GE Industrial Solutions GCM3 User Manual

Galaxy Vector Controller

GCM2, GCM3

Product Manual Select Code 167-792-115 Comcode 108894403 Issue 4 January 2008

Galaxy Vector Controller

GCM2, GCM3

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.

Galaxy Vector Controller GCM2, GCM3

1 Introduction

General Information 1 - 1 Customer Service Contacts 1 - 2

Customer Service, Technical Support,

Product Repair and Return, and Warranty Service 1 - 2 Customer Training 1 - 2 On-Line Power Systems Product Manuals 1 - 2 EasyView Software 1 - 2

2 Product Description

Overview 2 - 1

Batteryless Operation 2 - 1 GCM2 or GCM3 Control Board 2 - 3 User Interface Control Panel 2 - 3 BLJ3 Terminal Connection Board 2 - 7 Control Signal Inputs 2 - 13 BLJ3 Power Connections 2 - 13 BTJ2/BTJ3 Termination Board 2 - 14 BTJ2/BTJ3 Fuses and Connectors 2 - 15

3 Operation

Office Alarm Contacts 3 - 1 Alarm Descriptions 3 - 1 System Features 3 - 9

Battery Recharge Current limit 3 - 15 Battery Discharge Test 3 - 15 Plant Generator/Battery Test (PBT) 3 - 18 Remote Access and Monitoring 3 - 18 Remote Rectifier Standby 3 - 19 Dial-out On Alarm 3 - 19

Issue 4 January 2008 Table of Contents - 1

Galaxy Vector Controller GCM2, GCM3

4 Installation and Configuration

Wiring 4 - 1 Front Panel Operation 4 - 5

View Active Alarms Mode 4 - 5

Configuration 4 - 6

Battery Discharge Test Results 4 - 11 Battery Discharge Test Enable 4 - 12 Shunt Type/Size 4 - 12 Shunt Size 4 - 13 System Float Mode Settings 4 - 13 Very Low Voltage Threshold 4 - 14 Battery Recharge Current Limit Settings 4 - 14 Battery Thermal Compensation Settings 4 - 14 Low Voltage Disconnect Contactor 1 and 2 Settings 4 - 15 Plant Boost Mode Settings 4 - 16 Converter Settings 4 - 17 Voltage Calibration 4 - 17 Reserve Operation Engine 4 - 18 Serial Bus Updating and Clearing 4 - 18 Software Release Information 4 - 18

5 Troubleshooting

Replacing Circuit Packs 5 - 1 Checking the highest battery temperature 5 - 1 Inaccurate Plant Voltage Readings 5 - 2 Temperature Probe Alarm is present 5 - 3 Unexplained Rectifier Failure Alarm and Multiple

Rectifier Failure Alarm 5 - 3

Unexplained Converter Failure Alarm and Multiple Converter

Failure Alarm 5 - 3 Rectifier Id conflict alarm is asserted 5 - 3 Converter Id (Cid) 5 - 3

6 Product Warranty

2 - Table of Contents Issue 4 January 2008

Galaxy Vector Controller GCM2, GCM3

Appendix A Communications

Modem A - 1

Port Settings A - 1 Logging in A - 2

Galaxy Gateway A - 4

Introduction A - 4 Preparation A - 5 Precautions A - 5 Tools/Equipment Required A - 6 Unpacking the Galaxy Gateway A - 6 Vector Controller Configuration A - 7 Gateway Installation for Vector Controller A - 7 Galaxy

Configuring Network Communications A - 10 Logging In to the Galaxy Gateway A - 10 Configuring Static Network Parameters A - 11 Logging Out of the Galaxy Gateway A - 12 Post Installation Procedures A - 13

Gateway Cable Connections A - 8

Appendix

Objects and Attributes B - 1

T1.317 Objects and Attributes

Commands B - 6

ala Report Active Alarms B - 6 bye Log-off B - 6 cha Change Value B - 7 login Login B - 7 ope Operate a Control B - 7 pas Change Passwords B - 7 sta Report Status B - 8 Error Messages B - 8

Appendix C Regulatory Statements

FCC Part 68 Regulatory Statement C - 1 Industry Canada Certification C - 2

Issue 4 January 2008 Table of Contents - 3

Galaxy Vector Controller GCM2, GCM3

List of Figures

Figure 2-1: Galaxy Vector Controller in a Typical GPS Plant 2 - 2

Figure 2-2: Galaxy Vector Controller in a Flexent Outdoor Plant 2 - 2

Figure 2-3: Galaxy Vector Controller GCM2 or GCM3 2 - 3

Figure 2-4: 848597563 Control Panel 2 - 4

Figure 2-5: Galaxy Vector Controller Display Menu Flow 2 - 6

Figure 2-6: Galaxy Vector Controller BLJ3 Terminal

Connection Board 2 - 7

Figure 2-7: Vector Controller BTJ2/BTJ3 Terminal

Connection Board (Used in Outdoor Systems) 2 - 14

Figure 3-1: Battery Thermal Compensation Set Points

(Standard) 3 - 11

Figure 3-2: Battery Thermal Compensation Set Points (Flexent) 3 - 12

Figure 4-1: 210E Thermistor Multiplexer Connections to BLJ3 4 - 3

Figure 4-2a: 210E Thermistor Multiplexer Connections with

847157674 Cable Set to BTJ2/BTJ3 4 - 4

Figure 4-2b: 210E Thermistor Multiplexer Connections with

8478669412 Cable Set to BTJ2/BTJ3 4 - 5

Figure A-1: BSM3 Modem Board A - 1

Figure A-2a: GPS with Metal Door and Vector Controller A - 4

Figure A-2b: GPS with Plastic Door (DA) and Vector Controller A - 5

Figure A-3: Gateway Connection to BLJ3 Terminal Board. A - 9

Issue 4 January 2008 List of Figures - 1

Galaxy Vector Controller GCM2, GCM3

List of Tables

Table 2-A: Galaxy Vector Controller Specifications 2 - 1

Table 2-B: 848597563 Control Panel Keys and Functions 2 - 4

Table 2-C: Control Panel LEDs and Functions 2 - 5

Table 2-D: BLJ3 Alarm Input Terminals 2 - 8

Table 2-E: LVD Contactor Configuration Jumpers 2 - 8

Table 2-F: LVD Drive Terminals 2 - 9

Table 2-G: BLJ3 Office Alarm Relay Output Terminals 2 - 9

Table 2-H: Battery Shunt Inputs 2 - 10

Table 2-I: Plant Voltage Sense Inputs 2 - 11

Table 2-J: J12 Jumper 2 - 11

Table 2-K: BLJ3 Control Signal Inputs 2 - 13

Table 2-L: Power Connections BLJ3 2 - 13

Table 2-M: BTJ2/BTJ3 Power Connections (J21) 2 - 15

Table 2-N: BTJ2/BTJ3 LVD1 Control Connections (J23) 2 - 16

Table 2-O: BTJ2/BTJ3 LVD2 Control Connections (J4) 2 - 16

Table 2-P: BTJ2/BTJ3 Office Alarm Relay Output

Connections (J6) 2 - 17

Table 2-Q: BTJ2/BTJ3 Thermal Input Connections (J9-J12) 2 - 18

Table 2-R: BTJ2/BTJ3 RS-232 Connections (J13) 2 - 18

Table 2-S: BTJ2/BTJ3 Display Connections (J14) 2 - 19

Table 3-A: Alarm Identification Standard Assignments 3 - 3

Table 3-B: Office Alarm Relay and Front Panel LED

Standard Assignments 3 - 4

Issue 4 January 2008 List of Tables - 1

Galaxy Vector Controller GCM2, GCM3

Table 4-A: Configuration Parameters 4 - 8

Table 5-A: Replacement Circuit Packs and Temperature Modules 5 - 1

Table B-1: Power System B - 2

Table B-2: DC Plant B - 2

Table B-3: Alarm Thresholds B - 2

Table B-4: Rectifier Management B - 2

Table B-5: Rectifiers (xx is 01 to 24) B - 3

Table B-6: Battery Reserve Management B - 3

Table B-7: Battery Sections B - 3

Table B-8: Controller Battery Temperature Channels B - 3

Table B-9: Converter Plant B - 4

Table B-10: Boost Management B - 4

Table B-11: Battery/Load Contactor B - 4

Table B-12: Slope Thermal Compensation B - 5

Table B-13: Call-Out B - 5

Table B-14: Serial Ports B - 5

Table B-15: Alarm Messages B - 6

Table B-16: Error Messages B - 8

2 - List of Tables Issue 4 January 2008

Galaxy Vector Controller GCM2, GCM3

1 Introduction

General Information

This product manual describes the Lineage Power GCM2 and GCM3 versions of the Galaxy Vector Controller. These controllers are an integral part of various Lineage Power GPS (Galaxy Power System) and OPS (Outdoor Power System) series power plants. They provide control and alarm monitoring functions over a digital serial interface that interconnects plant rectifiers and converters. Control includes the setting of converter output voltage, rectifier output voltage, current limit, high voltage shutdown, rectifier restart, sequencing and boost mode. This serial digital communication interface helps automate the installation and setup process. For example, the need to use potentiometers to separately set individual rectifier and converter output voltage levels is eliminated. Versions of the Vector Controller are available for both +24Vdc (GCM2) and 48Vdc (GCM3) plants, including the 24V Flexent Wireless™ indoor and outdoor systems and H569-453 (+24V) / H569-454 (-48V) OPS systems.

The following Lineage Power rectifiers can interface with the Galaxy Vector Controller:

Model Vdc Current

570A -48V 100A 595A, 595B, 595C -48V 200A 596A / 596D -48V 50A / 100A 596B +24V 100A / 125A 596F (Flexent) +24V 100A NP -48 24-50A

Note: The Galaxy to Rectifier protocol supports many different features and variables. Not all rectifiers support the complete feature set.

Issue 4 January 2008 Introduction 1 - 1

Galaxy Vector Controller GCM2, GCM3

In addition to rectifier and converter control, the Vector Controller provides:

• Visual alarm and plant status on the user front panel display assembly

• Form C or transfer type contacts for the various alarm conditions for external use

• Modem or network interface

• Low voltage battery disconnect

This manual describes the basic features, operation, installation and configuration, acceptance testing, troubleshooting, and repair of the Galaxy Vector Controller.

Customer Service Contacts

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

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

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

Customer Training Lineage Power offers customer training on many Power Systems

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

Downloads and Software

To download the latest product information, product software and software upgrades, visit our web site at http://www.lineagepower.com

1 - 2 Introduction Issue 4 January 2008

Galaxy Vector Controller GCM2, GCM3

2 Product Description

Overview The Galaxy Vector Controller is mounted on the inside front

door of a GPS plant with the user interface panel accessible from the front of the door. See Figure 2-1. In the Flexent Outdoor system, the controller is installed behind a swing-out control/ display panel. See Figure 2-2. Basic controller specifications are summarized in Table 2-A.

Table 2-A: Galaxy Vector Controller Specifications

GCM2 GCM3

Input voltage range 19 - 30V 36 - 60V

Maximum input power 4.5W

Form C Alarm contact ratings 60V at 0.3A Plant voltage measurement accuracy

(±.05% of full scale + 1 count)

Plant voltage measurement resolution .01V

Plant current measurement accuracy ±1% of full scale

Plant current measurement resolution 1A

Thermistor temperature measurement accuracy

Operating temperature range -40°C to +85°C

±30mV ±40mV

• ±3°C for battery temperatures from -5°C to +55°C

• ±5°C for battery temperatures from -10°C to -5°C

• ±5°C for battery temperatures from +55°C to +85°C+

Batteryless Operation The Vector Controller is suitable for use in power plants with or

without batteries. In batteryless plants, the loss of ac power causes an immediate loss of dc power to the controller and the activation of all office alarm relays. When ac power is restored, plant rectifiers will return to their last specified voltage set point, and the controller will automatically return to its last configuration.

Issue 4 January 2008 Product Description 2 - 1

Galaxy Vector Controller GCM2, GCM3

GCM

BLJ3

LCD Display Assembly

Inside of Cabinet Door

Figure 2-1: Galaxy Vector Controller in a Typical GPS Plant

BTJ2 Board

Controller Display (shown in open position)

Vector Controller

Figure 2-2: Galaxy Vector Controller in a Flexent Outdoor Plant

2 - 2 Product Description Issue 4 January 2008

Galaxy Vector Controller GCM2, GCM3

GCM2 or GCM3 Control Board

Figure 2-3 shows the Galaxy Vector Controller board. This board consists of an embedded microcontroller, A/D converters, timers, memory, and input/output alarm and control circuitry with connections to the terminal connection boards. There are two versions of the control board: GCM2 for +24V systems, and GCM3 for -48V systems. IC27 is the memory IC that contains the firmware which determines the controller operation, and the preset voltage and temperature thresholds for plant operation. Software is updated by replacing IC27. A simpler upgrade method is to replace the controller board. This avoids directly handling, and possibly causing damage to the memory IC. There are no hardware user-configurable items on the GCM boards.

IC27 - Peripheral Support and Memory IC

IC1 - Microcontroller

User Interface Control Panel

J1 J3

OUT-

OUT+

Figure 2-3: Galaxy Vector Controller GCM2 or GCM3

Figure 2-4 shows a view of the 848597563 user interface control panel. This assembly interfaces with the BLJ3 or BTJ2/BTJ3 connection boards via a 26 pin ribbon attached to P2. The 848597563 provides a comprehensive user interface to the controller. It is used to view plant voltage and load, configure thresholds and other system parameters, view active alarms and to initiate system operations. This interface consists of a 4 line x 20 alphanumeric character LCD, a nine key keypad, and three status LEDs. A standard DB9 connector is available for local terminal access, or remote access using an optional BSM3 modem board. The modem board also provides isolation to the local terminal connection. Note: If the BSM3 is not connected

J1 and J3 - Connect to BLJ3 or BTJ2 Boards

Issue 4 January 2008 Product Description 2 - 3

Galaxy Vector Controller GCM2, GCM3

then the local port is referenced to the battery side of the power system. Some teminal connections are referenced to true ground. For these cases, a commercially available external port isolation device is required. The BSM4 may also be purchased to internally perform this isolation.

Galaxy Vector Controller

Figure 2-4: 848597563 Control Panel

Four softkeys are located directly to the left of the display. The labels and functions of these buttons change dynamically as you make selections and perform system operations. Softkey labels appear in the display window and are preceded by a "←".

+27.74V 820A FLOAT-COMPENSATED CUTOFF View Alarms (5)

AUDIBLE ALRM

Four navigation keys (up, down, left, and right arrow keys) are located to the right of the display. These keys are used to navigate through the controller menus.

The home key, located directly to the left of the four softkeys, brings you:

• to the main menu from the default screen or any sub-menu

• to the default screen from the main menu

Table 2-B lists the user interface control panel keys and functions.

Table 2-B: 848597563 Control Panel Keys and Functions

Key Function

Softkeys

Left and Right

Arrow Keys

Up and Down

Arrow Keys

Home Key Return to top level of menu structure or default screen

Move through the various features and menu structure of the controller

Move through digits in edit screens

Scroll or select a configuration option or value in an edit screen

2 - 4 Product Description Issue 4 January 2008

Galaxy Vector Controller GCM2, GCM3

Three alarm status LEDs give a visual indication of system status. The Major and Minor alarm LEDs indicate when alarms are present, and then the actual alarm descriptions can be displayed on the LCD by pressing the Alarms softkey. LED indications are described in Table 2-C.

Table 2-C: Control Panel LEDs and Functions

LED Indication

MAJOR (red)

MINOR (amber)

OK (green)

A Major alarm is active. If the MAJOR LED is lit, MINOR and OK LEDs will not be lit.

A Minor alarm is active. If the MINOR LED is lit, there are no Major alarms active and the MAJOR and OK LEDs will not be lit.

No alarms are active. If the OK LED is lit, MAJOR and MINOR LEDs will not be lit.

The default screen displays system voltage and current, system mode (FLOAT or BOOST and other system conditions), and any active alarms. The display will return to the default screen from any menu whenever there has been no user initiated activity for three minutes.

All power system attributes are characterized into three main categories by the Vector Controller:

•Status

• Operations

• Configuration

as shown in Figure 2-5. Under Configuration are all of the system parameters that can be edited.

Configuration edit screens have values and settings that can be customized. There are two types of edit screens, numeric and scroll lists. Numeric edit screens are those on which you modify numbers by changing the individual digits in the number. An example is the Float Set Point screen. Scroll list edit screens are modified by pressing the UP and DOWN buttons to scroll through a list of possible settings. These lists may include numeric values or text. Selecting a Shunt Type is an example of a scroll list edit.

Issue 4 January 2008 Product Description 2 - 5

Main Menu

View Status

Galaxy Vector Controller GCM2, GCM3

Battery Test Results

Batteries

Converters

Rectifier Current

Current

Temperature Probes

TYPE

VOLTAGE

CURRENT

Float Voltage Alrms

HIGH MAJOR

HIGH MINOR

BD MAJOR

LOW MAJOR

Control/

Operations

Configuration

Alarm Thresholds

Enable/Disable

Info

SOFTWARE VER

Float Voltages

Rectifiers

Shunts

Batteries

Contactors

Converters

Boost

Communication

Ports

Calibrate to Meter

Boost Voltage Alrms

BATT TEMP MJ

Start/Stop

Battery Test

Start

Lamp Test

Update Serial Link

Start/Stop Boost

Set Point

Voltage Alarms

Current Limit

No. On Engine

Type

Shunt 1 Rated

Shunt 2 Rated

Type

Batt Test Enable

Batt Temp

Management

Limit Recharge

Contactor 1

Contactor 2

Set Point

Shutdown At

Shutdown Enable

Restart At

HIGH MAJOR

HIGH MINOR

BATTERY TEST

BOOST FEATURE

AUTO BOOST

CONV SHUTDOWN

TEMP COMP

LOW TEMP COMP

RECHARGE LIMIT

High Major

High Minor

BD Major

Low Major

Temp Alarm

Temp Compensation

Limit Enable

Limit At

Boost Enable

Set Point

Boost Voltage Alrms

Auto Boost

Manual Dur

Boost Current Lmt

Local Port

Modem Port

System Voltage

Converter Voltage

Temp Comp Enable

High Temp Comp

Nominal Temp

Low Temp Comp

High Major

High Minor

Auto Boost Enable

Auto Duration

Baud Rate

Handshake

Baud Rate

Handshake

Rings to Answer

Figure 2-5: Galaxy Vector Controller Display Menu Flow

2 - 6 Product Description Issue 4 January 2008

Galaxy Vector Controller GCM2, GCM3

BLJ3 Terminal Connection Board

Fuses

Power In/Out

Shunts 1 and 2

Unused

Alarm Outputs

Thermal Inputs

Figure 2-6 shows the BLJ3 Terminal Connection Board. Not all BLJ3 terminals are used by the Vector Controller. The following pages describe the required connections.

Contactors

Vector Controller

Vector Controller Board

Board Not Shown

(GCM2, GCM3)

System Configuration

DIP Switches

Plant Voltage

Regulation Input

Alarm Inputs

Unused

Bay

Alarm Out

Unused

To Rectifiers

Unused

To Modem/

Gateway/

Local Terminal

26 Conductor

Ribbon Cable

Front Panel

Control/Display

1S12345678

S1.1: Front Panel Configuration

- Enabled (shown)

- Disabled

S1.2: Software Mode

- Standard (shown)

- Flexent Default Configuration Parameters

1,2

S1.3: Option Card Availability

- Modem

- Galaxy Gateway Card (Internet)

1. Setting both SW1.2 and SW1.5 to "1" will result in activating the HV alarm cont act.

2. SW1.2 setting will only be read by the software when the GCM is powered up.

3. HV alarm contacts used for 2ACF alarm instead of HV alarm.

S1.4: Rectifier Class

01- Standard GPS Rectifiers

- NP Rectifiers

S1.5: Alarm Contact Select

- Standard HV, High Voltage

- VLV, Very Low Voltage

S1.6: - Set to 0

S1.7: Power Battery Test

- Disabled (shown)

- Active

S1.8: - Set to 0

Figure 2-6: Galaxy Vector Controller BLJ3 Terminal Connection Board

Issue 4 January 2008 Product Description 2 - 7

Galaxy Vector Controller GCM2, GCM3

SH3+, SH3-, SH4+, SH4-, V2+, V2-, V3+, V3-, V4+, V4-, B1, B2, M1, M2: These input terminals are not used by the Vector

controller.

Alarm input (IN1 - IN12): Basic office and contactor state alarm inputs. Individual pin descriptions are shown in Table 2-D.

Table 2-D: BLJ3 Alarm Input Terminals

Terminal Name

IN1 FAJ Closure to Batt Fuse major alarm input

IN2 FAN Not used

IN3 OS Not used

IN4 MAINT Open to Batt Maintenance (open connector)

IN5 AMJ Closure to Batt Auxiliary major alarm input

IN6 AMN Not used

IN7 LVD1C Not used

IN8 LVD2C Not used

IN9 LVD3C Not used

IN10 LV D1 O Closure to Batt

IN11 LVD 2O Closure to Batt

IN12 LV D3 O Not used

Alarm

Asserted

Description

Low voltage disconnect contactor 1 open status input

Low voltage disconnect contactor 2 open status input

J1, J2, J3: LVD1, LVD2, and LVD3 contactor configuration jumpers used to detect the presence of contactors. Table 2-E shows configuration information.

Table 2-E: LVD Contactor Configuration Jumpers

Jumper Across Pins 1 and 2 Across Pins 2 and 3

J1 LVD1 present LVD1 not present

J2 LVD2 present LVD2 not present

2 - 8 Product Description Issue 4 January 2008

LVD3 present

(not available)

LVD3 not present

(default for GCM)

Galaxy Vector Controller GCM2, GCM3

LVD1, LVD2, LVD3: Form C relay contact outputs for LVD contactor control. These terminals are connected to BJN contactor drive boards. LVD1 and LVD2 contacts are rated for 2 amps. LVD3 is not available in GCM controller applications. Table 2-F shows relay state information.

Table 2-F: LVD Drive Terminals

Terminal

Contactor Relay O C R

LV D1 K1

Normally open contact

LV D3 K3

Normally closed contact

Return (common)LV D2 K2

Office alarm relay outputs: All alarm output relays are isolated Form C or transfer type contacts, consisting of normally open (NO) and normally closed (NC) contacts, with a common return (RTN) contact. The de-energized state of these relays is the alarm state. An alarm condition results in a closure of the normally closed contact to the return contact, and an open between the normally open and return contacts. Individual relay pin descriptions are shown in Table 2-G.

Table 2-G: BLJ3 Office Alarm Relay Output Terminals

Terminal

Alarm Relay Alarm Description C O R

PMN K4 Power Minor

MJF K5 Major Fuse

BD K6 Battery on Discharge

ACF K7 Single AC Fail

High Voltage /

HV/2ACF/VLV* K8

PMJ K9 Power Major

* Relay assignment is determined by the settings of S1.2 and S1.5:

HV alarm S1.2-0, S1.5=0 2ACF alarm S1.2=1, S1.5=0 VLV alarm S1.2=0, S1.5=1 Setting both switches to 1 results in activating HV. The S1.2 setting is only read during GCM power up.

Multiple AC Fail / Very Low Voltage

Normally open contacts.

Closed to R when alarm condition exists.

Normally closed contacts.

Open to R when alarm condition exists.

Return (common)

Issue 4 January 2008 Product Description 2 - 9

Galaxy Vector Controller GCM2, GCM3

BAT: Connection to the battery discharge bus for controller power, and fused through F2 (1 1/3A). It is +24V for the GCM2, and -48V for the GCM3.

ABS: Auxiliary Battery Supply: connection to the battery discharge bus for user application (four terminals available), and fused through F1 (2A).

DG: Connection to battery return (discharge ground) bus. DG (five terminals available) provides the return for BAT (controller power), and ABS user applications if required.

Battery shunt inputs: The GCM recognizes two of the four available shunt inputs on the BLJ board. Shunt inputs are 50mv full scale. The BLJ3 requires 100K 1% resistors in series

with the shunt. See Table 2-H.

Table 2-H: Battery Shunt Inputs

Terminal Signal Name Description

SH1+ Shunt1+

SH1– Shunt1–

SH2+ Shunt2+

SH2– Shunt2–

Note: When no shunt is available to connect to Shunt 2 inputs, the Shunt 2 inputs must be jumpered together. When both shunts are used, they must both be configured as “Load” or “Battery” shunts. They cannot be mixed.

The more positive lead of a battery shunt during discharge

The more negative lead of a battery shunt during discharge

The more positive lead of a battery shunt during discharge (See note)

The more negative lead of a battery shunt during discharge (See note)

2 - 10 Product Description Issue 4 January 2008

Galaxy Vector Controller GCM2, GCM3

Voltage Sense Inputs: The GCM recognizes one of the four voltage sense inputs on the BLJ board. Sense inputs are 50mv full scale. Each of these leads should be fused at the source. See Table 2-I.

Table 2-I: Plant Voltage Sense Inputs

Terminal Signal Name Description

V1+ Vsense+

V1- Vsense–

Positive remote voltage regulation sense point for GCM.

Negative remote voltage regulation sense point for GCM.

J12: This jumper is factory set, and determines the controller ground (CG) reference. The controller ground reference is set according to the location of the plant shunts being monitored. If the shunts are located in the Battery side of the DC bus then J12 should be set to position 1-2. If the shunts are located in the Discharge Ground (DG) side of the DC bus then J12 should be set to position 2-3. For +24V and -48V GPS, J12 should be set to position 1-2.

Table 2-J: J12 Jumper

Jumper +24V System -48V System

J12 Across pins 1 and 2

Thermal probe connections: Four thermistor or 210E module inputs. Each thermistor is connected to the RTH#+ and RTN#, where # = 1 through 4. A strap is required across RTH#+ and EN#+ for each thermistor input used. The strap is not required when using 210E modules. For the indoor system, the thermal probe and cable are factory installed.

RTH ALM, RTH ALMR: Thermistor alarm input and return from 210E module. See Section 4 for 210E module connections.

CG: Controller Ground is the GCM reference ground, and should be connected to the bus on which shunt(s) are mounted. This pin should be used to reference the 210E ground to the Vector Controller ground.

Issue 4 January 2008 Product Description 2 - 11

Galaxy Vector Controller GCM2, GCM3

TPT1, TPT2: Thermistor protected test points for access to system voltage.

LAMP, LAMPR: The LAMP terminal is used to send battery voltage to the bay lamp. LAMPR is the LAMP return, and is connected to DG.

P2: 26 pin connector to the user interface control panel (848597563).

P1, P3: Two 96 pin connectors on which the GCM board mounts.

J7: A RJ45 connector for the serial rectifier interface.

J4: For the Vector Controller function, these jumpers must be

used to short each C and R pin on the J4 and J11.

P4: RS-232 serial communication port used with the optional BSM3 modem board or the EBW1 Gateway board (see Appendix A).

2 - 12 Product Description Issue 4 January 2008

Control Signal Inputs

Galaxy Vector Controller GCM2, GCM3

Table 2-K: BLJ3 Control Signal Inputs

BLJ3 Power Connections

(+) PWR Controller BAT F2 Charge Bus (Rectifier bus)

(-) PWR Controller DG Discharge Return Bus

LVD power #1 See note 1 NA Charge Bus (Rectifier bus)

LVD power #2 See note 1 NA Battery Bus

Aux. Bat. Source

Note 1: LVD control power, from the power buses for the indoor system, is connected to the BJNx LVD controller board Note 2: BLJ3 user available fused (F1) power terminations are labeled ABS. DG terminations are also provided for user termination on the BLJ3. These terminations are labeled DG.

Description

Control Signal

Name

RO Reserve Operation closure to BAT

PBT Power Battery Test closure to BAT

Description Indoor Input Connection

Power connections from the system to the BLJ3 (factory wired).

Table 2-L: Power Connections BLJ3

Input

Termination

ABS

See note 2

Associated

Fuse

F1 NA

Plant Termination

Issue 4 January 2008 Product Description 2 - 13

Galaxy Vector Controller GCM2, GCM3

BTJ2/BTJ3 Termination Board

LVD 1

J23

ALARM

OUT

Fuses

F1 F2 F3 F4 F5

J21

Figure 2-7 shows the BTJ2 (+24V) or BTJ3 (-48V) termination board used as the terminal and controller interface for Vector outdoor power systems. S1 is the system configuration DIP switch.

J2 J27

AMJ (BATT FUSE)

LVD 2

Vector Controller Board

(GCM2, GCM3)

LVD Forced Closed LED

FAJ

(DIST)

TEMPERATURE PROBES

#2 #3 #4

RS232

CONNECTION

J13

DISPLAY J14

PWR

S1.1: Front Panel Configuration

- Enabled (shown)

- Disabled

S1.2: Software Mode

- Standard (shown)

- Flexent Default Configuration Parameters

S1.3: Option Card Availability

- Modem

- Galaxy Gateway Card (Internet)

S1.4: Rectifier Class

01- Standard GPS Rectifiers

- NP Rectifiers

1. Setting both SW1.2 and SW1.5 to "1" will result in activating the HV alarm cont act.

2. SW1.2 setting will only be read by the software when the GCM is powered up.

3. HV alarm contacts used for 2ACF alarm instead of HV alarm.

J4 J28 J9 J10 J11 J12

1S12345678

1,2

1 0

S1.5: Alarm Contact Select

- Standard HV, High Voltage

- VLV, Very Low Voltage

S1.6: - Set to 0

S1.7: - Set to 0

S1.8: Low Voltage Disconnect

- Controller Controlled (shown)

- Manual Force Closed

Figure 2-7: Vector Controller BTJ2/BTJ3 Terminal Connection Board

(Used in Outdoor Systems)

2 - 14 Product Description Issue 4 January 2008

Galaxy Vector Controller GCM2, GCM3

BTJ2/BTJ3 Fuses and Connectors

All fuses are 5A.

• F1 – GCM Controller power

• F2 – Regulation battery fuse (Vsense)

• F3 – LVD power from Charge Bus (Rectifier)

• F4 – LVD power from Battery Bus

• F5 – Spare

Power connections: Power and sense connections from the system to the BTJ2/BTJ3 are shown in Table 2-M.

Table 2-M: BTJ2/BTJ3 Power Connections (J21)

Number

1 Shunt 1 (Chg)

2 NC

3 NC

4 Shunt 2 (Chg) Reserved for future use

5 NC

6 NC

8 Shunt 1 (Disch)

9 DG Controller power input ground

10 Vsense (Grd) Connection to DG bus, remote sense

11 Shunt 2 (Disch) Reserved for future use

14 Vsense (Chg) Connection to the charge bus, remote voltage sense

Signal Name Description

Connection to battery shunt terminal nearest charge bus (rectifier bus)

Controller

Power

LVD Battery

Bus

LVD Charge

Bus

Controller power input connection to the charge bus (rectifier bus)

Connection to the battery shunt terminal nearest the batteries

Battery bus power for LVD circuitry on the BTJ2/ BTJ3

Charge bus power for LVD circuitry on the BTJ2/ BTJ3

J2: RJ45 connector for rectifier communication. Pins 1 and 2 are the communication pair. Pin 3 is isolated ground. Pin 4 is chassis ground. All rectifiers are connected to this connector in a daisy chain fashion.

Issue 4 January 2008 Product Description 2 - 15

Galaxy Vector Controller GCM2, GCM3

J23: LVD1 control.

Table 2-N: BTJ2/BTJ3 LVD1 Control Connections (J23)

Number

1 LV D _N O Form-C output (see Note)

2 LVD_C Form-C output (see Note)

3 LVD_NC Form-C output (see Note)

4 Coil Controlled bus voltage to contactor coil

5 Maint RTN Current limited bus voltage for Maint alarm

6 Maint IN Maintenance alarm input

7 LVD1 RTN

8 LVD 1 S t ate Low voltage disconnect signal

Note: These outputs can be used to drive an external contactor board if

Signal Name Description

Current limited bus voltage for LVD1 state (LVD open alarm)

J15-17 are jumpered in the 2-3 position.

J4: LVD2 control.

Table 2-O: BTJ2/BTJ3 LVD2 Control Connections (J4)

Pin Number Signal Name

1 LVD2_NC

2 LVD2_C

3 LVD2_NO

4 NC

5 LV D2 _S TATE

6 NC

7 NC

8 NC

9 NC

10 NC

J5: Not used.

2 - 16 Product Description Issue 4 January 2008

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