GE Industrial Solutions GPS2436 User Manual
GPS2436 (H5692436)
User’s Guide
GPS2436 is available with Galaxy Millennium II or Galaxy Pulsar Plus controllers.
This manual is based on and includes information specific to the Galaxy Millennium II controller.
Refer to these documents for information specific to the Galaxy Pulsar Plus controller
• Galaxy Pulsar Plus Product Manual CC848815341
• GPS2436 Ordering Guide H5692436.
Product Manual
Comcode
850022020
Issue 1
August 2012
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.
© 2012 GE Energy
All International Rights Reserved
Printed in U.S.A.
Galaxy Power System GPS2436
Table of Contents
1 Introduction ....................................................................................................... 5
GPS2436 ..................................................................................................................... 5
Customer Service Contacts ........................................................................................ 6
2 System Description ............................................................................................. 7
Overview .................................................................................................................... 7
Architecture ............................................................................................................... 9
3 Galaxy Millennium II Controller ........................................................................ 13
Overview .................................................................................................................. 13
4 Rectifiers .......................................................................................................... 17
NE100AC24ATEZ ...................................................................................................... 17
5 AC Input Panels ................................................................................................ 21
Overview .................................................................................................................. 21
6 Battery Connection Panels ................................................................................ 23
Overview .................................................................................................................. 23
7 DC Distribution Panels ...................................................................................... 25
Function ................................................................................................................... 25
9 External Return Bars ......................................................................................... 33
Overview .................................................................................................................. 33
10 Millennium II Controller Operation ................................................................... 37
Controller Connections ............................................................................................ 39
Installing Circuit Packs ............................................................................................. 40
Thermal Probes ........................................................................................................ 44
USB Interface ........................................................................................................... 44
Local Port ................................................................................................................. 45
Wiring Alarm Outputs .............................................................................................. 45
Wiring Alarm and Control Inputs ............................................................................. 48
Fuses ........................................................................................................................ 51
Front Panel Display .................................................................................................. 51
Controller Defaults ................................................................................................... 55
Controller Display Menu Maps ................................................................................ 62
11 Acceptance Testing ........................................................................................... 74
Introduction ............................................................................................................. 74
Tools and Test Equipment ....................................................................................... 74
Test Precautions ....................................................................................................... 74
Test Sequences ........................................................................................................ 75
12 Circuit Boards ................................................................................................... 83
Overview .................................................................................................................. 83
13 Specifications ................................................................................................... 85
GPS2436 ................................................................................................................... 85
Rectifier .................................................................................................................... 87
3 Safety ............................................................................................................... 90
Safety Statements .................................................................................................... 90
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14 Maintenance and Replacement ........................................................................ 92
Requirements ........................................................................................................... 92
Rectifier Installation and Replacement Procedures ................................................ 93
15 Troubleshooting Procedure .............................................................................. 94
Preliminary ............................................................................................................... 94
Troubleshooting Procedure ..................................................................................... 95
16 Product Warranty ............................................................................................. 96
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Galaxy Power System GPS2436
1 Introduction
GPS2436
Lineage Power developed the Galaxy Power System GPS2436 to support +24 volt
telecommunications powering solutions in worldwide markets. The GPS2436 combines
100-ampere, fan-cooled, switchmode rectifiers, microprocessor control technologies,
battery and load disconnect/reconnect options, and a comprehensive line of fuse and
circuit breaker dc distribution options in a modular front-access design. This modularity
ensures easy access, simplified installation and maintenance, and allows the system to
expand in capacity as power needs grow.
With 2000-ampere maximum capacity, distribution flexibility, and universal ac input
capability, the GPS2436 supports switching, transmission, and wireless applications in
central office locations and environmentally controlled remote sites (huts or vaults).
The main emphasis of this manual is to provide a general product description that will
familiarize the user with the main components of the system and to provide guidelines
for the basic maintenance of this Galaxy Power System.
GPS2436 is available with Galaxy Millennium or Galaxy Pulsar Plus controllers.
Both controllers provide many advanced functions and features, including;
• Alarm Detection, Identification, and Reporting
• System and Component Status
• System and Feature Configuration
• System Alarm Thresholds
• Battery Management (Slope Thermal Compensation/Recharge Current Limit)
• Battery discharge testing
• Reserve Time Prediction
• Float/Boost Mode Control
• Low Voltage Disconnect Management
• Remote Access Control And Multiple Level Password Security
• History
• Statistics
This manual is based on and includes information specific to the Galaxy Millennium II controller.
Refer to these documents for information specific to the Galaxy Pulsar Plus controller
• Galaxy Pulsar Plus Product Manual CC848815341
• GPS2436 Ordering Guide H5692436.
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Galaxy Power System GPS2436
Customer Service Contacts
Customer Service, Customer Training, Technical Support, Product Repair and Return, and Warranty Service
For customers in the United States, Canada, Puerto Rico, and the US Virgin Islands,
please dial +1 877 546 3243 (877 LINEAGE) or for all other countries, please call +1 972
244 9288. This number is staffed from 7:00 am to 5:00 pm USA Central Time Zone (GMT
-6), Monday through Friday, on normal business days. At other times, this number is still
available, but for emergencies only. Services provided 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
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.
On-Line Power Systems Product Manuals and Software
Power Systems product manuals and software are available on-line. Software includes
Easy View and SNMP MIB.
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Galaxy Power System GPS2436
2 System Description
Overview
Block Diagram
A basic block diagram of the Galaxy Power System 2436 is shown in Figure 2-1. It illustrates the arrangement and interconnection of the system components from the ac input to the dc output.
Figure 2-1 Block Diagram of the GPS2436
System
The power system accepts alternating current from the commercial utility or a
standby ac power source and rectifies it to produce dc power for the using
equipment. The system’s control and alarm functions interact with the
rectifiers and the office. In addition, the system provides overcurrent
protection and charge, discharge, and distribution facilities. Battery reserve is
connected in parallel and automatically provides a source of dc power if the
commercial or standby ac fails. Battery reserve can be engineered to supply
dc power for a specific period of time. In normal practice, battery capacity is
sized to provide 3 to 8 hours of reserve time.
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Galaxy Power System GPS2436
Components
AC Input connects the commercial and/or standby ac power sources to the
rectifiers within the system and provides overcurrent protection. In some
applications the ac service is wired directly to the rectifiers and overcurrent
protection is provided at the service panel.
Rectifiers convert an ac source voltage into the dc voltage level required to
charge and float the batteries and to power the using equipment.
Controller provides the local and remote control, monitoring, and diagnostic
functions required to administer the power system.
Batteries provide energy storage for an uninterrupted power feed to the
using equipment during loss of ac input or rectifier failure.
DC Distribution Panel provides overcurrent protection, connection points for
the using equipment, and bus bars used to interconnect the rectifiers,
batteries, and dc distribution.
Battery Connection Panel provides connection points for the battery strings
through battery disconnect fuses or contactors and current monitoring
shunts.
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Architecture
Configurations
The GPS2436 is a 7-foot cabinet that can provide up to 3600 amps of DC
power in a single cabinet. Figures 2-1 and 2-2 show diagrams of single
cabinets.
Each cabinet contains ac distribution, dc distribution panels, a battery
connection panel, rectifiers, termination points for load circuits, and a system
controller.
Illustrations
Figure 2-3 shows a block diagram of a two cabinet system. One supplemental
cabinet may be added to grow the system to 2,700 amperes. The rectifier
output buses are interconnected to permit the cabinet to share current and
ensure common voltage references for all system rectifiers.
Figure 2-2 Cabinet schematic
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Galaxy Power System GPS2436
Control
and
Monitor
To LoadsTo Loads
Battery
String
Battery
String
ACAC
Controller
Rectifier
Battery
Distribution
Rectifier
Battery
Distribution
Cabinet
Rectifier
Battery
Distribution
Cabinet
AC
Ground
AC
Ground
Cabine
Ground
Cabinet
Ground
To Loads
Battery
String
AC
AC
Ground
Cabinet
Ground
System (CO)
Ground
Shared DC Pow erShared DC Pow er
Figure 2-3 Schematic of two-cabinet system architecture
Figure 2-4 Schematic of Three-cabinet System Architecture
1800A Maximum per system.
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AC P anel
Circuit Breakers or
Terminal strip
Rectifier S helves
3 , 6, or 9
Mis cellan eous DC
Distr ibution Panels
Figure 2-4 GPS2436 Six shelf cabinet with door removed
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3 Galaxy Millennium II Controller
Overview
Introduction
The GPS2436 comes equipped with the Galaxy Millennium II Controller. This
section describes the controller operation and general information about the
features of the front panel keys, LEDs, and display.
The Galaxy Millennium II Controller provides advanced local and remote
monitoring and data acquisition features. The controller monitors system
parameters; such as, system voltage and current, and components; such as
rectifiers, and distribution circuits. The controller reports the status and issues
appropriate alarms in the event a failure occurs.
User Interface
and Display
Each cabinet is equipped with a bay interface card (BIC). The BIC acts as an
interface to the cabinet control and alarm signals.
The Millennium II’s primary user interface is a backlit LCD front panel display
that can be viewed in English or Spanish, two rows of LEDs, an array of
pushbutton keys, and a pair of test jacks.
Figure 4-1 illustrates the front panel.
Default Display
The default display shows basic system status; system voltage, load current,
and plant state. The controller returns to this display approximately three
minutes after a key is pressed. The information on the screen is updated
automatically approximately every two seconds.
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The default screen displays the following: The first line shows the number of
alarms and warnings present in the system, the date, and the time. The next
two lines show the system voltage and the system load. The last line shows
the system mode, which can be one of the following:
• FLOAT
• BOOST
• STC (Slope Thermal Compensation)
• BATT TEST
LEDs
Two rows of LEDs show the source and severity of various alarms. An alarm
lights one status LED and one or more alarm LEDs. If more than one alarm LED
lights, only the status LED of the most severe alarm will light.
• The first row includes four LEDs, labeled Alarm Status. They indicate the
severity of the reported alarm:
Test Jacks
Critical
Major
Minor
Normal
The Battery on Discharge LED is also in this row.
• The second row has seven LEDs, labeled Equipment Status. They
indicate the source of the alarm:
AC System
Battery
Controller
Distribution
Rectifier
Remote Modules
The Modem LED illuminates when the internal modem is in use.
A pair of test jacks allows direct measurement of the dc bus sense voltage
being monitored by the controller.
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Galaxy Power System GPS2436
Pushbutton Keys
A group of pushbutton keys below the backlit LCD display provides the
primary user interface with the controller. These keys are used singly or in
combination to navigate through the controller’s menus.
The following is a general description of the pushbutton keys:
• ESCAPE: Return to the immediate higher level menu.
• HELP: Displays limited on-line help information.
• MENU: View the MAIN menu.
• ENTER: Select a menu item.
• Up arrow: Moves the cursor up one line.
• Down arrow: Moves the cursor down one line.
Access Panel
• Left arrow: Moves the cursor left one field.
• Right arrow: Moves the cursor right one field.
• + and -: Increase or decrease parameter values.
• Lamp test: Tests the controller’s circuit board LEDs and front panel LEDs. It will
also test the indicators of serially connected rectifiers.
A rubber flap can be opened to access the local port connector. The DB-9 local
port connector supports standard RS232 serial communication. Refer to the
Galaxy Millennium II Controller product manual for additional details on port
configuration and isolation.
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Reference Material
Controller Product
Manuals
The Galaxy Millennium II Controller product manual (Comcode 108994645) is
available. Refer to this manual for information regarding configuration and
operation.
RPM System
Product Manual
Refer to the Galaxy Remote Peripheral Monitoring System product manual
(Comcode 107570517) for additional information regarding RPM module
operation.
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4 Rectifiers
NE100AC24ATEZ
Overview
The NE100AC24ATEZ Series rectifier (100A) operates from single-phase ac
service with a phase-to-phase voltage within the range of 95-275Vac.
The rectifiers are shipped separately from the cabinets for quick and
straightforward installation into rectifier shelves at the site. Interconnections
to ac input, dc output, and control signals occur automatically during
insertion. No settings or adjustments to potentiometers are necessary.
The NE100AC24ATEZ rectifiers are UL Recognized for both the U. S. and
Canada, comply with UL1950 (Information Technology Equipment), and meet
EN60950 requirements.
Front Panel Display
Status Indicators
Three LEDs on the rectifier’s faceplate indicate the rectifier’s condition.
• The Norm LED is green and is lit when the rectifier has AC input present and is
working properly.
• The ACF LED is amber and is lit when there is no AC input present to the
rectifier.
• The Fail LED is red and is lit if there is a failure in the rectifier.
Lamp Test
To test the LEDs on the rectifier front panel, press the Lamp Test button on
the controller.
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Galaxy Power System GPS2436
Features
Output Current “Walk-in”
This circuit controls the time (up to eight seconds) required for the rectifier to
reach normal operating conditions after it is turned on. This feature minimizes
the starting surge on the customer's power source.
Output Protection
Rectifier is equipped with an internal fuse for plant protection if a fault occurs
in a rectifier.
Electronic Current Limit
When the output current tends to increase above the current limit set point,
the current limit circuit overrides the voltage regulating signal and safely limits
the output current of the rectifier, thus preventing damage to itself or the
load.
High Voltage Shutdown (HVSD)
The rectifier senses the voltage at its output terminals. If this voltage is too
high, the rectifier will shut down to prevent the high voltage from damaging
itself or the load.
Restart
Upon shutdown, the rectifier will attempt to restart. The rectifier will also
accept a restart command from the controller for a remote restart. The
rectifier will attempt to restart three times before issuing a rectifier fail alarm
to the controller.
Fan Alarm and Control
The rectifier contains a cooling fan. The fan’s speed, which is based on
ambient temperature and output power level, is lowered during low-load and
low-temperature conditions to minimize audible noise and maximize fan life.
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Thermal Alarm
The rectifier senses the internal operating temperature and will issue a
thermal alarm if the internal temperature exceeds a safe operating level.
Ambient temperatures above the maximum rating will result in a rectifier
shutdown and the issuing of a thermal alarm (TA).
Autonomous Operation
Rectifiers will continue to power the load if the controller fails or if
communication is lost.
Controller Communications Alarm
When communications between the rectifier and controller are interrupted,
the rectifier continues to operate and the red Fail LED on the rectifier blinks.
Connectorized
“Forced” Load
Sharing
The rectifiers provide the controller with a full complement of status and
alarm signals. The rectifier status and alarm signals, ac input, and dc output
are all connectorized for easy installation and maintenance. System
connections are made when the rectifier is plugged into the shelf. No
additional connections are required.
Internal rectifier circuitry will allow rectifiers to share load in the event
communication to the controller is lost or the controller malfunctions.
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Galaxy Power System GPS2436
Figure 6-1: AC Input Terminal strip Panel
5 AC Input Panels
Overview
AC Service
The ac input panel provides the facility to terminate 3-phase ac service to the GPS2436 system
or to distribute individual 1-phase ac supplies to each of the system rectifier positions.
Depending upon the option ordered, the panel will connect 3-wire (three phases), 4-wire (three
phases + neutral), or individual 2-wire (single phase, either 2 hot leads or 1 hot lead and neutral)
input ac service.
Some options provide circuit breakers to protect the conductors providing ac service to the
individual rectifiers. Other systems contain a terminal strip and the conductors are protected by
circuit breakers located in the building’s ac service panel.
Note: All wire sizes based on the US National Electric Code.
Figure 5-2: AC block.
Factory wiring from AC block to rectifier shelf shown.
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Galaxy Power System GPS2436
Figure 6-3: AC Input circuit Breaker Panel
CB1
CB2
CB3
CB4
CB5
CB6
CB7
CB8
CB9
CB10
CB11
CB12
G11
G12
G21
G22
G31
G32
G41
G42
G51
G52
G61
G62
G13
G14
G23
G24
G33
G34
G43
G44
G53
G54
G63
G64
Figure 6-4: AC circuit breaker wiring and rectifier positions
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Galaxy Power System GPS2436
6 Battery Connection Panels
Overview
Function
Batteries are connected to the GPS2436 cabinets on battery connection panels located in the
cabinet directly below or behind the ac input panel. All panels include the battery shunt and an
alarm card that communicates with the controller to provide battery current and status
information. The panel includes a low voltage battery disconnect/reconnect (LVBD/R) contactor.
When equipped with contactors, a contactor control card provides local/manual control of the
contactors and a shunt to monitor battery charge/discharge current.
Illustrations
Battery connection panel is shown in Figures 7-1.
Note: Battery connection panels are blue; dc distribution panels are white.
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Galaxy Power System GPS2436
Figure 6-1: H5692436 G39 (ED83143-31 G36)
Panel is equipped with a Low Voltage Battery Disconnect/Reconnect contactor rated at
2000 amps, and a 3000 amp shunt to monitor battery charge/discharge current.
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Galaxy Power System GPS2436
7 DC Distribution Panels
Function
A variety of dc distribution panels is available for the GPS 4827 system, including DIN standard
fuse holders and circuit breakers and U. S. standard fuse holders and circuit breakers. All panels
are equipped with an alarm card. When a fuse operates or a circuit breaker trips, a red LED on
the alarm card lights, the cabinet alarm lights, and the alarm is transmitted to the controller.
Distribution panels are also available with contactors to provide low voltage load disconnect.
Illustrations
The dc distribution panels are illustrated in Figures 7-1 through 7-11.
Note: DC distribution panels are white; battery connection panels are blue.
Note: DC distribution panels are white; battery connection panels are blue.
Issue 1 August 2012 25
Galaxy Power System GPS2436
Figure 7-1: H569-4827 G42 (ED83143-31 G2)
Figure 7-2: H569-4827 G43 (ED83143-31 G1)
DC Distribution Panel
DC Distribution Panel
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Galaxy Power System GPS2436
Figure 7-3: H569-4827 G48 (ED83143-31 G5)
Figure 7-4: H569-4827 G96 (ED83143-31 G15)
DC Distribution Panel
DC Distribution Panel
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Galaxy Power System GPS2436
Figure 7-5: H569-4827 G52 (ED83143-31 G53)
Figure 7-6: H569-4827 G53 (ED83143-31 G55)
DC Distribution Panel
DC Distribution Panel
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Galaxy Power System GPS2436
Figure 7-7: H569-4827 G60/61/65/66 (ED83143-31 G71)
Figure 7-8: H569-4827 G67 (ED83143-31 G22)
DC Distribution Panel
DC Distribution Panel
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Galaxy Power System GPS2436
Alarm/Terminal Card
Connects to
Charge Return Bus
G97: 6" R EF (152m m )
G98: 9" R EF (229m m )
Figure 7-9 H569-4827 G68 (ED83143-31 G21)
DC Distribution Panel
Figure 7-10 H569-4827 G97, G98 (ED83143-31 G17)
DC Distribution Panel
Issue 1 August 2012 30
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