphic will depict the number of shelves, rectifiers in place with their appropriate outputs, empty slots, and indicate which rectifiers are in alarm.

High-level summary for the Batteries, Distribution, Alarms present, and controller summary are shown. There are also quick link tabs that take you to specific features. These tabs are the Home, Reports, Maintenance, Settings, and Installation.

Reports

The reports tab displays reports that the system controller can display through web pages. These reports include Event History, Inventory, Statistics, Trends, and Battery on Discharge. Individual history groups like Alarm History, Boost History, Login History, and Rectifier history are also available.

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Maintenance

Allows remote access to Control/Operation commands assessable through the front panel. These include restarting rectifiers/ringers, starting alarm or battery tests, asserting boost, clearing history and statistics, clearing latched events and missing equipment, placing rectifiers/ringers in and out of Standby.

Settings

Installation

Note: The “Factory Defaults” button under system loads the default settings assigned to a specific battery type as defined in the defaults configuration file. Presently this function is unavailable since hard coded defaults are utilized and there is no default configuration file.

Items in this menu are used to configure all the individual system parameters, features, and thresholds. These fields are arranged by System, Reserve, Communication and Programming.

This tab allows a quick configuration of the primary items that need to be set for a site. These items include selecting the battery type, date, time, and the site ID mentioned during the front panel configuration start-up section.

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This page is provides the minimum configuration for configuring the Millennium II for Basic plant operation.

Web pages will be improved for usability as well as for features. The best method of understanding the functions and features available through the Craft port is by clicking on the individual items and exploring to become more familiar with the items. More details on the front panel capabilities and Craft port web pages are found in the controller section.

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6 Acceptance Testing

NOTE: The controller may report a limited recharge alarm during these tests.

NOTE: At any time you encounter difficulty with these steps, refer to the Troubleshooting

Section.

Communication with Rectifiers and Converters

Step Action

Place external battery disconnect switches in the ON (connected) position if equipped.

Turn on all ac circuit breakers supplying rectifiers.

Adjust the contrast (if needed) for the site’s ambient condition by using the up and down arrow keys at the Main Menu. Contrast adjust is also available at :

MENU > CONFIGURATION > SYSTEM SETTINGS > DISPLAY CONTRAST.

After approximately 30 seconds, are all lit LEDs on all components including

rectifiers, the controller, LVD control boards, and Aux Displays green?

Yes – Go to Step 7. No – Proceed to Step 4. Initiate the “Clear Events” and “Uninstall Equipment” operations found under MENU

> CONTROL / OPERATIONS menu. Reference to Appendix A: Pulsar Controller

User Interface as needed. If the controller appears not to be powered or not responsive, remove and reseat the

controller. If all lit LEDs still aren’t green, review the installation procedure or refer to the

Troubleshooting section in this manual. The controller display should indicate “0 ALARMS”. The system float voltage, total load current, and system operating mode should be observable as indicated for no alarms and the system rectifier voltage should be displayed.

If Slope Thermal Compensation (STC) is active, turn off STC by disconnecting and reconnecting the probes. An alarm may occur, and will retire when the probes are

reconnected.

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Step Action

Check the voltage readings on the controller display.

The Millennium II is factory configured with a rectifier Float voltage set-point of -

54.50V Note that if STC is active or if the connected batteries are not fully charged, the voltages

may be lower.

(If possible, open the external battery disconnect prior to making measurements to eliminate these effects. If QS873 temperature probes have all ready been installed in the system, then STC may be active. This will be indicated by the Plant Mode “FLOAT – TEMP COMP”.)

Remove and Replace Rectifier and Verify Results:

Remove a rectifier from its slot.

Verify the controller LED and display light amber and indicate a missing rectifier condition.

When the controller prompts to remove equipment press enter ■. Verify the controller LED and display light green. Replace the removed rectifier in its original slot. Verify the controller LED and displays remain lit green.

Miscellaneous Alarms (Batteries must be connected)

Distribution Alarms

Step Action

Manually connect a piece of wire from the circuit breaker feed bus to the distribution

alarm strip. Verify an FAJ – Fuse Alarm Major is reported by the controller.

Remove the wire. Verify the alarm clears.

Repeat test for each distribution panel or sub-system.

ac Fail Alarms

Step Action

Turn off ac circuit breaker feeding a single rectifier.

Verify ACF – ac Fail Minor is reported for the correct rectifier ID.

Restore ac and verify alarms clear and the controller returns to Normal.

Remove ac from two or more rectifiers.

Verify ACF2 – Multiple ac Fail Major is reported for the correct rectifier IDs.

Turn on ac circuit breaker turned off in Step 1 and verify alarms clear and the controller

returns to Normal.

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Battery On Discharge Alarms

Step Action

Change BD alarm to 2 volts below float voltage (MENU > CONFIGURATION >

FLOAT SETTINGS > VOLTAGE ALARMS > BD).

Adjust the load to 50 amperes.

Verify the BD alarm occurs when the system voltage decreases to BD threshold.

Verify the BD alarm clears once the voltage has exceeded 0.5V above the BD alarm

threshold. Restore the BD alarm threshold to its previous setting.

High Voltage Alarms

Step Action

Confirm the HV alarm threshold (MENU > CONFIGURATION > VOLTAGE

ALARMS > FLOAT VOLTAGE ALARMS). Adjust the float voltage to a value greater than this threshold (MENU >

CONFIGURATION > FLOAT SETTINGS > SET POINT).

Verify an HV alarm is reported by the controller.

Restore the float voltage back to its original setting.

Restore the HV setting back to its original setting.

Verify the alarms clear and the controller returns to Normal.

Manual Contactor Control and Alarms

Step Action

Open the contactor by controller command (MENU > CONTROL / OPERATIONS

> DISCONNECTS).

Verify the controller reports a Contactor Open alarm.

Close the contactor by controller command.

Verify the alarms clear and the controller returns to Normal.

Automatic Contactor Control and Alarms

WARNING: If this is an operating plant with loads, skip this test.

Step Action

Check the disconnect thresholds (MENU > CONTROL / OPERATIONS >

DISCONNECTS).

Adjust the float voltage to a value less than this threshold (MENU >

CONFIGURATION > FLOAT SETTINGS > SET POINT).

Disconnect the batteries in the plant.

Verify the battery disconnect opens and the controller reports a Contactor Open alarm.

Restore the plant voltage back to its original setting.

Verify the contactor closes.

Verify the alarms clear and the controller returns to Normal.

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7 Troubleshooting

Controller

Status Display

No Alarms

MIN AC Fail

Power

Unit

LEDs

rectifier)

(one

Dist.

Module

LED

Possible

Problem(s)

Normal Operation

• Single rectifier not receiving ac power.

• AC input circuit breaker has opened.

• AC input voltage is out of range.

• A rectifier has been removed from the system while it is unpowered.

Possible Solution(s)

1. Verify rectifier input circuit breaker is closed.

2. Verify ac power to rectifier is available and in range.

3. If problem not corrected, replace rectifier.

1. Issue the “uninstall equipment” under the operations menu for any rectifier that was removed while unpowered.

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Controller

Status Display

MIN AC Fail, MAJ Multiple AC

Fail

MAJ Battery on

Discharge

Power

Unit

LEDs

(multiple

rectifiers)

Dist.

Module

LED

Possible

Problem(s)

• Multiple rectifiers not receiving ac power.

• AC input circuit breakers have opened.

• AC input

voltage is out of range

• One or more rectifiers have been removed from the system while it is unpowered.

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

Possible Solution(s)

1. Verify rectifier input circuit breakers are closed.

2. Verify ac power to rectifiers is available and in range.

3. If problem not corrected, replace rectifiers.

1. Issue the “uninstall equipment” under the operations menu for any rectifier that was removed while unpowered.

1. Investigate other alarms that may be present such as rectifier related problems.

2. If ac power is present but the system voltage remains low, call your local field representative

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Controller

Status Display

MIN Rectifier Fail

MIN Rectifier Fail, MAJ Multiple

Rectifier Fail,

MAJ Battery on

Discharge

Power

Unit

LEDs

(one

rectifier)

(multiple

rectifiers)

Dist.

Module

LED

Possible

Problem(s)

• Rectifier output has dropped below 18V (36V), rectifier has shut down

• Excessive ambient temperature, rectifier has shut down.

• Clogged air filter

∗.

• A rectifier has

failed.

• Multiple rectifier outputs have dropped below 18V (36V), rectifiers have shut down*.

• Excessive ambient temperature, multiple rectifiers have shut down

• Multiple

rectifiers have failed

Possible Solution(s)

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

2. If equipped, replace or clean air filter

2. Reset the rectifier by removing the rectifier, waiting approximately 30 seconds, and replacing the rectifier.

3. If problem persists, replace the rectifier.

4. If problem still persists, call your local field representative.

1. Reset the rectifiers by removing the rectifiers, waiting approximately 30 seconds, and replacing the rectifiers.

2. If problem not corrected, replace rectifiers.

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

2. Reset rectifies by removing them, waiting approximately 30s and replacing them.

3. If problem persists, replace the rectifiers.

4. If problem still persists, call your local field representative.

∗

When a power unit senses an over- or under-voltage condition it will shutdown, wait 10 seconds, and then attempt to restart. If the over- or under-voltage condition remains it will cycle again. If the over- or under-voltage condition remains after 3 restart attempts the power unit will lock out, and user intervention is required to restart.

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Controller

Status Display

MAJ High Voltage

MAJ Fuse Major

Power

Unit

LEDs

(all

rectifiers)

(one or

multiple

rectifiers)

Dist.

Module

LED

Possible

Problem(s)

• All rectifier outputs have dropped below 18V (36V), all rectifiers have shut down*.

• Defective

controller.

• High output voltage from rectifier(s)

• Rectifier(s) high voltage shut down

• Internal

rectifier(s) failure

Possible Solution(s)

1. Remove controller and reset the rectifiers by removing the rectifiers, waiting approximately 30 seconds, and replacing the rectifiers.

2. If output voltage does not go to set-point previously set by user, call your local field representative.

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

2. If problem persists,

∗.

replace rectifier(s).

3. If problem still persists, call your local field representative.

• One or more

MAJ Contactor

Open

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output circuit breakers or fuses have opened.

• One or more LVD contactors is manually forced open.

1. Clear circuit fault(s).

2. Reset circuit breaker(s) or replace fuse(s).

1. Place disconnect switch(s) in ON position.

CPS6000-M2 Installation Guide H5694720

Controller

Status Display

MIN Battery High

Temperature

MIN Thermal

Probe Fail

No response

Power

Unit

LEDs

Dist.

Module

LED

Possible

Problem(s)

• Batteries have exceeded temperature threshold set by user.

• Battery thermal

probe failed

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

Possible Solution(s)

1. Call your local field representative.

1. Ensure thermal probe is properly connected to thermal probe cable.

2. Ensure cable is properly connected to the rear of the Distribution Module.

3. If problem persists, replace thermal probe.

4. If problem still persists, call your local field representative.

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

2. Remove the controller board for 1 minute and then reset.

3. If problem persists, replace controller with new controller board.

4. If problem still persists, call your local field representative.

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Controller

Status Display

MIN Minor

Communication Fail

MAJ Major

Communication Fail

Power

Unit

LEDs

Dist.

Module

LED

Possible

Problem(s)

Possible Solution(s)

1. Reset the rectifier by removing the rectifier, waiting approximately

• Rectifier lost communicati

(one

on with controller.

rectifier)

30 seconds, and replacing.

2. If problem persists, replace the rectifier.

3. If problem still persists, call your local field representative.

• Rectifier removed from a running system, but not uninstalled.

• LVD Board lost communicati on with the controller.

1. Issue the “uninstall equipment” under the operations menu for any rectifier that was removed.

1. Replace Distribution Module Board.

2. If problem persists, call your local field representative.

MIN Clock

Battery Low

1. The battery is not field replaceable. The controller unit must be replaced.

• Internal Lithium Battery Is Low

2. Off-load all desired information such as alarm history, statistics, and any field configuration that is different than the standard.

3. Replace controller, and upload any non-standard configuration.

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Controller

Status Display

No Alarm, but individual Shunt Currents are displayed at or above their maximum display values (≥600A for loads, ≥800A for battery)

Power

Unit

LEDs

Dist.

Module

LED

Possible

Problem(s)

• One or both of the QS871A shunt inputs is opencircuit.

Possible Solution(s)

1. Verify that the respective shunt has its green and yellow wire connections attached used for the current measurements.

2. Verify the shunt connection to the QS871A is good by verifying the green and yellow wire connections from the shunt follows through to the 10-pin connector at the respective QS871A.

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Troubleshooting Controller Circuit Pack

After power up, or after a reset, the multicolor LED (Located to the right of the MCR2 board) will be RED while self diagnostics are in progress (which will take about 10 seconds). If all diagnostics pass, the red LED will change to green. If failures are detected during diagnostics the LED will change to Amber. If a terminal is attached to the local port during diagnostics, the diagnostic messages will show which test failed. During normal operation if a failure occurs, the green LED will change to amber. When a failure occurs, perform the following steps.

Step Action

Press the reset switch (System Reset, located to the right of the serial port connector at

the bottom of the MCR1 board). If all diagnostics pass, it is possible that some type of “one time” abnormality occurred to cause the failure, such as hot-insertion of option boards, shorting connector pins when installing optional equipment, etc. If the diagnostics did not pass, or if the problem reoccurs, go to the next step. Remove all optional circuit packs then again press the reset switch on the MCR1

board. If the problem is not resolved, proceed to the next step. If all diagnostics pass, install optional packs one at a time, verifying operation after each. Replace the MCR1/MCR2 boards and verify the failure is resolved before installing

and connecting any optional circuit packs.

Modem and Data Switch Cards

The intelligent option boards (Modem and Data switch) are diagnosed by the microprocessor. If problems are detected the option board’s amber LED is lit, otherwise the green LED is lit. If the amber LED is lit, first reset the MCR1 board and see if the problem clears. If the problem reoccurs, replace the option board.

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Controller Alarm Descriptions

Alarm Description Explanation

ACO Active

Alarm Battery Supply

AC Fail

Auxiliary Major

Auxiliary Minor

Alarm Test Active

Alarm Test Aborted

Memory Backup Battery Low

Battery Type Conflict

Battery On Discharge

Battery Test Failed

Bay Interface ID Conflict

Battery Test Active

Configuration Changed

Converter Distribution Fuse

Converter ID Conflict

Alarm Cut-Off has been initiated to silence local audible alarms. Any subsequent Power Critical, Power Major, or Power Minor alarm disables ACO. A programmable ACO time-out period for each alarm severity resets silenced alarms.

Operated ABS fuse (F2) on Millennium II’s MCR1 card. A rectifier is reporting an ACF to the controller. A resistive battery potential is present on the AMJ alarm input BSL-64,

indicating a major alarm is active in the external equipment connected to this point.

A resistive battery potential is present on the AMN alarm input BSL-66, indicating a minor alarm is active in the external equipment connected to this point.

Alarm Test is currently active. Any real alarm with a severity of Critical, Major or Minor, other than RFA or HV, aborts an active Alarm Test.

Alarm Test has been aborted by an alarm. This is a latched event, remaining active until cleared by a user.

The controller memory battery requires replacement.

The DC Plant – Battery Type and Battery Management – Battery Test Class attributes (sealed vs. flooded) do not match.

The plant voltage is below the threshold set for BD in the present plant mode, FLOAT or BOOST/BTP. This alarm will not retire immediately upon rectifier restoration after an extended discharge. Plant voltage will not fully recover until depleted battery energy has been replaced. Do NOT adjust the rectifier voltage adjustments if they are at or near rated output currents.

A Battery Test was aborted before a reserve time could be established. This is a latched event, remaining active until cleared by a user.

The ID for a BIC (Bay Interface Card) connected to the controller’s serial bus is the same as that of a previously installed BIC.

A Battery Test session has been initiated. (Available only in plants with all serial rectifiers. Rectifier voltage has been lowered and the batteries are discharging.) The BD LED and BD relays are active and both the BD and VLV alarm thresholds along with STC (Slope Thermal Compensation) are inhibited while the Battery Test is active.

A change has been made to a configuration setting. This is a latched event, remaining active until cleared by a user.

A converter distribution module connected to the controller’s serial bus is reporting an operated fuse in its output distribution.

The ID for a converter connected to the controller’s serial bus is the same

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Specifications and Main Features

Frequently Asked Questions

User Manual

CPS6000-M2 Frame-Mounted Battery Plant

Table of Contents

1 Introduction

Document Objectives

Additional Product Documentation

Customer Service Contacts

2 Product Description

Architecture

Millennium II Controller

Rectifier Shelves

QS-Series Rectifiers

QS-Series Ringers

AC Input

Battery Options and Monitoring Features

DC Distribution and Battery Termination

Specifications

3 Safety

Warning Statements and Safety Symbols

Precautions

Handling Batteries

Special Installation Notes

4 Installation

Preparation

Anchoring Frame

Connecting Frame Ground

Connecting Central Office Ground (COG)

Connecting AC Utility

Installing Batteries

Installing and Wiring DC Loads

Installing QS-Series Rectifiers

Installing QS-Series Ringers

Controller Connections

Installing Optional Circuit Packs

5 Controller User Interface

Controller Display Menu Maps

Controller Defaults

Web Interface

6 Acceptance Testing

7 Troubleshooting

Troubleshooting Controller Circuit Pack

Modem and Data Switch Cards

Controller Alarm Descriptions