GE Industrial Solutions GPS 4812 User Manual
Galaxy Power System 4812/24
(GPS 4812/24)
H569-436
User’s Guide
Select Code 167-792-161
Comcode 108313057
Issue 9
Januray 2008
User’s Guide
Select Code 167-792-161
Comcode 108313057
Issue 9
Januray 2008
Galaxy Power System 4812/24
(GPS 4812/24)
H569-436
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.
© 2008 Lineage Power
All International Rights Reserved
Printed in U.S.A.
Galaxy Power System 4812/24
Table of Contents
1 Introduction
GPS 4812/24 1-1
Overview 1-1
Illustrations 1-1
Customer Service Contacts 1-4
Customer Service, Technical Support, Product Repair and
Return, and Warranty Service 1-4
Customer Training 1-4
Downloads and Software 1-4
2 System Description
Overview 2-1
Block Diagram 2-1
System Components 2-2
Architecture 2-3
Configurations 2-3
Illustrations 2-3
3 Galaxy Controllers
Overview 3-1
Introduction 3-1
Galaxy Millennium Controller 3-2
Design 3-2
User Interface and Display 3-2
Default Display 3-2
LEDs 3-3
Test Jacks 3-3
Pushbutton Keys 3-4
Access Panel 3-4
Galaxy Vector Controller 3-5
Design 3-5
User Interface and Display 3-5
Default Display 3-5
LEDs 3-5
Pushbutton Keys 3-6
Access Panel 3-6
Reference Material 3-7
Controller Product Manuals 3-7
RPM System Product Manual 3-7
Issue 9 Januray 2008 Table of Contents - 1
Galaxy Power System 4812/24
4 Rectifiers
596 Series A and D 4-1
Overview 4-1
Front Panel Display 4-1
Power Switch 4-1
Status Indicators 4-1
Current Display 4-2
Lamp Test 4-2
Features 4-3
Output Current “Walk-in” 4-3
Output Protection 4-3
Electronic Current Limit 4-3
High Voltage Shutdown (HVSD) 4-3
Restart 4-3
Fan Alarm and Control 4-3
Thermal Alarm 4-3
Autonomous Operation 4-3
Controller Communications Alarm 4-3
Connectorized 4-4
“Forced” Load Sharing 4-4
5 AC Input Panels
Overview 5-1
AC Service 5-1
Illustrations 5-1
6 Battery Connection Panels
Overview 6-1
Function 6-1
Illustrations 6-1
7 DC Distribution Panels
Overview 7-1
Function 7-1
Illustrations 7-1
2 - Table of Contents Issue 9 Januray 2008
Galaxy Power System 4812/24
8 Circuit Boards
Overview 8-1
Function 8-1
Terminal Boards 8-1
Alarm Boards 8-1
Alarm/Terminal Boards 8-1
BLJ Terminal Board 8-1
Overview, continued 8-2
Contactor Control Board 8-2
Millennium Systems 8-2
Vector Systems 8-2
9 Specifications
GPS 4812/24 9-1
Rectifier 9-3
AC Input Panels 9-5
Applications and Cross Reference 9-5
Battery Connection Panels 9-6
DC Distribution Panels 9-7
10 Safety
11 Maintenance and Replacement
Requirements 11-1
System 11-1
Batteries 11-1
Rectifiers 11-1
Rectifier Fan Assembly 11-2
Replacement Procedures 11-3
Installing or Replacing a Rectifier 11-3
Replacing a Rectifier Fan Assembly 11-5
Replacement Parts 11-6
System 11-6
Millennium Controller Circuit Boards 11-7
Vector Controller Circuit Boards 11-7
Additional Ordering Information 11-8
Documentation 11-8
Software 11-8
Issue 9 Januray 2008 Table of Contents - 3
Galaxy Power System 4812/24
12 Troubleshooting Preparations
Preliminary 12-1
Introduction 12-1
Safety 12-1
Tools 12-1
Troubleshooting Procedure 12-2
Purpose 12-2
Cabinet Alarm 12-2
System Status 12-3
Alarms Menu 12-3
Troubleshooting Tables 12-4
Identifying Problems 12-5
Reference Figures 12-6
Figure Numbers and Titles 12-6
Millennium Controller 12-7
Vector Controller 12-9
Rectifiers 12-10
Low Voltage Battery Disconnect 12-11
AC Input 12-12
DC Distribution 12-13
Low Voltage Load Disconnect 12-14
13 Troubleshooting Millennium Systems
Introduction 13-1
In This Section 13-1
Preparation 13-1
Technical Assistance 13-1
Troubleshooting Tables 13-2
Organization 13-2
Table Reference 13-2
Millennium Display Reference 13-2
AC System Alarm LED 13-3
Battery Alarm LED 13-4
Controller Alarm LED 13-6
Distribution Alarm LED 13-11
Rectifier Alarm LED 13-12
Battery on Discharge and Remote Modules Alarm LEDs,
or No LED 13-16
4 - Table of Contents Issue 9 Januray 2008
Galaxy Power System 4812/24
14 Troubleshooting Vector Systems
Introduction 14-1
In This Section 14-1
Preparation 14-1
Technical Assistance 14-1
Troubleshooting Tables 14-2
Organization 14-2
Table Reference 14-2
Vector Display Reference 14-3
AC Alarms 14-4
Battery Alarms 14-5
Controller Alarms 14-6
Distribution Alarms 14-7
Rectifier Related Alarms 14-8
Miscellaneous Alarms 14-11
15 Product Warranty
Issue 9 Januray 2008 Table of Contents - 5
Galaxy Power System 4812/24
List of Figures
Figure 1-1: GPS 4812/24 Half Height Initial
Cabinet (with Battery Stand) 1-2
Figure 1-2: GPS 4812/24 Full Height Initial Cabinet 1-3
Figure 2-1: Block Diagram of the GPS 4812/24 2-1
Figure 2-2: Schematic of Half Height Cabinet 2-4
Figure 2-3: Schematic of Full Height Cabinet 2-5
Figure 2-4: Schematic of Two-cabinet System Architecture 2-6
Figure 2-5: Half Height GPS 4812/24 with Door Open 2-7
Figure 2-6: Full Height GPS 4812/24 with Door Open 2-8
Figure 3-1: Galaxy Millennium Controller Front Panel 3-2
Figure 3-2: Galaxy Vector Controller Front Panel 3-5
Figure 4-1: Rectifier Front Panel 4-2
Figure 5-1: AC Input Circuit Breaker Panels 5-2
Figure 5-1: AC Input Terminal Strip Panels 5-3
Figure 6-1: H569-436 G30 (ED83143-31 G32)
Battery Connection Panel 6-2
Figure 6-2: H569-436 G31 (ED83143-31 G31)
Battery Connection Panel 6-2
Figure 6-3: H569-436 G34 (ED83143-31 G41)
Battery Connection Panel 6-3
Figure 6-4: H569-435 G35 (ED83143-31 G42)
Battery Connection Panel 6-3
Figure 6-5: H569-436 G36H (ED83143-31 G33)
Battery Connection Panel 6-4
Figure 6-6: H569-436 G37F/38F (ED83143-31 G60/61)
Battery (OLE) Connection Panel 6-4
Issue 9 Januray 2008 List of Figures - 1
Galaxy Power System 4812/24
Figure 6-7: H569-436 G80/81/82 (ED83143-31 G31/43)
Battery Connection Panel 6-5
Figure 6-8: H569-436 G84H (ED83143-31 G34)
Battery Connection Panel 6-6
Figure 6-9: H569-436 G85F (ED83143-31 G35)
Battery Connection Panel 6-6
Figure 6-10: H569-436 G86/87 (ED83143-31 G63/64)
Battery Connection Panel 6-7
Figure 7-1: H569-436 G40/50 (ED83143-31 G11)
DC Distribution Panel 7-2
Figure 7-2: H569-436 G41/51 (ED83143-31 G12)
DC Distribution Panel 7-2
Figure 7-3: H569-436 G42 (ED83143-31 G2)
DC Distribution Panel 7-3
Figure 7-4: H569-436 G43 (ED83143-31 G1)
DC Distribution Panel 7-3
Figure 7-5: H569-436 G44 (ED83143-31 G5)
DC Distribution Panel 7-4
Figure 7-6: H569-436 G46 (ED83143-31 G15)
DC Distribution Panel 7-4
Figure 7-7: H569-436 G52 (ED83143-31 G53)
DC Distribution Panel 7-5
Figure 7-8: H569-436 G53 (ED83143-31 G55)
DC Distribution Panel 7-5
Figure 7-9: H569-436 G60/61/65/66 (ED83143-31 G71)
DC Distribution Panel 7-6
Figure 7-10: H569-436 G67 (ED83143-31 G22)
DC Distribution Panel 7-6
Figure 7-11: H569-436 G68 (ED83143-31 G21)
DC Distribution Panel 7-7
Figure 9-1: Output Current vs. Temperature 9-5
Figure 11-1: Detail of Rectifier Position 11-3
Figure 12-1: Location of Cabinet Alarm 12-2
2 - List of Figures Issue 9 Januray 2008
Galaxy Power System 4812/24
Figure 12-2: Millennium Controller Display 12-8
Figure 12-3: Location of Millennium Controller Fuses
and Boards 12-8
Figure 12-4: Vector Controller Display 12-9
Figure 12-5: Location of Vector Controller Fuses
and Boards 12-9
Figure 12-6: Rectifier Display 12-10
Figure 12-7: Low Voltage Battery Disconnect Contactor
Control Switches 12-11
Figure 12-8: Detail of AC Input Panel and Rectifier Shelf 12-12
Figure 12-9: Detail of DC Distribution Panel 12-13
Figure 12-10: Low Voltage Load Disconnect Contactor
Control Switches 12-14
Issue 9 Januray 2008 List of Figures - 3
Galaxy Power System 4812/24
List of Tables
Table 9-A: Galaxy Power System 4812/24 Specifications 9-1
Table 9-B: Rectifier Specifications 9-3
Table 9-C: AC Input Panels 9-5
Table 9-D: Battery Connection Panels 9-6
Table 9-E: Battery Connection Panels 9-7
Table 11-A: GPS 4812/24 System Replacement Parts 11-6
Table 11-B: Galaxy Millennium Controller Circuit Boards 11-7
Table 11-C: Galaxy Vector Controller
Circuit Boards and Temperature Module 11-7
Table 11-D: Product Documentation 11-8
Table 13-A: AC Alarms 13-3
Table 13-B: Battery Alarms 13-4
Table 13-C: Controller Alarms 13-6
Table 13-D: Distribution Alarms 13-11
Table 13-E: Rectifier Related Alarms 13-12
Table 13-F: Miscellaneous Alarms 13-16
Table 14-A: AC Alarms 14-4
Table 14-B: Battery Alarms 14-5
Table 14-C: Controller Alarms 14-6
Table 14-D: Distribution Alarms 14-7
Table 14-E: Rectifier Related Alarms 14-8
Table 14-F: Miscellaneous Alarms 14-11
Issue 9 Januray 2008 List of Tables - 1
Galaxy Power System 4812/24
1 Introduction
GPS 4812/24
Overview Lineage Power developed the Galaxy Power System (GPS) 4812/24 to
support -48 volt telecommunications powering solutions in worldwide
markets. The GPS 4812/24 combines 55-ampere and 110-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 and features as power needs grow.
With 7,040-ampere maximum capacity, distribution flexibility, and
universal ac input capability, the GPS 4812/24 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.
Note Prior to Issue 6 of this manual, the GPS 4812/24 cabinet had a metal
door and the Galaxy Vector Controller consisted of a BIC3 board. For
information on these systems, see Issue 5 of this manual.
Illustrations Figures 1-1 and 1-2 illustrate the GPS 4812/24 half height and full
height cabinets.
Issue 9 Januray 2008 Introduction 1 - 1
Galaxy Power System 4812/24
Figure 1-1: GPS 4812/24 Half Height Initial Cabinet (with Battery Stand)
1 - 2 Introduction Issue 9 Januray 2008
Galaxy Power System 4812/24
Figure 1-2: GPS 4812/24 Full Height Initial Cabinet
Issue 9 Januray 2008 Introduction 1 - 3
Galaxy Power System 4812/24
Customer Service Contacts
Customer Service, Technical Support, Product Repair and Return, and Warranty Service
For customers in the United States, Canada, Puerto Rico, and the US
Virgin Islands, call 1-800-THE-1PWR (1-800-843-1797). This number
is staffed from 7:00 am to 5:00 pm Central Time (zone 6), Monday
through Friday, on normal business days. At other times this number is
still available, but for emergencies only. Services provided through this
contact include initiating the spare parts procurement process, ordering
documents, product warranty administration, and providing other
product and service information.
For other customers worldwide the 800 number may be accessed after
first dialing the AT&T Direct country code for the country where the
call is originating, or you may contact your local field support center or
your sales representative to discuss your specific needs.
Customer Training Lineage Power offers customer training on many Power Systems
products. For information call 1-972-284-2163. This number is
answered from 8:00 a.m. until 4:30 p.m., Central Time Zone (Zone 6),
Monday through Friday.
Downloads and Software
To download the latest product information, product software and
software upgrades, visit our web site at
http://www.lineagepower.com
1 - 4 Introduction Issue 9 Januray 2008
Galaxy Power System 4812/24
2 System Description
Overview
Block Diagram A basic block diagram of the Galaxy Power System 4812/24 is shown
in Figure 2-1. It illustrates the arrangement and interconnections of the
system components from the ac input to the dc output.
AC Input
Rectifiers
AC Input
Power
Chg
Bus
(-)
Return
Bus
(+)
DC Distribution
LVLD
Control
Board
LVL D
Battery Distribution
LVBD
Control
Board
Battery
Shunt
LVB D
To 48 Volt
Loads
DISCHG RTN
48V
Returns
BAT BUS
Battery (-)
CHG RTN
Battery (+)
CO
GND
Sense/Control
Connections
Controller
Figure 2-1: Block Diagram of the GPS 4812/24
Issue 9 Januray 2008 System Description 2 - 1
Galaxy Power System 4812/24
Overview, continued
System Components
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 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.
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.
2 - 2 System Description Issue 9 Januray 2008
Galaxy Power System 4812/24
Architecture
Configurations The GPS 4812/24 is available in two configurations:
• The half height cabinet, shown in Figures 1-1 and 2-2, mounts on
top of a battery stand and can provide up to 800 amperes of dc
power.
• The full height (7-foot) cabinet, shown in Figures 1-2 and 2-3, can
provide up to 1,600 amperes of dc power.
Each cabinet contains ac distribution, dc distribution panels, a battery
connection panel, rectifiers, termination points for load circuits, and a
system controller.
Illustrations Figure 2-4 shows how supplemental full-height cabinets may be added
to grow the system to 7,040 amperes. The rectifier output buses are
interconnected to permit the cabinet to share current and ensure
common voltage references for all system rectifiers.
Figures 2-5 and 2-6 show open-door views of the half height and full
height cabinets.
Issue 9 Januray 2008 System Description 2 - 3
Galaxy Power System 4812/24
AC
Battery
Shunt
Control
and
Monitor
Cabinet
Ground
AC
Ground
System (CO)
Ground
To Loads
Battery String(s)
Mounted Below
Half Height Cabinet
Figure 2-2: Schematic of Half Height Cabinet
2 - 4 System Description Issue 9 Januray 2008
Galaxy Power System 4812/24
AC
AC
Ground
Battery
String
Cabinet
Ground
System (CO)
Ground
Battery
Shunt
Control
and
Monitor
To Loads
Figure 2-3: Schematic of Full Height Cabinet
Issue 9 Januray 2008 System Description 2 - 5
Galaxy Power System 4812/24
Battery
Shunt
AC
Input
Monitor
Control
and
Battery
String
Battery
String
AC
Input
Battery
Shunt
To LoadsTo Loads
Initial Cabinet Supplemental Cabinet
Figure 2-4: Schematic of Two-cabinet System Architecture
2 - 6 System Description Issue 9 Januray 2008
Galaxy Power System 4812/24
Controller Access Panel
AC Panel
(Circuit Breakers)
LVBD
Control
Circuit
Miscellaneous
DC Distribution
Panels
LVLD
Control
Circuit
596 Rectifier
Figure 2-5: Half Height GPS 4812/24 with Door Open
Rectifier
Shelves
Issue 9 Januray 2008 System Description 2 - 7
Galaxy Power System 4812/24
Controller Access Panel
AC Panel
(Terminal Strip)
Low Voltage Battery
Disconnect Panel
Miscellaneous
DC Distribution
Panels
LVLD
Control
Circuit
Rectifier
Shelves
Figure 2-6: Full Height GPS 4812/24 with Door Open
2 - 8 System Description Issue 9 Januray 2008
Galaxy Power System 4812/24
3 Galaxy Controllers
Overview
Introduction The GPS 4812/24 is available with either the Galaxy Millennium
Controller or the Galaxy Vector Controller.
This section describes the operation of each controller. It also provides
detailed information about the features of their front panel keys, LEDs,
and displays.
Note If your cabinet has a metal door and a Galaxy Millennium Controller,
some components of the controller will look different than in this
manual, but operation is the same.
If your cabinet has a metal door and a Galaxy Vector Controller, your
controller differs substantially from the version shown in this manual.
Refer to Issue 6 of this manual for information pertaining to your
controller.
Issue 9 Januray 2008 Galaxy Controllers 3 - 1
Galaxy Power System 4812/24
Galaxy Millennium Controller
Design The Galaxy Millennium Controller is equipped with a Basic control
board (BSH) for basic operations and an optional Intelligent control
board (BSJ) that provides advanced local and remote monitoring and
data acquisition features. These CPU control boards monitor each
other’s status and issue appropriate alarms in the event a failure occurs.
Each cabinet used with the Galaxy Millennium Controller requires a bay
interface card (BIC). The BIC acts as an interface to the cabinet control
and alarm signals.
User Interface and Display
The Millennium’s primary user interface is a panel that includes 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 3-1 illustrates the Millennium’s front panel.
Galaxy Millennium Controller
Alarm Status
Critical
Major
Minor
Normal
Battery on
Discharge
V
Equipment Status
AC System
Battery
Controller
Distribution
Rectifier
Remote
Modules
Modem
Escape Help
Menu Enter
Figure 3-1: Galaxy Millennium Controller Front Panel
Default Display The default display shows basic system status. The controller returns to
this display approximately three minutes after the last time a key is
pressed. The information on the screen is updated automatically
approximately every two seconds.
The default screen display is similar to the following: The first line
shows the number of alarms (0) and warnings (0) 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
3 - 2 Galaxy Controllers Issue 9 Januray 2008
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