GE Industrial Solutions GPS2436 User Manual

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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.

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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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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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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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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Control

and

Monitor

To LoadsTo Loads

Battery

String

Battery

String

ACAC

Controller Rectifier Battery Distribution

Rectifier Battery Distribution Cabinet

AC Ground

Cabine Ground

Cabinet Ground

To Loads

Battery

String

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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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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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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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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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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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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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.

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Figure 7-1: H569-4827 G42 (ED83143-31 G2)

Figure 7-2: H569-4827 G43 (ED83143-31 G1)

DC Distribution Panel

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Figure 7-3: H569-4827 G48 (ED83143-31 G5)

Figure 7-4: H569-4827 G96 (ED83143-31 G15)

DC Distribution Panel

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Figure 7-5: H569-4827 G52 (ED83143-31 G53)

Figure 7-6: H569-4827 G53 (ED83143-31 G55)

DC Distribution Panel

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Figure 7-7: H569-4827 G60/61/65/66 (ED83143-31 G71)

Figure 7-8: H569-4827 G67 (ED83143-31 G22)

DC Distribution Panel

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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

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300A Shunt (in back of panel) per Pos ition

5 Large TPL-B Fus e Positions

9" REF

(229mm)

Connects to Charge Return Bus

Alarm/Terminal Card

Maximum Panel Capaci ty

1125A 800A with LVLD

Shunt Monitoring Connection Points to RPMs

6" REF

(152mm)

TPL-C Fuse Head Furnished with Block. Order 408472322 TPL-B Fuse Bloc k Head for 70A - 250A Fuses.

Connects to Charge Return Bus

Figure 7-11 H569-4827 G54 (ED83143-31 G21)

DC Distribution Panel

Figure 7-12 H569-4827 G59 (ED83143-31 G21)

DC Distribution Panel

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8 External Return Bars

Overview

Modular external return bus bar kits are available for the GPS2436 system. These kits are alternatives to the standard internal return buses. These kits allow for modular growth of the bars from bay to bay and offer additional cable landings.

Illustrations

External return bars are illustrated in Figures 8-1 through 8-3.

Figure 8-1 Standard Architecture 600mm External Return Bus Kit

CC848805160 for distributed architecture cabinets

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CC109170511 Standard Bay CC109170197 Wide Bay

Modular Distribution Bay Overhead Buses

CC109170180 Modular Rectifier Bay Overhead Bus

Figure 8-2 Horizontal Rectifier Standard and

Wide Distribution Bay bus bar system

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CC109170412 Modular Distribution Wide Bay Overhead Bus

Field Option A Field Option B

CC109170404 Rectifier Bay Overhead Bus

Wide distribution bay return bus bar systems

Figure 8-3 Vertical rectifier standard and

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The following

•

installed.

But BEFORE:

• Connecting the batteries to the plant charge and discharge bus

bars or turning up the plant rectifiers.

Observe ESD protection while installing circuit packs.

Wear grounded antistatic wrist straps when handling all circuit packs. The wrist strap must contact the skin and is not to be worn over clothing.

Never hand a circuit pack from a grounded to a non-grounded person or vice-versa.

9 Millennium II Controller Operation

The Millennium II is factory pre-installed and pre-configured with industry standard defaults for thresholds and feature operability in GPS cabinet applications. In addition, customer specific default controller settings may be available upon request. This section provides:

Preparation and Precautions

Procedures for the proper addition of optional packs

Input and output wiring to the controller and the installation and wiring of optional features

Controller default configuration information such as alarm severity and description, system voltage, shunt information

Controller configuration information

Preparation

Installation procedures should be performed AFTER:

Precautions

All the equipment frames (initial and supplemental bays, freestanding rectifiers, etc.) are anchored in place.

• The battery stands have been erected and the batteries

installed.

• The overhead cable racks have been installed and the power

cables have been run and terminated.

• The plant’s charge and discharge bus bar assemblies have been

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Action

Verified

Always consider personal safety before beginning any procedure. Review the Safety section.

Be aware of the presence of unfused battery potential in the vicinity of the controller.

Use only insulated tools.

Make sure the system is properly grounded per the National Electrical Code and local building codes.

Remove all metal jewelry before beginning the installation.

Item

Verified

Wire cutters and strippers

18 to 22 AWG wire

Jewelers screwdriver (Flat and Phillips)

Small needle nose pliers

Digital meter, +/- 0.02%

Screw Drivers (flat-blade and Phillips)

ESD wrist strap

Wire-wrap tool or Amp alarm punch-down tool

Safety

Installation Materials

Figure 9-1: Millennium II

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Reference

Description

10/100 Base-T LAN/Ethernet interface

Connectorized interface for 10K/30K thermistor probe options or 210E

Major Fuse alarm (Same connection as on the Millennium)

monitoring devices

RJ45 receptacle for isolated RS485 system component monitoring and control of rectifiers,

bus)

P15

Connectorized interface for future smaller serial format LCD

P205

Option board connector

(RPM) connections

options

Controller Connections

Figure 9-2: Millennium II Controller Connections

Table 9-A: Millennium II Interface Reference

Interface

P1 Connectorized interface for large parallel format 8x40 LCD assembly

P6 Connectorized input for input power, monitoring of two shunts, plant sense voltage, and

P7 RJ45 receptacle for ground referenced Auxiliary RS485 circuit and One-Wire temperature

P8 BSL1-4 circuit pack Interface connector for Input/Output to controller

converters, low voltage disconnect contactors, and bay level alarm inputs (Serial Rectifier

P13 Factory test connector (not used in the field)

P14 Connectorized interface for future smaller serial format LCD

P201 Connectorized interface for optional Modem

P202 Ground referenced DB-9 for local RS232 serial port

TB1 Terminal block interface for RS232/RS485 Auxiliary port and Remote Peripheral Module

TB2 Terminal block interface for three additional 10K thermistor probe or 210E connection

J10 USB interface (reserved for future use)

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Step

Action

NOTE:

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

Note: This step may be performed at a later time

Controller Reset is to the right of the serial connector.

Installing Circuit Packs

Figure 9-3: Millennium II Controller Connections

Modem Card

The optional Modem card may require field installation. To do so, perform the following steps:

necessary.

1. Remove the controller front cover.

2. Install the BSM on the 4 standoffs, to left of the controller MCR1 board using four 845143866 screws.

3. Connect the 848091798 cable assembly between the BSM J100 plug and P201 on the MCR1 board.

Install phone line wiring from Connect the existing telephone cable to the RJ11 connector at the top of the board OR 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.

5. Operate the reset switch on the MCR1 board in the lower left corner of the MCR1 board. (see Figure 4-3)

NOTE: The Password Reset button is to the LEFT of the serial port connector, and the

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Step

Action

is not necessary.

procedures.

seated.

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

Data Switch Card

NOTE: Installation or replacement of this pack can be done “hot”; power removal

2. Install two 407882133 standoffs on the BSJ intelligent board. Screw threads are protruding just below TB1, located at the upper left hand corner of the MCR1 board.

3. Place BSW pack inside the 847950938 insulator.

4. Plug BSW pack into the P205 connector on the BSJ intelligent controller board

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

NOTE: To install the Data Switch Extension board, please see the User’s Guide for

Millennium II Controller Advanced Features manual.

Alarm Termination Board

Alarm Termination board options provide for wire wrapped or insulation displacement (punch down) terminations. The Alarm Termination Board for a specific application may require field installation. To do so, perform the following steps:

Step Action

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

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

3. Holding the board on both sides, slowly, but firmly, remove the alarm board from the P8 connector.

4. Unpack the new board from its box, carefully observing proper ESD

5. Connect the alarm board to P8 and press down firmly, until the board is

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At the controller, connect one end of the network interface cable to P2.

the User’s Guide for Millennium II Controller Advanced Features manual.

NOTE:

For new installations, the Millennium II rectifier cabling has been factory

properly.

Verify that the cable connector is properly seated into P9, and that it is not

RPM provides data acquisition capability far beyond that normally available in a power

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

Gateway (LAN) Connections

Step Action

NOTE: The Gateway card has been designed into the MCR1/MCR2 boards and

requires no additional circuit packs.

NOTE: The Gateway has an IEEE 802.3 compliant 10Base-T network interface.

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

This connector is located at the bottom center of the MCR1 board, and immediately below the MCR2 board.

2. Connect the other end to an IEEE 802.3 compatible network.

3. Configure the Gateway for the network by contacting the customer’s network administrator. Detailed configuration information may be found in

Rectifier Cabling

Step Action

wired and installed to the cabinet BIC/BLJ board for alarm and rectifier communication.

NOTE: For connector integrity, verify that the cable is installed and connected

1. Verify that the rectifier cable is connected to P9, and NOT P7(AUX) cable connector.

loose.

3. Verify that the rectifier cable terminating on the BIC/BLJ board is connected to P9 and also not loose.

Remote Peripheral Monitoring (RPM)

system controller. Monitoring modules available consist of:

• Shunt monitors (6 channels + 1 temperature channel)

• 0-100mV dc Voltage monitors (6 channels + 1 temperature channel)

• 0-3V dc Voltage monitors (6 channels + 1 temperature channel)

• 0-16V dc Voltage monitors (6 channels + 1 temperature channel)

• 0-200V dc Voltage monitors (6 channels + 1 temperature channel)

• Temperature monitor (7 Channels)

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

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Step

Action

NOTE:

The Remote Peripheral Monitoring feature has been designed into the

Advanced Features manual.

Using the RPM bus cable (comcode 407377704), wrap the cable through the

Color

Blue or White

Power/Communications

Blue or White

Power/Communications

faced bottom of the connection unit.

Make the connections to TB2 on the connection unit:

TB-2 Pin

RPM

RPM Conductor

SHIELD

Bare wire

Shield

In the lower right hand side of the control unit (inside), are two rotary

1 (LO) to 1. The module will be recognized as 01 by the

Carefully attach the control unit to the connection unit using the ribbon

MCR1 board and requires no additional circuit packs. Monitoring and control modules ARE required, based on the application.

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 User’s Guide for Millennium II Controller

1. EMI inductor bead twice. Place the bead approximately 3 inches from the end of the cable.

2. Connect the bus cable to:

TB-1 Pin

Assignments

TB-1 Pin

Descriptions

RPM

Conductor

RPM Conductor

Description

9 or 10 FGND Bare wire Shield

*connections of the bus wire are NOT polarity sensitive.

3. Secure the module connection unit and route the wires through the open-

Assignments

Conductor

Description

Color

IN Blue or White Power/Communications

OUT Blue or White Power/Communications

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

5. Locate the control unit. This is the half with circuitry on it.

6. switches. Set SWcontroller. Other modules added cannot have the same address or 00 for the address.

7. connector.

NOTE: This connector/cable is not keyed, so be careful to line up the pins properly.

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After approximately 1 minute, the green LED on the front of the module will blink once approximately every 5 seconds. Detailed troubleshooting information may be found in the User’s Guide for Millennium II Controller Advanced Features manual.

Without thermal probes, many of the controller’s battery management features will not

High Temperature Disconnect

Location

10/30K

Mux

1 Wire Temperature

P7 Pin

Description

Probe 2

Probe 4 RTN

This interface is reserved for future use.

Thermal Probes

function, or produce erroneous results. Some features requiring thermal inputs are:

• Slope Thermal Compensation

• Reserve Time Prediction

• High Temperature Alarm

• Ambient High and Low Temperature Alarms

•

Step Action

NOTE: The controller supports a number of thermal probe inputs. The type of

probe used determines where it is connected on the controller. Detailed thermal probe and battery management information may be found in the User’s Guide for Millennium II Controller Advanced Features manual.

1. The following table shows the type of probe and connector location on the Millennium:

Type of Probe Comcode

210E Thermal Probe

Controller Connection

Monitoring Devices Terminal Block

TB2 Interface for 3 additional 10k probes or 210E connection

2 Probe 2 RTN 3 Probe 3 4 Probe 3 RTN 5 Probe 4

USB Interface

Issue 1 August 2012 44

Galaxy Power System GPS2436

Form-C Alarm Contact Ratings

60Vdc, 0.3A

integrity)

Number

Signal Name

Number

Signal Name

Number

Signal Name

PCRAO

MJFR

FAN

PCRAC

MNFR

AMN

PCRAR

MNFC

TFLT

PCRVR

MNFO

TBST

PCRVC

BDO

TRTN

PCRVO

BDC

PBTR

PCREO

BDR

PBT

PCREC

ACFR

PCRER

ACFC

TR1

PMJAR

ACFO

TEQ

PMJAC

RFAO

ETR

PMJAO

RFAC

ETRR

PMJEO

RFAR

PMJEC

HVR

ROR

PMJER

HVC

TR2

PMJVR

HVO

TR4

PMJVC

UR1O

RBRPO

Local Port

Software

EasyView software is a Windows-compatible communications package designed specifically for use with Galaxy controllers. Download EasyView software from http://www.lineagepower.com

Wiring Alarm Outputs

These external alarms may be wired to customer external office alarms at their destination.

Conductor Size for terminating on Alarm board

Refer to Table 9-B and 9-C for lead designations and their descriptions for leads terminating on the BSL alarm interface board.

Table 9-B: Controller Alarm Descriptions and Pin Numbers

18 – 22AWG (if less than 18AWG, use multi-conductor cable for mechanical

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Galaxy Power System GPS2436

Number

Signal Name

Number

Signal Name

Number

Signal Name

PMJVO

UR1C

TBD

I/O-1

PMNAO

UR1R

USR1PRESENT/

I/O-2

PMNAC

CTLRR

LVD1

PMNAR

CTLRC

TR3

PMNVR

CTLRO

86 - 23

PMNVC

UR2O

4-20mA in

PMNVO

UR2C

4-20mA Rtn

UR2R

USR3PRESETN/

26 - 58

UR3R

Now VLVR

USR3DETECT/

BTMJ

27 - 59

UR3C Now VLVC

0-5V in

PMNER

UR3O Now VLVO

0-5V Rtn

PMNEC

LVD2

ABS

PMNEO

LVD2R

ABS

MJFO

FAJ

MJFC

AMJ

Critical-Audio

PCRAO

PCRAC

PCRAR

Critical-Visual

PCRVR

PCRVC

PCRVO

Critical-External

PCREO

PCREC

PCRER

Power Major-Audio

PMJAR

PMJAC

PMJAO

Power Major –External

PMJEO

PMJEC

PMJER

Power Major –Visual

PMJVR

now general

BTP

now general

BTPFLT

now general I/O-

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PMJVC

PMJVO

Power Minor-Audio

PMNAO

PMNAC

PMNAR

Power Minor –Visual

PMNVR

PMNVC

PMNVO

Power Minor –External

PMNER

PMNEC

PMNEO

Major Fuse

MJFO

MJFC

MJFR

Minor Fuse

MNFR

MNFC

MNFO

Battery On Discharge

BDO

BDC

BDR

AC Fail

ACFR

ACFC

ACFO

Rectifier Fail

RFAO

RFAC

RFAR

High Voltage

HVR

HVC

HVO

User Relay 1

UR1O

UR1C

UR1R

Controller Fail

CTLRR

CTLRC

CTLRO

User Relay 2

UR2O

UR2C

UR2R

Very Low Voltage

VLVR

VLVC

VLVO

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Alarm

Number

Signal Name

Low Voltage 2 Disconnect State Detect

LVD2

Fuse Alarm Major

FAJ

Fuse Alarm Minor

FAN

Auxiliary Alarm Major

AMJ

Auxiliary Alarm Minor

AMN

Timer Float Control

TFLT

Timer Boost Control

TBST

Plant Battery Test

PBT

Open String Detect

Transfer Rectifier 1

TR1

General Purpose Input 4

IN-4 previously TEQ

General Purpose Input -5 (Previously

Engine Transfer)

IN-5 Previously ETR

Reserve Operation

Transfer Rectifier 2

TR2

Transfer Rectifier 4

TR4

Reserve Battery-Emergency Power Off

RBRPO

General Purpose Input 1

IN-1

BTP or General Purpose Input 2

IN-2/BTP

Low Voltage 1 Disconnect State Detect

LVD1

Transfer Rectifier 3

TR3

General Purpose 4-20mA Measuring

Circuit

4-20mA

General Purpose 4-20mA Measuring

Circuit-RTN

4-20mAR

BTPFLT or Generic Input 3

IN-3/ BTPFLT

Low Voltage 3 Disconnect State Detect

Battery Thermal Protect Major

LVD3/ BTMJ

General Purpose 0-5Vdc Measuring

Circuit

0-5V

General Purpose 0-5Vdc Measuring

Circuit-RTN

0-5VR

Wiring Alarm and Control Inputs

In a standard Galaxy Power System configuration, plant level alarms are sent to the controller via the Bay Interface Card through serial data communication. The following alarm inputs are provided for discretionary use in non-standard applications.

Table 9-C: Controller Alarm and Control Inputs

Also

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BSL-63 FAJ: Fuse Alarm Major

An optional battery 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

A battery potential input is required, which 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

A battery potential input is required, which must use an external 1K ohm 2W current limiting resistor at the source. This circuit is used to signal Galaxy 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

A battery potential input is required, which must use an external 1K ohm, 2W current limiting resistor at the source. This circuit is used to allow Galaxy 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

A battery potential input is required, which must use an external 1K ohm, 2W current limiting resistor at the source. This circuit is used to allow Galaxy 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 A battery potential input is required, which must use an external 1K ohm, 2W current limiting resistor at the source if not using standard Lineage Power LVD circuit boards or controller. This circuit is used to inform Galaxy that the monitoring circuit of a Low Voltage Disconnect device has failed. In standard Galaxy Power Systems, the Bay Interface board monitors these alarms and informs the Controller through the serial interface connection.

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 Galaxy that the a Low Voltage Disconnect device has opened. In standard Galaxy Power Systems, the Bay Interface board monitors these alarms and informs the Controller through the serial interface connection.

External Boost Option

A variety of external devices may be used to initiate boost in Galaxy. 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. Additional information on External Boost can be found in the User’s Guide for Millennium II Controller Advanced Features manual.

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TR Signal

Rectifiers Affected

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

Cable Assembly

Connects to:

848152997

KS20472 round cell thermistor

848152989

ring or paddle type thermistors

848153003

210E Thermal Probe Multiplexer

Signal Name

Pin No.

ABS

Rectifier Sequence Option

The controller is capable of sequencing rectifiers on line after detecting a 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 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:

Table 9-D: TR leads and Associated Rectifiers

Additional information on the Rectifier Sequence Options can be found in the User’s Guide for Millennium II Controller Advanced Features manual.

Battery Temperature Option

Slope Thermal Compensation and Battery Reserve Time Prediction features of the controller, require that battery temperature be monitored. If either of these features is to be configured in Galaxy software, a battery temperature input must be connected to P3 temperature probe connector on the Controller board. Three optional cables are used to connect to various battery arrangements:

Refer to User’s Guide for Millennium II Controller Advanced Features manual for additional information on these features.

Alarm Battery Supply Signals

Table 9-E: ABS Pin Numbers

ABS 93

DG 95

DG 96

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FUSE

Description

Fuse Size

Controller Input Power

F2 Alarm Battery Supply (ABS)

1.3A

Fused Battery Supply 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.

BSL-95,96 DG: Discharge Ground

Plant ground/return source for user alarm systems.

Fuses

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

Figure 9-4: Millennium Controller Fuses

Front Panel Display

LCD

The primary local interface for the Millennium II is an eight-line LCD assembly mounted to the front of the primary GPS cabinet door. This user interface is a panel that includes a backlit LCD module, two sections of status LEDs, system voltage test jacks, and an array of simple push-button controls. This controller supports multiple LCD display assemblies. It is backwards compatible to both existing Millennium LCD assemblies L51 and L50 shown in Figure 10-5. It is also compatible with the enhanced L52 LCD display

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Galaxy Power System GPS2436

assembly (see figure 4-6) specifically developed for the Millennium II. This new display assembly is compatible to existing GPS cabinet doors and is functionally backwards compatible to the Millennium. It looks very similar to the L51 option. LCD assembly, but the L52 also provides a built-in audible alarm and digital contrast adjust that are only available when used with the Millennium II controller.

Figure 9-5: Controller Front Panel Displays

Figure 9-6: Detailed Controller Front Panel Display – L51/52

LEDs

Depending on the LCD option utilized, the LCD assemblies contain two rows of LEDs at the right side of the interface board or two columns of LEDs at the left side of the

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Use to navigate the menu; press the key to move the

ADJUST Minus

Press this key any time to bring the MAIN menu on

line help

Use this key to save a value that has been changed, or

interface board as seen in figure 4-5. The segregated sections of LEDs provide an indication of the alarm source (rectifier, battery, distribution, communication, controller, remote modules) and the severity (Critical, Major, Minor, Nominal) of the various alarms. Operation of the status LEDs can be reconfigured via the local or remote controller interfaces.

Push Buttons

A group of push-button keys identified in table 4-F, provides the primary method of locally interacting with the Galaxy Millennium II controller. These keys are used singly or in combination to navigate through the menus and follow industry standard functionality. Following is the general description of all the keys.

Table 9-F: Push-Button Key Functionality

Key Function

Up arrow

cursor up one line.

Down arrow

cursor down one line.

Left arrow Use to navigate the menu; press the key to move the

cursor left one field.

Right arrow

cursor right one field.

ADJUST Plus (+) Use to adjust (increase) the value of a field.

Use to adjust (decrease) the value of a field.

(-)

line.

HELP Press this key to display limited on-

information.

ENTER

to select a menu item.

ESCAPE Use this key to abort a change, or to go back to the

immediate higher level menu.

Lamp Test

Use this key to test the display and LEDs

(L50 Only)

Test Jacks

The Millennium II LCD panel assemblies also provide test jacks to provide the ability of using an external meter to monitor the Plant Voltage as seen in figure 4-7. Voltages to the front panel test jacks are current limited and ESD protected. The controller

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• Disabled for ALL Alarms

• Audible on PCR

• Audible on PMJ

• Audible on PMN

•

setting. Once the desired setting is reached, release the button.

•

clockwise or counter clockwise until the display contrast is set.

measures this voltage to regulate the system bus voltage as well as display it as the battery plant bus voltage. The value of this voltage is used for many other controller related features.

Serial (PC) Port

A ground referenced RS-232 local port is provided at the front of the display to allow easy connection to a personal computer or terminal using ANSI T1.317 object oriented command language. Lineage Power’s EasyView is also available to provide a user friendly system interface locally or remotely. See figure 4-6.

Alarm Buzzer

The audible alarm buzzer is located on the front panel display assembly. It can be programmed from the front panel display to operate as follows:

Contrast Adjust

For L50, L52 Displays:

For L51 Displays:

Press the + or – keys and hold until the display changes it’s contrast

Using a small flat head jeweler’s screwdriver, insert it into the small opening at the top of the display assembly (above the UP arrow). Turn

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Switch Position

Default

Description

Closed (1)

Open (0)

SW202-8

Front Panel Configuration

ENABLED

DISABLED

SW202-7

Modem/Aux/Local/Gateway/USB/ IRDA Port Setting Configuration (Remote Access)

ENABLED

DISABLED SW202-6

Enhanced Security Mode (See table 4-H, for features affected

ENABLED

DISABLED SW202-5

Auxiliary Port Configuration

RS-232

RS-485

SW202-4

Remote Rectifier in Standby

ENABLED

DISABLED

SW202-3

Boost Mode

ENABLED

DISABLED

SW202-2

Reserved for Future Use

ENABLED

DISABLED

SW202-1

Reserved for Future Use

ENABLED

DISABLED

Controller Defaults

Dip Switch Settings

The Millennium has 8 dip switch positions (SW202) that may be changed. SW202 is located on the MCR1 board, above the MCR2 board. (See figure 4-7)

Figure 9-7: Millennium II Controller Dip Switches

Table 9-G: Millennium II Controller Dip Switch Settings

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The modem and auxiliary ports can be configured for full access and read-only using DIP

security feature are listed in this table.

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

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

Table 9-H: Enhanced Remote Security Features

switch 202-7. Restricted access is also available. This prevents changes ia the modem and auxiliary ports that will affect the state of the plant, even when logged in as a SuperUser or Administrator. This enhanced remote security is enabled and disabled with DIP switch SW202-6. The functions and parameters restricted with the enhanced remote

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Low

High

Default

24V

20.00

25.50

23.00

24V Float

23.00

28.00

25.00

48V Float

46.00

55.00

51.00

24V Float

24.75

29.75

26.50

48V Float

50.00

60.00

53.00

24V Float

24.75

29.75

26.8

48V Float

50.00

60.00

53.6

48V Boost

52.00

60.00

53.6

24V

20.00

25.00

22.00

Severity

AMJ

Auxiliary Major

Major

None

Voltage Threshold Ranges and Default Values

Table 9-I: Voltage Threshold Ranges and Default Values

Very Low Voltage (VLV)

48V 40.00 51.00 46.00

Battery on Discharge (BD)

24V Boost 23.00 28.00 25.00

48V Boost 46.00 55.00 51.00

High Float Voltage (HFV)

24V Boost 25.75 31.75 26.50

48V Boost 52.00 60.00 53.00

High Voltage Shutdown Alarm (HV)

24V Boost 25.75 31.75 26.8

Rectifier On Threshold (ROT)

48V 40.00 51.00 44.00

Controller Alarm Severity, LED and Relay Default Values

Table 9-J: Controller Alarm Severity, LED and Relay Default Values

Symbol Default Designation Default

Default LED Default Relay

AAC ACO Active RO None None

ABS Alarm Battery Supply Fuse Major CTLR CTLR

AMN Auxiliary Minor Minor None None

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Galaxy Power System GPS2436

Symbol

Default Designation

Default

Default LED

Default Relay

ATA

Alarm Test Active

None

ATF

Alarm Test Failed

Warning

None

BDA

Battery on Discharge

Major

BID

Bay Interface ID Conflict

Major

CTLR

BTN

Battery Thermal Minor

Minor

BAT

None

CDFA

Converter Distribution Fuse

Major

RECT

MJF

CLC

Clock Changed

None

CMFA

Multiple Converter Fail

Major

RECT

None

CNF3

Contactor 3 Failed

Major

BAT

None

CNO2

Contactor 2 Open

Major

BAT

None

COR

Number Did Not Respond

Warning

None

CRA

Controller Fail

Major

CTLR

EPD

Excess Plant Drain

Minor

RECT

None

EPR

External Password Reset

Warning

None

FAJ

External Fuse Major

Major

DIST

MJF

Severity

ATB Alarm Test Aborted RO None None

BBL Memory Backup Battery Low Warning None None

BCA Battery Type Conflict Warning None None

BFA Battery Test Failed Minor BAT None

BTA Battery Test Active RO BD BD

BTJ Battery Thermal Major Major BAT None

CCH Configuration Changed RO None None

CDID Converter ID Conflict Major RECT None

CFA Converter Fail Minor RECT None

CMA Minor Communications Failure Minor CTLR None

CNF1 Contactor 1 Failed Major BAT None

CNF2 Contactor 2 Failed Major BAT None

CNO1 Contactor 1 Open Major BAT None

CNO3 Contactor 3 Open Major BAT None

COF Queue Overflow Warning None None

CPA Circuit Pack Fail Major CTLR CTLR

DID Rectifier ID Conflict Major RECT None

EMD Energy Management Disabled Warning None None

EPO Emergency Power Off Critical BATT None

ETO Engine Transfer Timeout Minor AC None

EXL Excessive Login Attempts Warning None None

FAN External Fuse Minor Minor DIST MNF

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Symbol

Default Designation

Default

Default LED

Default Relay

HCL

History Cleared

None

HVA

High Voltage

Major

RECT

LVDA

Low Voltage Disconnect Fail

Minor

BAT

None

MDF

Module Failure

Minor

None

NNC

Number Not Configured

Warning

None

PFD

Password At Default

Warning

None

POR

Number Did Not Respond

Warning

None

RPI

Rectifier/Plant Inconsistency

Warning

None

STF

Self Test Failed

Minor

CTLR

URC

User Relay Conflict

Warning

None

ZID

ID Not Configured

Major

RECT

None

Severity

HFV High Float Voltage Minor RECT None

LMR Limited Recharge Minor RECT None

LVD Low Voltage Disconnect Minor BAT None

MCM Major Communication Fail Minor CTLR None

MOR Measurement Out Of Range Minor RM None

MTC Module Type Conflict Warning None None

OSA Open String Minor BAT None

PGI Program Line Invalid Major None None

PHT Processor Halt RO None None

RLS1 Redundancy Loss Ninor RECT None

RTL Reserve Time Low Minor BAT None

SNC Shunt Not Configured Warning None None

TPA Thermal Probe Failure Minor CTLR CTLR

VLA Very Low Voltage Critical BAT UR3

VSF Sense/Control Fuse Major CTLR CTLR

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ACF

AC Fail

Minor

ACF

ETS

External Transfer Shutdown

Minor

RECT

None

LCA

Low Current Alarm

Minor

RECT

None

MAN

Manual Off

Minor

RECT

None

MMAN

Multiple MAN Alarm

Major

RECT

None

PHA

Phase Or Low Output

Minor

None

RFA

Rectifier Fail

Minor

RECT

RFA

# of Alarms

# of Warnings

Date

Time

Plant Voltage

Plant Load (Current)

Table 9-K: Rectifier Alarm Defaults

Symbol Default Designation Default

Default LED Default Relay

Severity

CLM Rectifier Current Limit RO None None

ERD Excess Rectifier Drain Minor RECT None

HPA Half Power Minor RECT None

LSF Load Share Fuse Minor RECT None

MACF Multiple AC Fail Major AC ACF

MFA Multiple Rectifier Fail Major RECT RFA

RIC Rectifier Incomplete Config Warning None None

Default Display

The default display shown in figure 4-8 provides basic system status. The controller returns to this display after approximately three minutes after the last time a key is pressed.

Figure 9-8: Millennium II Controller Default Display

The first line shows:

The larger text in the middle of the screen shows:

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Galaxy Power System GPS2436

An Hourglass may appear in the lower left hand corner of the screen.

volatile memory.

Audible Alarm Cutoff State(Toggle) (Only shown if an alarm is active)

Plant Mode (Default Float)

The bottom line(s) show:

This indicates that a configuration change is being saved to non-

Screen information is updated approximately every two seconds. The front panel display offers a series of menus that allow the user to:

• Configure

• Control

• View Status

• View History

• View Statistics

• Perform Diagnostics

These menu operations are accomplished by navigating through different screens.

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Controller Display Menu Maps

Configuration Menu Map

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Control and Operations Menu Map

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Status Menu Map

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History Menu Map

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Statistics Menu Map

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Step

Configuration

Change

Menu Path/Action

Customer

DATE/TIME

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

Month

Use this field to change the month; the

Day

Use this field to change the day of the 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

Minimum Configuration

Front Panel

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 only the basic operations that must be performed so that the controller is minimally configured. For more advanced operations, please see the User’s Guide for Millennium II Controller – Advanced Features.

Attribute to

Value

<press <ENTER> to save the change.

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possible value is from 1 to 12.

month; the possible value is from 1 to 31.

Galaxy Power System GPS2436

Format This field allows you to select one of the

> key to select the desired

format and press <ENTER> to save the

Time

Daylight

SYSTEM SHUNT

Type

This selection allows the operator to configure the type of shunt that is connected to the controller. Possible values are LOAD, BATTERY, or NONE. The configuration is determined by the plant architecture. Refer to the GPS Power Plant Product Manual for a

In a plant using distributed architecture a

this arrangement, up to 32 shunts, located between batteries and plant bus bars, can be connected to the Bay Interface Cards in the system bays. The controller reads the shunt

ved from the

total of battery currents and the total of

In a plant using centralized architecture, either LOAD or BATTERY should be selected. A maximum of two shunts of the same amperage can be connected through P6 on

ype of LOAD means that a load shunt, located between load and plant bus bars, is connected. The load current displayed on the front panel is the sum of the two shunt currents. A shunt type of BATTERY means that a battery shunt located between

The load current displayed on the front panel is derived from the total battery current and

following time display formats: 12 or 24 hour. Use the <+> or <-

change.

Allows you to change/set the time.

Enables or Disables Daylight Savings.

Issue 1 August 2012 68

description of these architectures.

shunt type of NONE should be selected. In

currents over the serial data connection. The load current displayed is deri

rectifier currents.

the BSH. A shunt t

the batteries and plant bus bars is connected.

Galaxy Power System GPS2436

the total rectifier output current.

> key to change the field

The first item to configure is the Plant Voltage shunt. Make sure the cursor is on the

100, 150 mV). Select the one that best suits

R> key to

save the change.

Move the cursor to the SHUNT I field by using

> key to step through

99999). Select the

desired value; press <ENTER> to save the

ALARM

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

key to adjust the High Voltage shut down alarm for FLOAT mode to the desired level.

High Voltage Float

When the plant voltage exceeds this

Minor LED, activate the PMN contact closure

is high probably due to an adjustment in the

Use the <+> or <values. Press <ENTER> to save the changes.

SHUNT mV field and use the <+> or <-> key to step through the available values (25, 50, 60,

the application; press the <ENTE

the <UP>/<DOWN>/<LEFT>/<RIGHT> ARROW keys. Use the <+> or <the available values (0-

change.

THRESHOLDS

Issue 1 August 2012 69

cursor to the fields and use the <+> or <->

Press <ENTER> to save the change.

threshold, the plant High Float Voltage Alarm (HFV) is turned ON, and this will also light the

(assuming there is no alarm with CRITICAL or MAJOR severity level active). The purpose of this alarm is to indicate that the plant voltage

Galaxy Power System GPS2436

plant rather than due to a failure. This alarm allows the High Voltage (HV) shutdown

to be raised slightly, thus reducing the number of nuisance shutdowns without decreasing the plant reliability. Move the

key to adjust the High Voltage shut down alarm for FLOAT mode to the desired level

ly less than the HV threshold). Press

<ENTER> to save the change.

Battery on

If the plant voltage is less than the threshold

ON, this in turn activates the PMJ and BD

key to adjust the threshold to the desired

Very Low Voltage

This alarm threshold is used to indicate that the system voltage 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.

<ENTER> to save the change.

Rectifiers

Setpoint

This value sets the system voltage for all

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

HVSD

The configuration of this field sets the internal high voltage shutdown value of all

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

threshold

cursor to the fields and use the <+> or <->

(normal

Discharge

value, the Battery Discharge alarm is turned

relay, light the MAJ and BD LEDs. Move the cursor to the fields, and use the <+> or <->

level. Press <ENTER> to save the change.

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

Issue 1 August 2012 70

serial rectifiers. Move the cursor to the field and use the <+> or <-

Galaxy Power System GPS2436

change.

Batteries

Model

The configuration of this field selects the

defined battery types used in reserve time prediction and enhanced battery test features. Move the cursor to the field and

value. Press <ENTER> to save the change.

Strings

The configuration of this field selects the number of battery strings in the system. This

and enhanced battery test features. Move

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

Cells/String

The configuration of this field selects the number of installed 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

> key to adjust the threshold

value. Press <ENTER> to save the change.

Type

The configuration of this field selects the

(sealed). This parameter is used in reserve time prediction and enhanced battery test features. Move the cursor to the field and

> key to adjust the threshold

value. Press <ENTER> to save the change.

Thermal Comp

cell battery voltage as a function of temperature.

Enabled

Enables or Disables the Thermal

installed battery type from a list of pre-

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

parameter is used in reserve time prediction

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

use the <+> or <-

batter type, Flooded or Valve Regulated

use the <+> or <-

Issue 1 August 2012 71

This feature allows dynamic control of sealed

Galaxy Power System GPS2436

Compensation Feature. Move the cursor to

to save the

change.

High Temp Comp

This feature allows the system to compensate for high temperatures.

Volt Step

Battery step temperature can be set from

185F. At this temperature, the system

voltage is reduced by 0.17 X # of cells/string.

High Comp Limit

This sets the maximum temperature for which thermal compensation is active.

Decrease

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

Nominal

This field set the temperature at which no

The system

voltage is at the setpoint float mode.

Low Temp Comp

This feature allows the system to compensate for low temperatures.

Low T Comp

This enables or disables the low temperature compensation feature.

Low Comp Limit

This sets the minimum temperature for which thermal compensation is active.

Increase

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

Recharge Current

This feature sets the total amount of current

Limit

The configuration of this field enables or disables the feature.

Limit to

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

the field and use the <+> or <-> key to Enable or Disable. Press <ENTER>

Limit

Down

Temp

113-

compensation is required.

that will be allowed to recharge the batteries.

Issue 1 August 2012 72

from this screen.

Galaxy Power System GPS2436

Contactor 1-3

Type

This setting identifies the type of contactor,

, LOAD or NONE that has been installed in the plant. Be sure that the wiring for the contactor being configured matches the type chosen here. For standard GPS configurations using BIC cards, Contactor 1 is

and control only LOAD contactors. To toggle between the various contactor types, move the cursor to one of the fields and use the

> key to select the desired type.

Press <ENTER> to save the change.

Disconnect

This setting configures the plant voltage at

Reconnect

This setting configures the plant voltage at

BATTERY

wired to and controls all BATTERY contactors in the plant. Contactors 2 and 3 are wired to

<+> or <-

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.

which the contactor will reconnect to the bus. To prevent the contactor from reoperating 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.

Issue 1 August 2012 73

Galaxy Power System GPS2436

Tools and Test Equipment Required for Acceptance Testing

Digital Voltmeter (DVM) with dc accuracy of at least 0.05%

Short length of wire or clip lead for jumper

Jeweler’s screwdriver

Follow these steps to test plant alarms when installing the Galaxy Millennium Controller in a new plant. In a new installation, begin the sequence with the rectifiers running with a dummy load on the plant bus bar.

For these tests, it is assumed that:

• All rectifiers are functioning properly.

•

load.

If you are testing a controller in a live plant:

• Some tests will cause a battery discharge. Insure that plant batteries are capable

of supporting the load.

• Alarms will be generated. Notify the appropriate alarm monitoring personnel.

10 Acceptance Testing

Introduction

The Galaxy Millennium Controller is tested before it leaves the factory, but many users wish to add some test procedures as part of installation and turn-up. The tests described here will simulate various alarm conditions and verify that the controller functions properly. Follow the steps listed below in the order they are given.

Tools and Test Equipment

Test Precautions

Plant batteries have received their original charges and are ready to support a

Issue 1 August 2012 74

Galaxy Power System GPS2436

This test verifies that All of the LEDs on the front panel of the controller are functioning

Step

Action

From the Default Screen, press the Menu button for the Main Menu.

Using the Up/Down Arrows, Scroll to Control/Operations and press Enter.

Select Start Lamp Test, and press Enter.

Press Enter again to start the test, or Escape to return to the menus.

Observations:

NO alarms are generated from this test

Using a calibrated digital voltmeter, measure the plant voltage from the front panel test jacks. Follow these steps to calibrate the front panel meter display for Voltage and

Test Sequences

Lamp Test

properly. No alarms are generated from this test.

• LCD Refreshes

• Front Panel LEDs ALL turn on momentarily and return to normal

•

Front Panel Display Meter Calibration

Current readings:

Issue 1 August 2012 75

Galaxy Power System GPS2436

Step

Action for Voltage Calibration

Using the Meter Calibration Menus, reset the plant voltage reading by

will remove any pre-existing user calibrated values if they exist.

Wait at least 5 seconds and press the ESCAPE key.

Select CALIBRATE VOLTAGE. Use the Arrows, and UP/DOWN keys to calibrate the system voltage. Press ENTER to save.

NOTE:

The controller will not allow changes greater than +/- 0.5V of the displayed voltage.

Press the <ESCAPE> key until the default screen is displayed. Verify that the plant voltage reading now agrees with the calibrated DVM.

NOTE:

The DVM reading will be the one to change since Rectifier Manager will adjust rectifier outputs as necessary per the calibration performed.

Step

Action for Current Calibration

NOTE:

The following procedure is applicable only in plants with Load shunts in a plant configured for “Centralized Architecture.”

Using a calibrated DVM, measure the plant load from the sense

selecting RESET VOLTAGE. Press the Enter key to reset the voltage. This

Issue 1 August 2012 76

Galaxy Power System GPS2436

connection points on the plant shunt(s).

Calculate the plant load, in amperes, as measured by the DVM.

This value is the plant load measured by the DVM, in amperes.

Using the Meter Calibration Menus, reset the plant Plant Current

ing RESET LOAD. Press the Enter key to reset the Load.

This will remove any pre-existing user calibrated values if they exist.

Wait at least 5 seconds and press the ESCAPE key.

Select CALIBRATE LOAD. Use the Arrows, and UP/DOWN keys to calibrate the system Load. Press ENTER to save.

NOTE:

The maximum total change is +/-10% of the cuurent load value.

Press the <ESCAPE> key until the default screen is displayed. Verify that the plant current reading has been changed.

NOTE:

This operation is performed and verified ONLY if plant load is constant during the calibration procedure.

Observation:

• Displayed System load changes to new value.

Step

Action for Testing the High Float Voltage Alarm

NOTE:

Clear all controller alarms for this test.

NOTE:

The high voltage alarm test is completed by raising the plant voltage above the threshold set for HFV (High Float Voltage) .

NOTE:

Raising the plant voltage on a working system is left to the discretion of

If the test is performed, verify that the plant is in FLOAT

Rectifier voltage has been set to the normal level after completing the test.

Using the Voltage Alarms Menu Screens, note High Float Alarm threshold value. _________

Using the Float Settings Menu Screens, select Set Point and note the value. ________

NOTE:

The next step WILL RAISE the system voltage.

Use the Arrows, and UP/DOWN keys to change the system float voltage setpoint to 0.1V above the High Float Alarm Threshold.. Press ENTER to save.

Observe:

• RECT and MIN LEDs are illuminated

a) Divide the mV DVM reading by the rated shunt mV value b) Multiply this result by the shunt ampere rating

reading by select

High Float Voltage Alarm – New Installations

the user.

• This test could disrupt power to working equipment.

•

mode

•

Issue 1 August 2012 77

• Power Minor alarm (PMN) is generated

• The plant voltage increases to the set voltage

Galaxy Power System GPS2436

Using the Float Settings Menu Screens, select Set Point.

Use the Arrows, and UP/DOWN keys to change the system float voltage setpoint to it’s original value. Press ENTER to save.

Observe:

RECT and MIN LEDs are extinguished

Step

Action for Testing the High Float Voltage Alarm

NOTE:

Clear all controller alarms for this test.

NOTE:

The System Voltage WILL NOT change.

NOTE:

The high float voltage alarm test is completed by changing the threshold for this condition below the system voltage to make it active.

Using the Float Settings Menu Screens, select Set Point and note the value. ________

Using the Voltage Alarms Menu Screens, note the High Float Alarm threshold value. _________

Use the Arrows, and UP/DOWN keys to change the High Float Alarm Threshold to 0.1V below the System Voltage. Press ENTER to save.

Observe:

RECT and MIN LEDs are illuminated

Using the Voltage Alarms Menu Screens, change the High Float Alarm threshold value to it’s original value. Press ENTER to save.

Observe:

RECT and MIN LEDs are extinguished

STEP

Action for Testing High Voltage Shutdown Alarm

NOTE:

The High Voltage Shutdown Test is recommended only for new

office load, and batteries are connected.

NOTE:

There are three requirements for a serial rectifier to shut down upon a

The plant voltage must be above the level set for the High

The rectifier must be delivering a current of at least 10% of its capacity.

• The plant voltage decreases to the original set voltage

• Power Minor alarm (PMN) retires

•

High Float Voltage Alarm – Systems with Actual Loads

• Power Minor alarm (PMN) is generated

•

• Power Minor alarm (PMN) retires

•

High Voltage Shutdown – New Installations Only

installations where a dummy load is available prior to the application of

controller initiated High Voltage Alarm.

Voltage alarm at the VOLTAGE ALARMS menu screen: MENUCONFIGUREFLOAT SETTINGSVOLTAGE ALARMS

Issue 1 August 2012 78

Galaxy Power System GPS2436

3. The rectifier’s current output must be unbalanced by more than

Because item 3 is difficult to achieve in a simulation test of properly functioning serial rectifiers, (even with load share disabled), rectifiers are tested one at a time, rather than as a group. Slightly different test

rectifiers have their own internal restart circuits which will function 3 times before the rectifier locks itself out and initiates a High Output

ficient interval between restart and a subsequent shutdown the rectifier resets its restart counter. The controller initiates a restart signal a few seconds

first RFA (HO) alarm is received. After the second RFA (HO) is received,

aits 5 minutes before sending one additional restart

Verify the Auto Restart is enabled from the front panel menus:

Turn off all rectifiers except the rectifier under test by operating their power switches to STBY.

Adjust the dummy load to provide 10 to 30% of the rectifier’s output capacity.

Using the Voltage Alarms Menu Screens, note High Voltage Alarm threshold value. _________

Using the Float Settings Menu Screens, select Set Point and note the value. ________

NOTE:

The next step WILL RAISE the system voltage.

Use the Arrows, and UP/DOWN keys to change the system float voltage

to save.

Controller Observations:

When the voltage increases to the HV (FLOAT) level the

• After 5-6 seconds the rectifier initiates its own restart

10% from the average output currents of the other rectifiers.

procedures are used for special applications in batteryless plants. Serial

Rectifier Fail Alarm to the controller. If there is a suf

after the

the controller w signal.

setpoint to 0.1V above the High Voltage Alarm Threshold.. Press ENTER

• The plant voltage increases

• Power Major alarm (PMJ) is generated

• RECT and MAJ LEDs are illuminated

Rectifier Observations:

•

rectifier shuts down.

• The Green ON LED on the rectifier blinks, the ALM LED on

the rectifier is not lit.

Issue 1 August 2012 79

Galaxy Power System GPS2436

signal again raising the plant voltage. The rectifier will shutdown and restart two additional

Upon the third shutdown, the rectifier’s ALM LED lights

ON LED on the

Upon the fourth shutdown, the rectifiers ALM LED lights

s and issue one final restart signal initiating the final sequence of shutdown and restart events before the rectifier locks out, requiring

Prior to this occurring, change the value of the

Restart the rectifier from the front panel by using

Using the Float Settings Menu Screens, select Set Point.

Use the Arrows, and UP/DOWN keys to change the system float voltage

This value must be at least 0.5V below the HV alarm threshold setting. Press ENTER to save.

10.

Controller Observations:

• Rectifier is operating normally

•

times.

•

and the rectifier’s display indicates “HO”.

• The controller receives the RFA signal from the rectifier

and initiates a restart signal 5-6 seconds later.

• The rectifier restarts again raising plant voltage.

• The rectifier shuts down and restarts 3 additional times.

• During these shutdowns the Green

rectifier blinks and the ALM LED on the rectifier is not lit.

•

and the rectifier’s display indicates “HO”.

• Any external RFA office alarm has occurred.

• The controller will wait 5-6 minute

personnel intervention.

system voltage to its original value. Press ENTER to save the change.

the menus:

setpoint to its original value

• The plant voltage returns to it’s original value

• Power Major alarm (PMJ) retires

• RECT and MAJ LEDs are extinguished

Rectifier Observations:

Issue 1 August 2012 80

Galaxy Power System GPS2436

STEP

Action for Testing the Battery on Discharge Alarm

NOTE:

If the BD alarm was observed during the High Voltage Shutdown test this test can be disregarded.

From the front panel follow the path(Voltage Alarms):

Note the setting of the Battery on Discharge Threshold. ________

With a dummy load added to the plant, operate all rectifiers to STBY until the plant voltage drops below the BD (FLOAT) threshold.

Controller Observations:

BD and MAJ LEDs are illuminated

Turn on all rectifiers

Controller Observations:

System Voltage is normal

The RFA alarm was observed during the High Voltage Shutdown Test so no separate test is required.

Major Fuse Alarm may be tested by placing a blown fuse in the alarm fuse position of

indicating hole of its fuse holder.

For distribution circuit breakers, temporarily connect the pins 8 and 9 of any KS22010

BNL1 alarm board.

Observation:

• Remove alarm condition and verify that DIST,MAJ LEDs and MJF relay retire.

Alarms should be tested in each distribution bay of the plant to verify the integrity of the alarm bus throughout the plant.

If the distribution bays are equipped with “Bay Fuse Alarm” indicating LEDs, also verify

not in any other).

Battery on Discharge Alarm

• PMJ Alarm is active

•

• PMJ Alarm retires

• BD and MAJ LEDs are extinguished

•

Rectifier Fail Alarm

Major Fuse Alarm

any distribution fuse position in the plant or by inserting a paper clip into the alarm

or KS22012 style circuit breakers together. This is accomplished on the ED83143-30 circuit breaker panels by shorting the (-) panel bus to pin 1 on the P4 connector of its

• The DIST and MAJ LEDs and Power Major and MJF alarm relays will be active.

that this LED activates during these tests for the bay in which the alarm originates (and

Issue 1 August 2012 81

Galaxy Power System GPS2436

This feature is useful when there is a need to remove unnecessary historical data from

operation. There may be history that is of no use to the customer. Also, since

the history log has a finite number of entries, user can save the history using a PC, and

Step

Action

From the Default Screen, press the Menu button for the Main Menu.

Using the Up/Down Arrows, Scroll to Control/Operations and press Enter.

Select Clear History, and press Enter.

Press Enter again to clear the History Log, or Escape to return to the menus.

Clear History

the controller. An example might be after installation and testing and the controller is ready for

then clear the logs.

Issue 1 August 2012 82

Galaxy Power System GPS2436

it is used to calculate current. Terminal boards located on the battery connection

11 Circuit Boards

Overview

Function

Circuit boards (sometimes referred to as “cards”) are included in the battery connection and dc distribution panels to provide data to the controller.

Terminal Boards

Terminal boards are used to provide shunt voltage data to the controller, where

panels provide data that is used to calculate battery current; data from terminal boards located on the dc distribution panels is used to calculate load current.

Alarm Boards

Alarm boards perform two functions:

• monitor panel functions and activate local indicators when faults occur on

the panel

• provide alarm data to the controller

Alarm/Terminal Boards

Alarm/terminal boards combine the functions of alarm boards and terminal boards.

BLJ Terminal Board

The BLJ terminal board is located inside the cabinet door. The BLJ is the termination point for all signal cables in each cabinet and between cabinets.

Issue 1 August 2012 83

Galaxy Power System GPS2436

Overview, continued

based on maintenance switch

Contactor Control Board (installed only on systems with contactors)

Contactor control boards provide four functions:

• Monitor and report shunt voltage to the controller

• Monitor and report contactor status to the controller

• Operate the contactor based on controller commands

• Operate or block the contactor from operating

settings

Bay Interface Card (BIC)

Every cabinet in a Galaxy Power System has a Bay Interface Card (BIC). The BIC provides controller access to alarm monitoring, battery voltages, battery currents, and temperature probes in the cabinet through the serial rectifier bus.

Issue 1 August 2012 84

Galaxy Power System GPS2436

Galaxy Power System 2436 Specifications

Electrical

AC Input

• 50A circuit breaker per rectifier for individual feeds

• 8 gauge/10 mm

- per rectifier for individual feeds

Cabinet Output +24V

System Output +24V

2 x Full Height

Maxi mum System

1. With Galaxy Millennium Controller

12 Specifications

GPS2436

Input Distribution

NE100AC24ATEZ

Minimum Wire Size

NE100AC24ATEZ

Output Current

NE100AC24ATEZ 100 - 2000A

• 125A circuit breaker per 2-shelf cabinet

• 150A circuit breaker per 3-shelf cabinet

• 25A circuit breaker per rectifier for individual feeds

• 110 / 125A circuit breaker per 1-shelf cabinet

• 2 x 110 / 125A circuit breaker per 2-shelf cabinet

• 2 x 150A circuit breaker per 3-shelf cabinet

• 2 gauge/35 mm

• 1/0 gauge/50 mm

• 10 gauge/6 mm

• 2 gauge/35 mm

• 2 x 2 gauge/35 mm

• 2 x 1/0 gauge/50 mm

- 1 and 2-shelf cabinet

- 3-shelf cabinet

- per rectifier for individual feeds

- 1-shelf cabinet

- 2-shelf cabinet

- 3-shelf cabinet

Output Current

NE100AC24ATEZ

100 - 2000A

Issue 1 August 2012 85

2000A

Galaxy Power System GPS2436

Galaxy Power System 2436 Specifications (continued)

Mechanical

Cabinet

Full Height

(82.6 H x 23.6 W x 23.6 D in.)

Units Per Initial Cabinet

Full Height

Rectifiers

1 - 36

Controller

Battery Disconnect Modules

0 - 1

installed in other cabinets.

Units Per Supplementa l C abinet

Rectifiers

1 - 36

Battery Disconnect Modules

0 - 1

installed in other cabinets.

Environmental

Altitude

-50 to 4000 meters

temperature by 0.656°C per 100 meters.

Humidity

5% to 95% non-condensing

Radiated and Conducted

EN50082-1, EN50082-2, EN50081, EN61000 Electromagnetic Immunity

Level B

Earthquake Rating

Zone 4, upper floors

Standards Compliance

Agency Appro va ls

CE Marked, UL

Nominal Cabinet Dimensions (H x W x D)

DC Distribution Maximum discharge is 1600 amps per cabinet. No distribution panels can be

Operating Ambient Temperature

NE100AC24ATEZ

2100 H x 600 W x 600 D mm

installed in a rectifier only cabinet, as many distribution panels as will fit can b e

-40°C to +75°C

Note: For altitudes between 1500 and 4000 meters, derate the maximum

Emissions

Underwriters Laboratories (UL) Listed per Subject Letter 1801, DC Power Distribution Centers for T e le communic a tions Equipment

Issue 1 August 2012 86

Galaxy Power System GPS2436

Rectifier Specifications

Electrical

Input

(150 Vac - 300 Vac with reduced performance)

Frequency Range

45 - 66 Hz

Power Factor

> 0.98 at > 50% rated output

810Vpeak 100A peak (8 x 20s)

Output All

Float: Boost: Equalize:

Float/Boost: Equalize:

1. Selectable/programmable through Galaxy Controller

Output NE100AC24ATEZ

1 ampere per degree C (+65°C to +85°C)

Float/Boost Voltage

21-29Vdc

Total Harmonic Distortion

<5% at full load

Regulation

±0.5%

Ripple

100 mVrms

Noise

< 2mV psophometric

Rectifier

850022020 GPS2436 Prod Man r01.docx

Voltage Range 175-275Vac, 2-wire, single phase

AC Surge Protection: It is important that ac surges reaching rectifiers do not exceed the capacity of the rectifier internal surge protection. Protection must be provided external to the GPS system, if necessary, to limit surge energy reaching the rectifiers. Site surge protection must be coordinated with rectifier internal surge protection and must clamp at a lower voltage than the rectifier internal protection. The internal protection voltage and current characteristics of the rectifiers are as follows:

Phase to Phase Voltage MOV Conduction Current 320Vac (RMS) 0A

620V maximum clamping 1mA (DC test current)

High Voltage Shutdown

Internal Selective High Voltage Shutdown (ISHVSD)

Backup High Voltage Shutdown (BUHVSD)

Factory default settings – actual range is 44 - 60Vdc Factory default settings – Float/Boost range is 58.51 - 60.53Vdc,

Equalize range is 65.2 - 67.0Vdc

Output Power1 3,000W maximum

Output Current1 55Adc maximum from -40°C to +65°C

Issue 1 August 2012 87

56.0Vdc Nom.1,

59.52 ± 1Vdc Nom.1,

59.52Vdc

66.0Vdc3

42.5Adc at +75°C 30Adc at +85°C Rectifier derates at approximately

Galaxy Power System GPS2436

Current Limit Set Point

15A-55A

Issue 1 August 2012 88

Galaxy Power System GPS2436

Output NE100AC24ATEZ (Continued)

1, 2

2.5 amperes per degree C (+60°C to +75°C)

Float/Boost Voltage

42-58Vdc

Total Harmonic Distortion

<5% at Nominal Vac and >50Adc

Regulation

±0.5%

Ripple

100 mVrms

Noise

< 2mV psophometric

Current Limit Set Point

30A-110A

Mechanical

Width

5.25 in. (133.35 mm)

Height

8 in. (203.2 mm)

Depth

19.75 in. (501.65 mm)

Weight

20 lbs. (9 kg)

Environmental

Efficiency

> 90% typical

Heat Release

54.5Vdc, 110A

Per rectifier:

666W [2,266 BTU/hr]

Storage Relative Humidity

5% to 90%

Audible Noise

< 52dBA

EMC

EN 50022, level B, conducted and radiated (CISPR 22)

Standards Compliance

Safety Standard

EN 60950 (IEC950)

Body and have outputs classified as SELV.

Output Power

Output Current

6,000W maximum

110Adc maximum from -40°C to +45°C

85Adc at +60°C 60Adc at +70°C

47.5Adc at +75°C

Rectifier self-derates at approximately

1.5 amperes per degree C (+45°C to +60°C)

NE100AC24ATEZ 52Vdc, 40A

52Vdc, 50A

54.5Vdc, 40A

54.5Vdc, 50A 55Vdc, 55A

NE100AC24ATEZTEZ 52Vdc, 80A

52Vdc, 100A

54.5Vdc, 80A

54.5Vdc, 100A

Certification Marks UL, VDE, CE

231W [788.9 BTU/hr] 288W [983 BTU/hr] 242W [827 BTU/hr] 302W [1,030 BTU/hr] 332W [1,133 BTU/hr]

463W [1,578 BTU/hr] 577W [1,966 BTU/hr] 485W [1,654 BTU/hr] 605W [2,060 BTU/hr]

Rectifiers are individually UL Recognized and/or CSA Certified to UL1950 and CSA C22.2 No 234/950. Rectifiers are also approved to IEC-950/EN60950 by an EC Notified

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13 Safety

Please read and follow all safety instructions and warnings before servicing the GPS2436. Reference the GPS Installation Guide for safety statements specific to the modules.

Safety Statements

Please read and follow all safety instructions and warnings before installing, maintaining, or repairing the system:

• The CE Mark demonstrates compliance with the European Union Council

Directives for Low Voltage and EMC.

• The UACD is Underwriters Laboratories (UL) recognized per Subject Letter 1801,

DC Power Distribution Centers for Telecommunications Equipment.

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

closets, or the like) in accordance with articles 110-26, 110-27, and 110-18 of the U.S. National Electric Code (NEC-2011), 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 5°C to 55°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.

• The shelf in combination with the EP300048ATEZ has not been evaluated for hot-

swapping.

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

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

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• All input and output connections comply with SELV requirements.

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

conductors based on listed recommendations. Wiring internal to enclosed equipment cabinets should be rated at 105° Celsius (minimum).

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

product documentation.

• Alarm contacts on the office alarm connector are not fused within the controller;

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.

• In enclosed equipment cabinets, the chassis must be connected directly to the

cabinet ac service ground bus. For applications in huts, vaults, and central offices, the chassis must be connected to the system integrated ground grid.

• This product operates equally well if installed as part of the Isolated Ground

Plane (Isolated Bonding Network) or the Integrated Ground Plane (MeshBonding Network, aka, Common Bonding Network). Lineage recognizes there are different grounding techniques that are equally successful. Adhere to a commonly accepted and consistent grounding approach to ensure personnel safety, network protection, and proper equipment operation. Multiple low impedance paths to Earth ground are essential.

• The equipment and subassembly ports are suitable for connection to intra-

building or unexposed wiring or cabling. The equipment and subassembly ports can be connected to shielded intra-building cabling grounded at both ends.

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14 Maintenance and Replacement

Requirements

System

With the exception of the batteries, periodic maintenance specific to the power system is not required. The ac service for the building must be maintained with ANSI specified limits. The temperature and humidity within the power room must be maintained within the limits specified in this product manual.

Batteries

The batteries must be maintained as directed by the battery manufacturer’s requirements.

Rectifiers

Rectifiers are repaired by replacement. Refer to “Installing or Replacing a Rectifier” in this section.

Rectifier Fans

Rectifier fans are not field replaceable. See the Customer Service Contacts section of this manual for return information.

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Step

Action

to the rectifier position that is being installed or replaced.

Caution

the rectifier.

Slide the rectifier into the slot until it engages with the rear

Verify the faceplate is latched.

Rectifier Installation and Replacement Procedures

Installing or Replacing a Rectifier

Locate and turn off the ac service to the rectifier position that is being installed or replaced.

Note: Do not turn off ac service to the entire system, only

Rear portion of the rectifier that is in operation may be HOT to the touch. Use appropriate precautions.

(This step is for replacement only. For a new installation,

proceed to the next step). Open the faceplate by sliding the faceplate latch to the left

until the faceplate releases and swings outward. Remove

Remove rectifier from its shipping package. Slide the

rectifier into the slot approximately ¾ of the way.

Open the faceplate by sliding the faceplate latch to the left

until the faceplate releases and swings outward.

of the shelf. Swing the faceplate closed to seat the rectifier.

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Table 1: Warnings

15 Troubleshooting Procedure

Preliminary

Introduction

This section provides information needed in preparation for locating and interpreting visual indicators to help identify problems.

When replacing a part does not correct the problem or visual indicators do not identify a defective part, notify Lineage Power Technical Support.

Safety

Review all safety instructions and warnings in the Safety section of the GPS Installation Guide before troubleshooting the GPS2436.

• Hazardous ac and dc voltages and/or energy are present.

Caution should be exercised. Tools must be insulated to help prevent accidental contact with live surfaces.

• Coordinate all troubleshooting activities with other personnel

that may be working on the system.

Tools

The following tools are necessary in order to troubleshoot the GPS2436:

• Calibrated digital voltmeter (DVM)

(0.05% accuracy on dc scale)

• ESD wrist strap

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Figure 12-1: Location of cabinet alarm indicators

Troubleshooting Procedure

Purpose

The troubleshooting procedure described below is used when a trouble condition has been identified and a technician has been dispatched to the system as a first step in diagnosing and correcting the problem.

For all trouble conditions, proceed as follows:

Cabinet Alarm

1. Locate the Galaxy controller. When a trouble condition exists, the red alarm on the

top of the cabinet will be illuminated and the display screen on the controller will typically have LED’s illuminated. See Figure 12-1.

2. Determine the system status. For most problems, one or more alarm and status

LEDs will be illuminated. Depending on the controller type, the following will be displayed:

– system voltage – system current – system mode – system number of alarm/warnings

If the screen is blank, but alarm and status LEDs are illuminated, call technical support. If the entire panel is blank, check the controller fuses. Verify that the controller is getting power. If not, replace fuse. If the display is still blank, call technical support.

3. To view the Alarms Menu: If the default screen appears normal, press the MENU

button. The main menu appears with “Alarms” blinking. Press ENTER to obtain the Alarms menu. Additional data appears that will help to identify the problem.

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Table 1: Warranty Period

Product Type

New Product

Repaired Product*

Power Equipment

*The Warranty Period for a repaired Product or part thereof is six (6) months

16 Product Warranty

A. Seller warrants to Customer only, that:

1. As of the date title to Products passes, Seller will have the right to sell, transfer, and assign such

Products and the title conveyed by Seller shall be good;

2. During the warranty period stated in Sub-Article B below, Seller’s Manufactured Products

(products manufactured by Seller), which have been paid for by Customer, will conform to industry standards and Seller’s specifications and shall be free from material defects;

3. With respect to Vendor items (items not manufactured by Seller), Seller warrants that such

Vendor items, which have been paid for by Customer, will be free from material defects for a period of sixty (60) days commencing from the date of shipment from Seller’s facility.

B. The Warranty Period listed below is applicable to Seller’s Manufactured Products furnished pursuant

to this Agreement, commencing from date of shipment from Seller’s facility, unless otherwise agreed to in writing:

Central Office

or, the remainder of the unexpired term of the new Product Warranty Period, whichever is longer.

C. If, under normal and proper use during the applicable Warranty Period, a defect or nonconformity is

identified in a Product and Customer notifies Seller in writing of such defect or nonconformity promptly after Customer discovers such defect or nonconformity, and follows Seller's instructions regarding return of defective or nonconforming Products, Seller shall, at its option attempt first to repair or replace such Product without charge at its facility or, if not feasible, provide a refund or credit based on the original purchase price and installation charges if installed by Seller. Where Seller has elected to repair a Seller’s Manufactured Product (other than Cable and Wire Products) which has been installed by Seller and Seller ascertains that the Product is not readily returnable for repair, Seller will repair the Product at Customer’s site. With respect to Cable and Wire Products manufactured by Seller which Seller elects to repair but which are not readily returnable for repair, whether or not installed by Seller, Seller at its option, may repair the cable and Wire Products at Customer’s site.

D. If Seller has elected to repair or replace a defective Product, Customer shall have the option of

removing and reinstalling or having Seller remove and reinstall the defective or nonconforming Product. The cost of the removal and the reinstallation shall be borne by Customer. With respect to Cable and Wire Products, Customer has the further responsibility, at its expense, to make the Cable and Wire Products accessible for repair or replacement and to restore the site. Products returned for repair or replacement will be accepted by Seller only in accordance with its instructions and procedures for such returns. The transportation expense associated with returning such Product to Seller shall be borne by Customer. Seller shall pay the cost of transportation of the repaired or replacing Product to the destination designated by Customer.

24 Months 6 Months

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E. Except for batteries, the defective or nonconforming Products or parts which are replaced shall

become Seller's property. Customer shall be solely responsible for the disposition of any batteries.

F. If Seller determines that a Product for which warranty service is claimed is not defective or

nonconforming, Customer shall pay Seller all costs of handling, inspecting, testing, and transportation and, if applicable, traveling and related expenses.

G. Seller makes no warranty with respect to defective conditions or nonconformities resulting from

actions of anyone other than Seller or its subcontractors, caused by any of the following: modifications, misuse, neglect, accident, or abuse; improper wiring, repairing, splicing, alteration, installation, storage, or maintenance; use in a manner not in accordance with Seller’s or Vendor’s specifications or operating instructions, or failure of Customer to apply previously applicable Seller modifications and corrections. In addition, Seller makes no warranty with respect to Products which have had their serial numbers or month and year of manufacture removed, altered, or experimental products or prototypes or with respect to expendable items, including, without limitation, fuses, light bulbs, motor brushes, and the like. Seller’s warranty does not extend to any system into which the Product is incorporated. This warranty applies to Customer only and may not be assigned or extended by Customer to any of its customers or other users of the Product.

THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER EXPRESS AND IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. CUSTOMER’S SOLE AND EXCLUSIVE REMEDY SHALL BE SELLER’S OBLIGATION TO REPAIR, REPLACE, CREDIT, OR REFUND AS SET FORTH ABOVE IN THIS WARRANTY.

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GE Industrial Solutions GPS2436 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Introduction

GPS2436

Customer Service Contacts

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

On-Line Power Systems Product Manuals and Software

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.

System

Components

Architecture

Configurations

3 Galaxy Millennium II Controller

Overview

Default Display

LEDs

Test Jacks

Access Panel

4 Rectifiers

NE100AC24ATEZ

5 AC Input Panels

Overview

AC Service

6 Battery Connection Panels

Overview

7 DC Distribution Panels

Function

Illustrations

8 External Return Bars

Overview

Illustrations

9 Millennium II Controller Operation

Preparation

Precautions

Safety

Installation Materials

Controller Connections

Installing Circuit Packs

Modem Card

Data Switch Card

Alarm Termination Board

Gateway (LAN) Connections

Rectifier Cabling

Remote Peripheral Monitoring (RPM)

Thermal Probes

USB Interface

Local Port

Software

Wiring Alarm Outputs

Wiring Alarm and Control Inputs

Alarm Battery Supply Signals

Fuses

Front Panel Display

LEDs

Push Buttons

Test Jacks

Serial (PC) Port

Alarm Buzzer

Contrast Adjust

Controller Defaults

Dip Switch Settings

Voltage Threshold Ranges and Default Values

Controller Alarm Severity, LED and Relay Default Values

Default Display

Controller Display Menu Maps

Configuration Menu Map

Control and Operations Menu Map

History Menu Map

Statistics Menu Map

Front Panel

10 Acceptance Testing

Introduction

Tools and Test Equipment

Test Precautions

Test Sequences