GE Industrial Solutions GPS 4812 User Manual

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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

10Safety

11Maintenance 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

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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

Customer Training

Downloads and

Software

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.

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.

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

 

 

 

 

 

Power

 

 

 

 

 

Chg

Return

DC Distribution

Bus

 

 

 

 

(-)

Bus

LVLD

 

 

 

 

(+)

Control

 

 

 

 

 

Board

 

 

 

 

 

 

LVLD

 

To 48 Volt

AC Input

 

 

 

 

Loads

 

 

 

 

 

DISCHG RTN

 

 

 

 

 

48V

 

 

 

 

 

Returns

 

 

Battery Distribution

 

 

 

 

 

BAT BUS

 

 

LVBD

 

 

 

 

 

Control

 

 

Battery (-)

 

 

Board

 

 

Rectifiers

 

 

 

 

 

 

 

Battery

LVBD

CHG RTN

 

 

Shunt

 

 

 

 

 

 

 

Battery (+)

 

CO

Sense/Control

 

 

 

GND

 

 

 

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

The power system accepts alternating current from the commercial

Components

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

 

Cabinet

 

Ground

 

AC

Battery

Ground

System (CO)

Shunt

Ground

 

 

To Loads

 

Control

 

and

 

Monitor

 

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

 

Battery

 

 

String

 

 

AC

 

 

 

Cabinet

 

AC

Ground

 

 

 

Ground

 

 

 

System (CO)

 

 

Ground

Battery

To Loads

 

Shunt

 

 

Control

 

 

and

 

 

Monitor

 

Figure 2-3: Schematic of Full Height Cabinet

Issue 9 Januray 2008

System Description 2 - 5

Galaxy Power System 4812/24

Battery

Battery

String

String

AC

AC

Input

Input

Battery

Battery

Shunt

Shunt

To Loads

To Loads

Control

 

and

 

Monitor

 

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

Rectifier

Shelves

596 Rectifier

Figure 2-5: Half Height GPS 4812/24 with Door Open

Issue 9 Januray 2008

System Description 2 - 7

GE Industrial Solutions GPS 4812 User Manual

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

User Interface and

Display

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.

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

Equipment Status

 

 

Critical

AC System

 

 

Major

Battery

 

 

Minor

Controller

 

 

Normal

Distribution

 

 

 

Rectifier

Escape

Help

 

 

 

Battery on

Remote

 

 

Discharge

 

 

 

Modules

 

 

V

Modem

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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