GE Industrial Solutions GPS 4848-100 User Manual

Download

Galaxy Power System 4848/100

with Dual Rectifier Shelf

and 595LT Rectifiers S2:0 and later

(GPS 4848/100)

H569-434

Notes: Refer to the Millennium II Product Manual 167-792-181 for Galaxy

Millennium II installation and setup. Instructions in this manual reference installation and setup of the Galaxy Millennium Controller.



Refer to User’s Guide Issue 3 for 595LT Series Rectifiers prior to S2:0.

User’s Guide Select Code 167-792-166 Comcode 108994042 Issue 5 September 2011

User’s Guide



Select Code 167-792-166 Comcode 108994042



Issue 5 September 2011

Galaxy Power System 4848/

100 with Dual Rectifier Shelf

and 595LT Rectifiers S2:0 and later



(GPS 4848/100)

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.

Note: Instructions in this manual reference installation and setup of the Galaxy

Millennium Controller. For Galaxy Millennium II installation and setup, refer to the Millennium II Product Manual 167-792-181.



Refer to User’s Guide Issue 3 for 595LT Series Rectifiers prior to S2:0.

H569-434

Galaxy Power System 4848/100 with Dual Rectifier Shelf

1 Introduction

GPS 4848/100 1-1

Overview 1-1 Related Documentation 1-1 Illustration 1-2 Safety 1-3 Electromagnetic Compliance 1-3 CE Marking 1-3 Telcordia 1-3

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 Bonding Network 2-2 Facility 2-2

Architecture 2-3

Introduction 2-3 Distributed 2-3 Centralized 2-5 Standard 2-7 Non-Traditional 2-7

3 Galaxy Millennium Controller

Overview 3-1

Mounting Location 3-1 Circuit Boards 3-1

Reference Material 3-1

Controller Product Manual 3-1 RPM System Product Manual 3-1

User Interface and Display 3-2

Front Panel 3-2 Default Display 3-2 LEDs 3-3

Issue 5 September 2011 Table of Contents - 1

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Pushbutton Controls 3-3 Test Jacks 3-4

4 Rectifiers

595 Series 4-1

Overview 4-1

Front Panel Display 4-2

Power Switch 4-2 Status Indicators 4-2 Current Display 4-2 Lamp Test 4-2 Illustration 4-2

Features 4-3

Output Voltage Adjustment 4-3 Output Current “Walk-in” 4-3 Electronic Current Limit 4-3 Selective High Voltage Shutdown (SHVSD) 4-3 Backup High Voltage Shutdown (BHVSD) 4-3 Restart 4-3 Output Circuit Breaker 4-3 Fan Alarm and Control 4-3 Thermal Alarm 4-4 Controller Communications Alarm 4-4 Autonomous Operation of the Rectifier 4-4 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

Introduction 6-1 Distributed Architecture 6-1 Centralized Architecture 6-1 Illustrations 6-1

7 DC Distribution Panels

Overview 7-1

2 - Table of Contents Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Function 7-1 Illustrations 7-1

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 Bay Interface Card 8-2 Contactor Control Board 8-2

9 Specifications

GPS 4848/100 9-1 Rectifiers 9-4 AC Input Panels 9-6 Battery Connection Panels 9-7 DC Distribution Panels 9-8

10 Safety

11 Maintenance and Replacement

Requirements 11-1

System 11-1 Batteries 11-1 Controller 11-1 Rectifier 11-2 Vacant Rectifier Positions 11-2 Rectifier Fan Assembly 11-2

Replacement Procedures 11-3

Installing or Replacing a Rectifier 11-3 Removing a Rectifier 11-6 Replacing the Rectifier Fan Assemblies 11-7

Testing 11-9

Testing Additional Alarms After Replacing Rectifiers 11-9 Testing Rectifiers and Load Share in Bay Expansions 11-9

Replacement Parts 11-10

System 11-10 Millennium Controller Circuit Boards 11-11

Additional Ordering Information 11-11

Issue 5 September 2011 Table of Contents - 3

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Documentation 11-11 Software 11-11

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 12-3 Identifying Problems 12-3

Reference Figures 12-4

Figure Numbers and Titles 12-4 Millennium Controller 12-4 Rectifier 12-6 Low Voltage Battery Disconnect 12-7 AC Input 12-8 AC Input 12-9 DC Distribution 12-10 Low Voltage Load Disconnect 12-11

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 Rectifier Display Messages and LEDs 13-2 Millennium Controller Display 13-3 AC Alarm LED 13-3 BATT Alarm LED 13-4 CTRL Alarm LED 13-5 DIST Alarm LED 13-9 RECT Alarm LED 13-10 BD and RM Alarm LEDs, or No LED 13-15

4 - Table of Contents Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

14 Product Warranty

Revision History

Issue 5 September 2011 Table of Contents - 5

Galaxy Power System 4848/100 with Dual Rectifier Shelf

6 - Table of Contents Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

List of Figures

Figure 1-1: GPS 4848/100 With Millennium Controller 1-2

Figure 2-1: Block Diagram of the GPS 4848/100

(Distributed Architecture) 2-1

Figure 2-2: Distributed Architecture 2-4

Figure 2-3: Distributed Architecture Initial and Growth Cabinets

2-4

Figure 2-4: Centralized Architecture 2-5

Figure 2-5: Centralized Architecture Cabinets 2-6

Figure 2-6: Non-Traditional Cabling Arrangements 2-7

Figure 3-1: Galaxy Millennium Controller Front Panel 3-2

Figure 4-1: Rectifier Front Panel 4-2

Figure 5-1: H569-434 G20/320/420 (ED83142-30 G3)

208/240V AC Input Circuit Breaker Panel - 4 Rectifier 5-2

Figure 5-2: H569-434 G21/23/321/323/421 (ED83142-30 G4)

208/240/480V AC Input Circuit Breaker Panel - 6 Rectifier 5-2



Figure 5-3: H569-434 G334/335 (ED83142-30 G24/25)

208/240/480V AC Input Circuit Breaker Panel - 12 Rectifier 5-3

Figure 5-4: H569-434 G22/322 (ED83142-30 G2)

480V AC Input Circuit Breaker Panel - 4 Rectifier 5-3

Figure 5-5: H569-434 G24/25/26/27/324/325/326/327/330/331

(ED83142-30 G5) 208/240/480V AC Input Terminal Strip Panel - 6 Rectifier 5-4

Figure 5-6: H569-434 G128/129/130/131 (ED83142-30 G18)

208/240/480V AC Input Terminal Strip Panel - 8 Rectifier 5-4

Figure 5-7: H569-434 G328/329/332/333 (ED83142-30 G26)

208/240/480V AC Input Terminal Strip Panel - 14 Rectifier 5-5

Figure 5-8: H569-434 G70/370/470 (ED83142-30 G10)

480V 65kAIC AC Input Circuit Breaker Panel - 4 Rectifier 5-5

Issue 5 September 2011 List of Figures - 1



Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 5-9: H569-434 G71/371/471 (ED83142-30 G11)

480V 65kAIC AC Input Circuit Breaker Panel - 6 Rectifier 5-6

Figure 6-1: H569-434 G30 (ED83143-31 G32)

Battery Connection Panel 6-2

Figure 6-2: H569-434 G31 (ED83143-31 G31)

Battery Connection Panel 6-2

Figure 6-3: H569-434 G32/32A (ED83143-31 G30/30A)

Battery Connection Panel 6-3

Figure 6-4: H569-434 G34 (ED83143-31 G41)

Battery Connection Panel 6-3

Figure 6-5: H569-434 G35 (ED83143-31 G42)

Battery Connection Panel 6-4

Figure 6-6: H569-434 G37/38 (ED83143-31 G60/61)

Battery (OLE) Connection Panel 6-4

Figure 6-7: H569-434 G80/81/82 (ED83143-31 G31/43)

Battery Connection Panel 6-5



Figure 6-8: H569-434 G86/87 (ED83143-31 G63/64)

Battery Connection Panel 6-6

Figure 6-9: H569-434 G39 (ED83143-31 G36)

Battery Connection Panel 6-6

Figure 7-1: H569-434 G40/45/50/55 (ED83143-31 G11)

400A DC Distribution Panel 7-2

Figure 7-2: H569-434 G41/46/51/56 (ED83143-31 G12)

400A DC Distribution Panel 7-2

Figure 7-3: H569-434 G42/47 (ED83143-31 G2)

600A DC Distribution Panel 7-3

Figure 7-4: H569-434 G43 (ED83143-31 G1)

1200A DC Distribution Panel 7-3

Figure 7-5: H569-434 G48 (ED83143-31 G5)

1000A DC Distribution Panel 7-4

Figure 7-6: H569-434 G52 (ED83143-31 G53)

600A DC Distribution Panel 7-4



Figure 7-7: H569-434 G53/57 (ED83143-31 G55)

1000A DC Distribution Panel 7-5

2 - List of Figures Issue 5 September 2011



Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 7-8: H569-434 G60/61/65/66 (ED83143-31 G71)

600A DC Distribution Panel 7-5

Figure 7-9: H569-434 G67 (ED83143-31 G22)

600A DC Distribution Panel 7-6

Figure 7-10: H569-434 G68 (ED83143-31 G21)

1200A DC Distribution Panel 7-6

Figure 7-11: H569-434 G96 (ED83143-31 G15)

510A DC Distribution Panel 7-7

Figure 7-12: H569-434 G97 (ED83143-31 G16) 14-Position, and

H569-434 G98 (ED83143-31 G17) 22-Position DC Distribution Panel 7-7

Figure 7-13: H569-434 G54 (ED83143-31 G54) 5-Position DC Dis-

tribution Panel 7-8

Figure 7-14: H569-434 G58 (ED83143-31 G58) 6-Position GMT DC

Distribution Panel 7-8

Figure 7-15: H569-434 G59 (ED83143-31 G56) 2-Position Fuse Dis-

tribution Panel 7-9



Figure 11-1: Installing a Rectifier in a Rectifier Shelf 11-4

Figure 11-2: Rectifier Fan Replacement 11-7

Figure 12-1: Location of Cabinet Alarm Light and Controller 12-2

Figure 12-2: Millennium Controller Display 12-5

Figure 12-3: Millennium Controller Fuses and Circuit Boards 12-5

Figure 12-4: Rectifier Display 12-6

Figure 12-5: Low Voltage Battery Disconnect

Contactor Control Switches 12-7

Figure 12-6: AC Input Panel and Rectifier Positions, 6 Rectifiers

12-8

Figure 12-7: AC Input Panel and Rectifier Positions, 12 Rectifiers

12-9

Figure 12-8: DC Distribution Panel 12-10

Figure 12-9: Low Voltage Load Disconnect Contactor

Control Switches 12-11



Issue 5 September 2011 List of Figures - 3

Galaxy Power System 4848/100 with Dual Rectifier Shelf

4 - List of Figures Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

List of Tables

Table 9-A: Galaxy Power System 4848/100 Specifications 9-1

Table 9-B: 595LT Series S2:x Rectifier Specifications 9-4

Table 9-C: Rectifier Display Messages and LEDs 9-5

Table 9-D: AC Panels 9-6

Table 9-E: Battery Connection Panels 9-7

Table 9-F: DC Distribution Panels 9-8

Table 11-A: GPS 4848/100 Replacement Parts 11-10

Table 11-B: Galaxy Millennium Controller Circuit Boards 11-11

Table 11-C: Product Documentation 11-11

Table 13-A: AC Alarms 13-3

Table 13-B: Battery Alarms 13-4

Table 13-C: Controller Alarms 13-5

Table 13-D: Distribution Alarms 13-9

Table 13-E: Rectifier Related Alarms 13-10

Table 13-F: Miscellaneous Alarms 13-15

Issue 5 September 2011 List of Tables - 1

Galaxy Power System 4848/100 with Dual Rectifier Shelf

1 Introduction

GPS 4848/100

Overview The Galaxy Power System (GPS) 4848/100 provides -48 volt

telecommunications powering solutions in worldwide markets. The GPS 4848/100 combines 220 and 200-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 14,080-ampere maximum capacity, distribution flexibility, and universal ac input capability, the GPS 4848/100 supports switching, transmission, and wireless applications in central office locations and environmentally controlled remote sites (huts or vaults). For centralized architecture, bus bars are available to 14,080A.

Notes This document includes information for 595LT series S2:0 and later

rectifiers. Refer to User’s Guide Issue 3 for 595LT Series Rectifiers

ior to S2:0. For information about 595A and 595B series rectifiers see

pr the GPS 4848/100 User’s Guide.

595A and 595B series rectifiers (full width, one per shelf) are fully supported by GPS 4848/100 with Dual Rectifier Shelves.

Illustration Figure 1-1 is an isometric view of the GPS 4848/100 with a Millennium

Controller.

Figure 1-1: GPS 4848/100 With Millennium Controller

1 - 2 Introduction Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

GPS 4848/100, continued

Safety •UL1 Listed (US and Canada): UL Subject 1801 with applicable

sections of UL1950/CSA2 950)

• VDE Licensed to VDE 0805/IEC950/EN60950

Electromagnetic

• Emission:

Compliance

– FCC Part 15 Class B

– EN55022 (CISPR 22) Radiated/Conducted Emission, Class B

• Immunity

– IEC/EN 61000-4-2 ESD level 3 and 4

– IEC/EN 61000-4-3 Radiated Immunity, 10V/m

– IEC/EN 61000-4-4 Electrical Fast transients/Burst, level 4

– IEC/EN 61000-4-5 Lightning Surge, level 4

CE Marking • CE marked per European Union Council Directives:

– Low-Voltage Directive (73/23/EEC) and

– EMC Directive (89/336/EEC) as amended by CE Marking

Directive (93/68/EEC)

Telcordia • GR-63 and GR-1089 NEBS (including Level 3 testing)

• Report by an independent test laboratory - NRTL

1.UL is a registered trademark of Underwriters Laboratories, Inc.

2.CSA is a registered trademark of Canadian Standards Association.

Issue 5 September 2011 Introduction 1 - 3

Galaxy Power System 4848/100 with Dual Rectifier Shelf

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 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

LVLD

DISCHG RTN

LVLD

Control

Board

Rectifiers

DC Distribution

Controller

Return

Bus

(+)

To 48 Volt Loads

AC Input

Power

48V Returns

LVBD

BAT BUS

CHG RTN

LVBD

Control

Board

Battery Distribution

Battery (-)

Battery

Shunt

Battery (+)

GND

Sense/Control

Connections

AC Input

Chg Bus

(-)

2 System Description

Overview

Block Diagram Figure 2-1 shows a basic block diagram of the Galaxy Power System

4848/100. It illustrates the arrangement and interconnections of the system components from the ac input to the dc output.

Figure 2-1: Block Diagram of the GPS 4848/100

(Distributed Architecture)

Issue 5 September 2011 System Description 2 - 1

Galaxy Power System 4848/100 with Dual Rectifier Shelf

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 fuse, contactors, current monitoring shunts, and equalize converters.

Bonding Network The GPS 4848/100 system is suitable for installation as part of a

Common Bonding Network (CBN) or an Isolated Bonding Network (IBN).

Facility The GPS 4848/100 system is suitable for installation in Network

Telecommunication Facilities and locations where NEC applies.

2 - 2 System Description Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Architecture

Introduction For the GPS 4848/100 system, the basic system components, i.e., ac

input panels, battery connection panels, dc distribution panels, rectifiers, and controller, can be configured to form two distinct system architectures: distributed or centralized.

Distributed In this system each cabinet contains ac distribution, dc distribution

panels, battery connection panels, rectifiers, termination points for load circuits, and a battery shunt. The initial cabinet also contains the system controller and, as such, it can function as a stand-alone system. The rectifier output buses are interconnected to permit cabinets to share current and ensure common voltage references for all system rectifiers. Because each cabinet is basically a self-contained system, the overall system capacity can be increased by simply adding cabinet/battery entities. However, growing the system requires a distinct, dedicated floor plan.

During normal operation, the readings from the battery shunts are summed and subtracted from the rectifier current to obtain the system load current. While the batteries are providing the system load power, the individual battery shunts may be monitored to determine the status of the individual battery sections.

Cabinets can be equipped with load and/or battery disconnect/reconnect contactors. Battery contactors prevent battery damage during deep discharges by disconnecting batteries. Load contactors can extend the time critical loads operate on battery discharge by disconnecting non-critical loads during discharge.

Figure 2-2 shows an example of GPS 4848/100 components configured in a distributed architecture; Figure 2-3 gives a front view of the distributed initial and growth cabinets.

Issue 5 September 2011 System Description 2 - 3

Control

and

Monitor

Battery Shunt

To Loads

Battery String

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Initial Cabinet

Growth Cabinet

Architecture, continued

Figure 2-2: Distributed Architecture

Figure 2-3: Distributed Architecture Initial and Growth Cabinets

2 - 4 System Description Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Charge Bus Charge Return Bus Discharge Return Bus

Battery Strings

Plant

Shunt

Control

and

Monitor

Loads

Architecture, continued

Centralized Figure 2-4 shows GPS 4848/100 components configured in a

centralized architecture; Figure 2-5 provides a view of the centralized architecture cabinets with and without controller.

Rectifiers, dc distribution panels, and batteries are cabled to external busbars where a single system shunt is provided to measure total system load current.

Rectifier cabinets contain ac distribution or ac terminal blocks, rectifiers, and cable termination points.

DC distribution cabinets contain load protectors, load cable termination points, and may include load disconnect/reconnect contactors.

The GPS 4848/100 controller may be provided in a dc distribution cabinet or a rectifier cabinet equipped with ac circuit breakers. The cabinet with the controller also contains termination points for the system interconnect cables.

This architecture requires extensive up-front planning to determine the ultimate system capacity and engineering to size the external busbars appropriately; however, the system plan is not constrained to dedicated layouts as required for distributed architecture systems.

Figure 2-4: Centralized Ar

Issue 5 September 2011 System Description 2 - 5

chitecture

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Architecture, continued

Cabinet with Controller

Cabinet without Controller

Figure 2-5: Centralized Architecture Cabinets

2 - 6 System Description Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

AC Input

Battery and DC Load Leads

AC Input

Battery and DC Load Leads

AC Input

Battery and DC Load Leads

"A" Arrangement "B" Arrangement "C" Arrangement

REMOVE BEFORE ADDING SECOND RECTIFIER

Cabinet Cabling Options

Standard Standard cabinets are designed so that ac, battery, and dc load cables are

run through the top of the cabinet.

Non-Traditional Any of the battery panels and dc load panels (shown in Sections 6 and

7) may be used in cabinets that have non-traditional cabling orientations. However, only G20, G22, G24, G26, and G27 ac panels (shown in Section 5) are available for these cabinets (see Figure 2-6). Suffixes of the ac panels indicate the cabling arrangements listed below:

Cabling Arrangement

Panel

Suffix

Note: Check

Through bottom of cabinet Through bottom of cabinet

Through bottom of cabinet Through top of cabinet

Through top of cabinet Through bottom of cabinet

H569-434 for availability.

AC Battery and DC Load

Figure 2-6: Non-Traditional Cabling Arrangements

Issue 5 September 2011 System Description 2 - 7

Galaxy Power System 4848/100 with Dual Rectifier Shelf

2 - 8 System Description Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

2 - 10 System Description Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

3 Galaxy Millennium Controller

Overview

Mounting Location The Galaxy Millennium Controller mounts inside the front door with the

display viewed from the outside.

Circuit Boards The Galaxy Millennium Controller is equipped with a Basic control

board for basic operations and an optional Intelligent control board that provides advanced local and remote monitoring and data acquisition features. These control boards monitor each other’s status and issue appropriate alarms in the event a failure occurs. Circuit packs are accessed by opening the hinged cover from the left side.

Reference Material

Controller Product Manual

RPM System Product Manual

A Galaxy Millennium Controller, Select Code 167-792-180, is furnished with every GPS 4848/100. Refer to the manual for information regarding configuration and operation.

Refer to the Galaxy Remote Peripheral Monitoring System product manual (Select Code 167-790-063) for additional information regarding module operation.

Issue 5 September 2011 Galaxy Millennium Controller 3 - 1

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Galaxy Millennium Controller

Alarm Status

Critical

Escape Help

Enter

Equipment Status

AC System

Battery

Controller

Distribution

Rectifier Remote

Modules

Major

Minor

Normal

Battery on Discharge

User Interface and Display

Front Panel The control panel displays alarm and status indicators and provides test

jacks to monitor the system output. Keys are provided for interacting with various menus that configure and monitor the system. The controller menus can be viewed in either English or Spanish.

The user’s primary interface with the controller is a panel that includes a backlit LCD front panel display, two rows of LEDs, test jacks, and an array of simple pushbutton controls. See Figure 3-1.

Default Display The default display shows basic plant status. The controller returns to

3 - 2 Galaxy Millennium Controller Issue 5 September 2011

Figure 3-1: Galaxy Millennium Controller Front Panel

this display three minutes after the last time a key is pressed. 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 time. The next two lines show the plant voltage and the plant load. The last line shows the plant mode, which can be FLOAT, BOOST, STC (Slope Thermal Compensation), BTP (Battery Thermal Protection, a boost mode that offers protection against thermal runaway), or BATT TEST mode.

The information on the screen is updated automatically approximately every two seconds.

Galaxy Power System 4848/100 with Dual Rectifier Shelf

User Interface and Display, continued

LEDs Two columns of LEDs show the severity and source of active alarms.

An alarm event may activate two LEDs: one Alarm Status LED and one Equipment Status LED. More than one of the Equipment Status LEDs may be active simultaneously. In that case, the Alarm Status LED that is active will be that of the most severe active alarm.

The first column has five LEDs. The first four indicate the severity of the reported alarms: Critical, Major, Minor, and Normal. The fifth LED, labeled Battery on Discharge, illuminates when the plant voltage is below the threshold set for this alarm condition in the plant configuration.

The second column includes seven LEDs, six of which indicate the source of the alarm: AC System, Battery, Controller, Distribution, Rectifier, or Remote Module. The final Modem LED will be active whenever the controller modem port is in use.

Pushbutton Controls

The pushbutton identified with an illuminated lamp icon can be used to test the controller’s circuit pack and front panel LEDs. It will also test the indicators of all serially connected devices.

A group of pushbutton keys beneath 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 the general description of these keys.

• Up arrow key: Use to navigate the menu; press the key to move the cursor up one line.

• Down arrow key: Use to navigate the menu; press the key to move the cursor down one line.

• Left arrow key: Use to navigate the menu; press the key to move the cursor left one field.

• Right arrow key: Use to navigate the menu; press the key to move the cursor right one field.

• MENU key: Press this key any time to view the MAIN menu.

• HELP key: Press this key to display limited on-line help information.

• ENTER key: Use this key to select a menu item.

• ESCAPE key: Use this key to return to the immediately higher level menu.

Issue 5 September 2011 Galaxy Millennium Controller 3 - 3

Galaxy Power System 4848/100 with Dual Rectifier Shelf

User Interface and Display, continued

Test Jacks A pair of test jacks allows direct measurement of the system voltage

being monitored, normally the battery voltage. This is the same point regulated as system voltage and displayed on the front panel.

3 - 4 Galaxy Millennium Controller Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

4 Rectifiers

595 Series

Overview Four rectifiers are available for the GPS 4848/100 system with dual

rectifier shelves: 595A Series, 595B Series, 595LTA Series, and 595LTB Series.

GPS4848/100 Rectifiers

Series

595A 200A 1 320-530Vac 595B 200A 1 170-260Vac 595LTA 220A 2 320-530Vac 595LTB 220A 2 170-260Vac

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. The rectifiers are keyed to prevent installation of a rectifier with incompatible ac input. No operational settings or adjustments to potentiometers are necessary. The installer must set the ID of each rectifier using its ON/STBY switch to allow the controller to identify the rectifier for status and alarm reporting.

595A and 595B series rectifiers (full width, one per shelf) are fully supported. See GPS 4848/100 User's Guide for views and other details of 595A and 595B series rectifiers.

Current

Rectifiers

per Shelf

3-Phase AC

Input Voltage

Issue 5 September 2011 Rectifiers 4 - 1

Galaxy Power System 4848/100 with Dual Rectifier Shelf

ABC12345678

Model: 595LTA

480V 48V

RECTIFIER

KZO41234567 SX:X

220A/48V

STBY

ALM LIM FAN

ALM

BST

Front Panel Display

Power Switch This three-position switch has two functions:

• It controls the on/standby state of the rectifier.

• It is used to set the rectifier ID.

Status Indicators In addition to the ON and STBY LEDs, four other LEDs on the

rectifier’s faceplate indicate the rectifier’s condition.

• The ALM LED is red and lights when a thermal alarm occurs or a rectifier fail condition occurs. This LED blinks when communication with the plant controller is not active.

• The LIM LED is yellow lights when the unit is in current limit.

• The FAN AL M LED is red and lights when the fan inside the rectifier is not functioning properly.

• The EQL LED is yellow and lights when the rectifier is in equalize mode.

Current Display This display indicates the current of the rectifier. Upon specific

no-power conditions, the 3-digit display will show informative messages.

Lamp Test To test the LEDs on the rectifier front panel, use the Lamp Test feature

of the controller.

Illustration

Figure 4-1: Rectifier Front Panel

4 - 2 Rectifiers Issue 5 September 2011

Features

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Output Voltage Adjustment

Output Current “Walk-in”

Electronic Current Limit

Selective High Voltage Shutdown (SHVSD)

Backup High Voltage Shutdown (BHVSD)

This feature allows the rectifier output voltage to be set and regulated by the controller.

This feature 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.

When the output current tends to increase above the current limit set point (30% to 100% of maximum output), the current limit circuit overrides voltage regulation and load share to safely limit the output current of the rectifier, thus preventing damage to itself, the battery, or the load.

This feature allows the rectifier to respond and shut down at the output high voltage threshold set through the Galaxy controller.

This is a hardwired feature independent of the rectifier’s microcontroller. This feature is always active and will operate whether communicating with the controller or not and whether the rectifier's microcontroller is active or failed.

Restart Upon shutdown, the rectifier will attempt to restart. The rectifier will try

to restart three times before issuing a rectifier fail alarm to the controller. The rectifier will also accept a restart command from the controller for a remote restart.

Output Circuit Breaker

Fan Alarm and Control

Issue 5 September 2011 Rectifiers 4 - 3

The output circuit breaker located on the front panel protects the power system from rectifier malfunction and may be used to disconnect the rectifier from the system output bus.

The rectifier contains two cooling fans whose speed is based on ambient temperature and output power level. The fan’s speed is lowered during low-load and low-temperature conditions to minimize audible noise and maximize fan life.

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Features, continued

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 may result in a rectifier shutdown and the issuing of a thermal alarm (TA).

Controller Communications Alarm

Autonomous Operation of the Rectifier

Connectorized The rectifiers provide the controller with a full complement of status and

“Forced” Load Sharing

When communications between the rectifier and controller are interrupted, the rectifier continues to operate and the red ALM LED on the rectifier blinks.

If communication with the Galaxy controller is lost, the rectifier will continue to operate and deliver regulated power to the system load.

alarm messages. The rectifier status and alarm signals, ac input, and dc output are all connectorized for easy installation and maintenance. All connections automatically occur as the rectifier is physically mated to its shelf.

The controller forces rectifiers to load share by sending messages to them. In the event communication to the controller is lost or the controller malfunctions, load share balance is maintained while ac or dc power is continuously applied to the rectifiers.

4 - 4 Rectifiers Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

5 AC Input Panels

Overview

AC Service The ac input panel provides the facility to terminate the 3-phase ac

service to the GPS 4848/100. Depending upon the option ordered, the panel will connect 3-wire delta or 3-wire wye service to provide the phase-to-phase ac voltage required for the rectifiers.

In some systems, circuit breakers are provided in the AC Input Panel to protect the conductors providing ac service to the individual rectifiers. In other systems, the circuit breakers protecting these conductors are located in the building’s ac service panel. In either case, conductors to each rectifier are protected by a dedicated circuit breaker.

Note: All wire sizes were based on the US National Electric Code.

Illustrations Circuit breaker panels are shown in Figures 5-1 through 5-4, 5-8, and

5-9. Terminal strip panels are shown in Figures 5-5 through 5-7.

Issue 5 September 2011 AC Input Panels 5 - 1

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 5-1: H569-434 G20/320/420 (ED83142-30 G3)

208/240V AC Input Circuit Breaker Panel - 4 Rectifier

Figure 5-2: H569-434 G21/23/321/323/421 (ED83142-30 G4)

208/240/480V AC Input Circuit Breaker Panel - 6 Rectifier

5 - 2 AC Input Panels Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 5-3: H569-434 G334/335 (ED83142-30 G24/25)

208/240/480V AC Input Circuit Breaker Panel - 12 Rectifier

Figure 5-4: H569-434 G22/322 (ED83142-30 G2)

480V AC Input Circuit Breaker Panel - 4 Rectifier

Issue 5 September 2011 AC Input Panels 5 - 3

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 5-5: H569-434 G24/25/26/27/324/325/326/327/330/331 (ED83142-30 G5)

208/240/480V AC Input Terminal Strip Panel - 6 Rectifier

Figure 5-6: H569-434 G128/129/130/131 (ED83142-30 G18)

208/240/480V AC Input Terminal Strip Panel - 8 Rectifier

5 - 4 AC Input Panels Issue 5 September 2011

SCREWTORQUE: 25 IN-LB

VACSERVICE

------------------

L1 L1 L1L2 L2 L2L3 L3 L3

L1 L1 L1 L1L2 L2 L2 L2L3 L3 L3 L3

INPUT9

INPUT10

INPUT11

INPUT12

INPUT1

INPUT2

INPUT3

INPUT4

L1 L1L2 L3

L1 L1L2 L2L3

INPUT13

INPUT5

INPUT6

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 5-7: H569-434 G328/329/332/333 (ED83142-30 G26)

208/240/480V AC Input Terminal Strip Panel - 14 Rectifier

Figure 5-8: H569-434 G70/370/470 (ED83142-30 G10)

480V 65kAIC AC Input Circuit Breaker Panel - 4 Rectifier

Issue 5 September 2011 AC Input Panels 5 - 5

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 5-9: H569-434 G71/371/471 (ED83142-30 G11)

480V 65kAIC AC Input Circuit Breaker Panel - 6 Rectifier

5 - 6 AC Input Panels Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

6 Battery Connection Panels

Overview

Introduction Batteries are connected to the GPS 4848/100 cabinets based on the

system architecture.

Distributed Architecture

Centralized Architecture

For distributed power architecture, the batteries are terminated on battery connection panels with shunts that monitor the battery charge / discharge current through circuits on the cabinet BIC (Bay Interface Card). These battery connection panels are located either in the very top of the cabinet (shunt-only panels) or directly below the ac input panel.

As options, these panels may also include fuses or low battery voltage disconnect/reconnect (LVBD/R) contactors. When equipped with contactor(s), contactor control card(s) provide local/manual control of the contactor(s) and communications with the controller for configured/ remote control.

Off Line Equalize (OLE) battery connection panels additionally provide means to manually equalize single battery sections. A plug-in dc to dc converter provides up to 65V to fully charge battery section cells, equalizing cell float voltages. This restores fully charged cell capacity to each cell in the section. A timer terminates the manually initiated equalize operation.

For systems with centralized architecture, the batteries are connected between the system charge and charge return buses. In turn, these buses are connected to rectifier termination buses located behind the ac input panels.

Illustrations The battery connection panels are illustrated in Figures 6-1 through 6-9.

Note: Battery connection panels are blue; dc distribution panels are white.

Issue 5 September 2011 Battery Connection Panels 6 - 1

Two 500AContactors

Contactor Control Cards

Two 1000AShunts

Connects to Charge Return Bus

9" REF (229mm)

Contactor Control Card

1200A Contactor

1500A Shunt

Connects to Charge Return Bus

6" REF (152mm)

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 6-1: H569-434 G30 (ED83143-31 G32)

Battery Connection Panel

Figure 6-2: H569-434 G31 (ED83143-31 G31)

Battery Connection Panel

6 - 2 Battery Connection Panels Issue 5 September 2011

Terminal Card

Alarm Card

(2) NH3 Fuse Holders

Connects to Charge Return Bus

9" REF (229mm)

Two 600AShunts

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 6-3: H569-434 G32/32A (ED83143-31 G30/30A)

Battery Connection Panel

Figure 6-4: H569-434 G34 (ED83143-31 G41)

Battery Connection Panel

Issue 5 September 2011 Battery Connection Panels 6 - 3

Alarm/Terminal Card

(1) NH3 Fuse Holder

Connects to Charge Return Bus

6" REF (152mm)

600A Shunt

Alarm/Terminal Card

(3) 600A Fuses

(3) 1000A Shunts

(1) 1200A Contactor and Contactor Control Board (G60 only)

M10 Connections

Connects to Charge Return Bus

15" REF (381mm)

Note: For more information, refer to the OLE Product Manual, Select Code 167-792-200

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 6-5: H569-434 G35 (ED83143-31 G42)

Battery Connection Panel

Figure 6-6: H569-434 G37/38 (ED83143-31 G60/61)

Battery (OLE) Connection Panel

6 - 4 Battery Connection Panels Issue 5 September 2011

Contactor Control Card

Alarm Cards

1200A Contactor

ED83143-31 G31

1200A Contactor

ED83143-31 G43

Two NH3 DIN Fuses Two 600AShunts

Connect to Charge Return Bus

G80

G81

G82

1 G31 1 G43 1 G31 2 G43

1 G31 3 G43 (shown)

H569-434

Includes:

24" REF (610mm)

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 6-7: H569-434 G80/81/82 (ED83143-31 G31/43)

Battery Connection Panel

Issue 5 September 2011 Battery Connection Panels 6 - 5

Alarm Card

Terminal Card

800A Contactor

6 Circuit Breaker Positions (Circuit breakers ordered separately)

Shunts (Provided with circuit breakers)

Connects to Charge Return Bus

12" REF (152mm)

3000A Shunt

2000A Contactor

Connects to Charge Return Bus

9" REF (229mm)

Contactor Control Card

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 6-8: H569-434 G86/87 (ED83143-31 G63/64)

Battery Connection Panel

Figure 6-9: H569-434 G39 (ED83143-31 G36)

6 - 6 Battery Connection Panels Issue 5 September 2011

Battery Connection Panel

Galaxy Power System 4848/100 with Dual Rectifier Shelf

7 DC Distribution Panels

Overview

Function A variety of dc distribution panels are available featuring large or small

fuses and circuit breakers of both domestic and European design. 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. Replacement fuses and plug-in circuit breakers are listed in the Replacement Parts section.

Illustrations The dc distribution panels are illustrated in Figures 7-1 through 7-14.

Note: DC distribution panels are white; battery connection panels are blue.

Issue 5 September 2011 DC Distribution Panels 7 - 1

Alarm/Terminal Card

14 Positions for U.S. Plug-in Circuit Breakers or Fuse Holders

Connects to Charge Return Bus

6" REF (152mm)

Alarm/Terminal Card

22 Positions for U.S. Plug-in Circuit Breakers or Fuse Holders

Connects to Charge Return Bus

9" REF (229mm)

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 7-1: H569-434 G40/45/50/55 (ED83143-31 G11)

400A DC Distribution Panel

Figure 7-2: H569-434 G41/46/51/56 (ED83143-31 G12)

400A DC Distribution Panel

7 - 2 DC Distribution Panels Issue 5 September 2011

Alarm/Terminal Card

3 Positions for Large U.S. Circuit Breakers with Shunts

Connects to Charge Return Bus

6" REF (152mm)

Alarm Card

Terminal Card

6 Positions for Large U.S. Circuit Breakers with Shunts

Connects to Charge Return Bus

12" REF (305mm)

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 7-3: H569-434 G42/47 (ED83143-31 G2)

600A DC Distribution Panel

Issue 5 September 2011 DC Distribution Panels 7 - 3

Figure 7-4: H569-434 G43 (ED83143-31 G1)

1200A DC Distribution Panel

Alarm Card

5 Positions for Large U.S. Circuit Breakers with Shunts

Connects to Charge Return Bus

Terminal Card

9" REF (229mm)

Alarm/Terminal Card

Connects to Charge Return Bus

10 Medium U.S. Fuse Holders

6" REF (152mm)

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 7-5: H569-434 G48 (ED83143-31 G5)

1000A DC Distribution Panel

Figure 7-6: H569-434 G52 (ED83143-31 G53)

600A DC Distribution Panel

7 - 4 DC Distribution Panels Issue 5 September 2011

Connects to Charge Return Bus

2 U.S. Large Fuse Holders

2 600A Shunts

Alarm/Terminal Card

9" REF (229mm)

Alarm Cards

14 Positions for DIN Circuit Breakers (1-63A) or DIN Fuse Holders (10 x 38mm fuses, 1-32A)

or 10 Positions for DIN Circuit Breakers (80-125A) or DIN Fuse Holders (14 x 51mm fuses, 1-50A)

Connects to Charge Return Bus

6" REF (152mm)

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 7-7: H569-434 G53/57 (ED83143-31 G55)

1000A DC Distribution Panel

Issue 5 September 2011 DC Distribution Panels 7 - 5

Figure 7-8: H569-434 G60/61/65/66 (ED83143-31 G71)

600A DC Distribution Panel

Alarm/Terminal Card

8 NH00 Fuse Holders

Connects to Charge Return Bus

6" REF (152mm)

Alarm/Terminal Card

Connects to Charge Return Bus

2 NH2 Fuse Holders

6" REF (152mm)

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 7-9: H569-434 G67 (ED83143-31 G22)

600A DC Distribution Panel

Figure 7-10: H569-434 G68 (ED83143-31 G21)

1200A DC Distribution Panel

7 - 6 DC Distribution Panels Issue 5 September 2011

Alarm/Terminal Card

10 Positions for Plug-in (Bullet Style) Circuit Breakers

Connects to Charge Return Bus

6" REF (152mm)

G16: 14 Positions G17: 22 Positions for Plug-in (Bullet Style) Circuit Breakers

Alarm/Terminal Card

Connects to Charge Return Bus

G16: 6" REF (152mm) G17: 9" REF (229mm)

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 7-11: H569-434 G96 (ED83143-31 G15)

510A DC Distribution Panel

Figure 7-12: H569-434 G97 (ED83143-31 G16) 14-Position, and H569-434 G98

Issue 5 September 2011 DC Distribution Panels 7 - 7

(ED83143-31 G17) 22-Position DC Distribution Panel

300A Shunt (in back of panel) per Position

5 Large TPL-B Fuse Positions

9" REF

(229mm)

Connects to Charge Return Bus

Alarm/Terminal Card

Maximum Panel Capacity

1125A 800A with LVLD

6 GMT Fuse Positions

Maximum Panel Ampacity

15A per G58 Panel

This panel mounts on the right side of the GPS cabinet and therefore takes up no space within the cabinet distribution area.

6-Pin Jack for Power / Alarm Cable Set per 848665147

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 7-13: H569-434 G54 (ED83143-31 G54) 5-Position DC Distribution Panel

Figure 7-14: H569-434 G58 (ED83143-31 G58) 6-Position GMT DC Distribution Panel

7 - 8 DC Distribution Panels Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Figure 7-15: H569-434 G59 (ED83143-31 G56) 2-Position Fuse Distribution Panel

Issue 5 September 2011 DC Distribution Panels 7 - 9

Galaxy Power System 4848/100 with Dual Rectifier Shelf

8 Circuit Boards

Overview

Function Circuit boards (sometimes referred to as “cards” or “circuit packs”) are

included in bays, battery connection panels, and dc distribution panels to provide data required by the controller and to control devices such as contactors and lamps.

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

where it is used to calculate current. Data from the terminal boards located on the battery connection panels are used to calculate battery current; data from terminal boards located on the dc distribution panels are used to calculate load currents.

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

BLJ Terminal Board

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

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 5 September 2011 Circuit Boards 8 - 1

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Overview, continued

Bay Interface Card Each cabinet has a Bay Interface Card (BIC) that attaches to the

cabinet’s terminal board (BLJ). The BIC provides controller access to alarm monitoring, battery voltages, battery currents, and temperature probes in the cabinet through the serial rectifier bus. The BIC also provides connection of the system serial rectifier bus to the bay rectifiers. See Figure 1-1.

Contactor Control Board

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 based on maintenance switch settings

8 - 2 Circuit Boards Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

9 Specifications

GPS 4848/100

Table 9-A: Galaxy Power System 4848/100 Specifications

Electrical

Nominal output voltage -48Vdc

Operating Voltage Range (Float or Boost)

Output Current (System Maximum) 14,080A

Nominal Input Voltage  (595LTA or 595A3 Rectifier)

Nominal Input Voltage  (595LTB or 595B3 Rectifier)

Input Voltage Range per phase (595LTA or 595A3 Rectifier)

Input Voltage Range per phase (595LTB or 595B3 Rectifier)

Input Frequency Range 47 Hz - 63 Hz

System Efficiency (including ac and dc cables)

Regulation (line and load range with controller)

Output AC Ripple <100mVrms

Output Noise - Voiceband 55dBrnC

Electromagnetic Immunity 10V/meter over 20 MHz - 2000 MHz

-44Vdc to -58Vdc

380-480Vac, 3-wire plus ground

200-240Vac, 3-wire plus ground

320Vac - 530Vac

176Vac - 254Vac

>92%

± 0.5%

Issue 5 September 2011 Specifications 9 - 1

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Table 9-A: Galaxy Power System 4848/100 Specifications (Continued)

Physical

Width, Depth 600 mm, 600 mm (23.6 in. x 23.6 in.)

Weight (approximate, per cabinet) 250 kg (551 lbs.)

Height (cabinet only) 2134 mm (84.0 in.)

Height (cabinet with link bus bar) 2274 mm (89.5 in.)

Environmental

Heat Release, per cabinet

(including 1% cabinet loss)

Number of Rectifiers

4 5 6 7

8 10 12 14

per Rectifier

Operating Temperature 0°C to 40°C

Operating Relative Humidity 5% - 95%

Rectifiers 595LTA / 595LTB: 0 - 12; 595A / 595B: 0 - 6

Controller 1

Battery Modules 0 - 3

DC Distribution 1 - 6 

Rectifiers 595LTA / 595LTB: 0 - 14; 595A / 595B: 0 - 7

Battery Modules 0 - 1

DC Distribution 1 - 6 

at 54Vdc, 200Adc

595LTA S2:x 595LTB S2:x

2,240W (7,700 BTU / hr) 2,480W (8,500 BTU / hr) 2,800W (9,600 BTU / hr) 3,100W (10,600 BTU / hr) 3,360W (11,500 BTU / hr) 3,720W (12,700 BTU / hr) 3,920W (13,400 BTU / hr) 4,340W (14,900 BTU / hr) 4,480W (15,300 BTU / hr) 4,960W (17,000 BTU / hr) 5,600W (19,200 BTU / hr) 6,200W (21,200 BTU / hr) 6,720W (23,000 BTU / hr) 7,440W (25,500 BTU / hr) 7,870W (26,800 BTU / hr) 8,680W (29,700 BTU / hr) 560W (1,900 BTU / hr) 620W (2,120 BTU / hr)

Units Per Cabinet with Controller

(maximum of 5 with battery disconnect)

Units Per Cabinet without Controller

(maximum of 5 with battery disconnect)

9 - 2 Specifications Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Table 9-A: Galaxy Power System 4848/100 Specifications (Continued)

Standards Compliance

Safety •UL3 Listed (US and Canada): UL Subject 1801 with applicable

sections of UL1950/CSA

• VDE Licensed to VDE 0805/IEC950/EN60950

UL is a registered trademark of Underwriters Laboratories, Inc.

CSA is a registered trademark of Canadian Standards Association.

Electromagnetic Compliance • Emission:

– FCC Part 15 Class A – EN55022 (CISPR 22) Radiated/Conducted Emission, Class A – GR1089 EMC Requirements

• Immunity – IEC/EN 61000-4-2 ESD level 4 – IEC/EN 61000-4-3 Radiated Immunity, 10V/m – IEC/EN 61000-4-4 Electrical Fast Transients/Burst, level 4 – IEC/EN 61000-4-5 Lightning Surge, level 4 – IEC/EN 61000-4-6 Conducted Immunity 10Vrms

CE Marking • CE marked per European Union Council Directives:

– Low-Voltage Directive (73/23/EEC) – EMC Directive (89/336/EEC)

as amended by CE Marking Directive (93/68/EEC)

Telcordia • GR-63 and GR-1089 NEBS (including Level 3 testing)

• Report by an independent test house

950)

Issue 5 September 2011 Specifications 9 - 3

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Rectifiers

Table 9-B: 595LT Series S2:x Rectifier Specifications

Electrical

Output Voltage 52Vdc typical Output Voltage Adjustment 44-58Vdc float/boost Regulation (with controller) ±0.5% Output Current 595LTA 595LTB

220A 0°C to 40°C 0°C to 37°C

At 50°C 200A 200A High Voltage Shutdown (selected by controller) Backup High Voltage Shutdown Float/boost 59-60Vdc (59.5Vdc nominal) Output AC Ripple 100mVrms Output Noise - Voiceband 55dBrnC Current Limit Set Point 60Adc - 220Adc

Nominal Input Voltage (3-wire plus ground) 380 - 480 Vac 200 - 240 Vac Input Voltage Range (per phase) 320 - 530 Vac 176 - 275Vac Input Current Specified



Rated Maximum

Typical Maximum

Float/boost 44-60Vdc (56Vdc default)

595LTA Rectifier 595LTB Rectifier

20A at 480Vac 40A at 208Vac 25A at 380Vac 35A at 240Vac

30A 50A 22A at 320Vac 41A at 176Vac 19A at 380Vac 36A at 200Vac 15A at 480Vac 33A at 208Vac

30A at 240Vac

Frequency Range 47 - 63 Hz Power Factor 0.99 from 50% to 100% load

Total Harmonic Distortion <5% from 50% to 100% load 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 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:

595LTA

Phase to Phase MOV Conduction

Vo l t a g e Current 625 Vac (RMS) 0 A 940 Vpeak 1 mA 1650 Vpeak 100 A

595LTB

Phase to Phase MOV Conduction

Vo l t a g e Current 320 Vac (RMS) 0 A 462 Vpeak 1 mA 810 Vpeak 100 A

9 - 4 Specifications Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Table 9-B: 595LT Series S2:x Rectifier Specifications (Continued)

Physical

Width 265 mm (10.4 in.) rear of unit Height 210 mm (8.25 in.) rear of unit Depth 470 mm (18.2 in.) overall, less connector Weight LTA - 17 kg (37 lbs) LTB - 15 kg (33 lbs)

Environmental

Efficiency - Typical From 100Adc to 220Adc

595LTA 595LTB

96% 95.5% Storage Temperature -40°C - +85°C Storage Relative Humidity 5% - 90% Altitude -50 to 4000 meters (Note: For altitudes

derate the temperature by 0.656° Celsius per 100 meters.) Audible Noise < 60dBA at room temperature, mounted in cabinet Heat Release Per Rectifier: 54Vdc, 160Adc 54Vdc, 200Adc 54Vdc, 220Adc

Standards Compliance

Safety • UL Recognized (US and Canada) and VDE

Electromagnetic Compliance: Emission and Immunity

CE Marking CE marked per European Union Council directives: Low-voltage

595LTA 595LTB 270W (920 BTU / hr) 360W (1,240 BTU / hr) 450W (1,550 BTU / hr) 510W (1,750 BTU / hr) 560W (1,930 BTU / hr) 630W (2,150 BTU / hr)

• UL1950, EN60950/IEC950, and CSA 234/950 (tested for SEL

V output)

• EN55022 (CISPR22) Radiated/conducted emission Class A

• FCC Part 15 Class A

• IEC/EN 61000-4-2 ESD levels 3 and 4

• IEC/EN61000-4-3 Radiated Immunity, 10Vm

• IEC/EN61000-4-4 Electrical Fast Transients/Burst, level 4

• IEC/EN 61000-4-5 Lightning Surge, level 4

Directiv 68/EEC)

e (73/23/EEC) as amended by CE Marking Directive (93/

above 1500 meters,

Table 9-C: Rectifier Display Messages and LEDs

State Display Message LED Illuminated

Normal Current On Output Limited Current LIM Manual Standby Blank STBY Remote Standby (Shutdown) tr STBY Output Breaker Open CB ALM Interlock Open ILC ALM AC Fail ACF None Phase Fail PF None OverTemperature Shutdown tA ALM Output Under Voltage Shutdown LO ALM High Voltage Shutdown HO ALM Internal Failure LS, ICS, IP5, IP6, IP7, SEN, FSE, InF ALM

Issue 5 September 2011 Specifications 9 - 5

Galaxy Power System 4848/100 with Dual Rectifier Shelf

AC Input Panels

Table 9-D: AC Panels

Va c AC Feeds Rectifiers ED83142-30 H569-434GPS4848/100

AC Circuit Breaker Panels - 595 Rectifiers

208/240 2 4 3 20, 220 208/240 2 6 4 21 480 1 4 2 22

480 2 6 4 23 65KIC 480 2 4 10 70, 270 65KIC 480 2 6 11 71

AC Terminal Strip Panels- 595 Rectifiers

208/240 4 4 5 24, 224

208/240 6 6 5 25

208/240 8 8 18 129, 131

480 4 4 5 26, 226

480 6 6 5 27

480 8 8 18 128, 130

AC Circuit Breaker Panels - 595LT Rectifiers

208/240 2 4 3 320, 420

208/240 2 6 4 321, 421

208/240 4 12 25 335 480 1 4 2 322 480 2 6 4 323

480 4 12 24 334 65KIC 480 2 4 10 370, 470 65KIC 480 2 6 11 371, 471

AC Terminal Strip Panels - 595LT Rectifiers

208/240 4 4 5 324

208/240 6 6 5 325

208/240 8 8 18 331

208/240 12 12 26

208/240 14 14 26 333 480 4 4 5 326 480 6 6 5 327 480 8 8 18 330 480 12 12 26 328 480 14 14 26 332

329

Distribution Only Panels, no ac

- None 28

- None 29

9 - 6 Specifications Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Battery Connection Panels

Table 9-E: Battery Connection Panels

Fuse or

Circuit Breaker LV BD Shunt ED83143-31

No Battery Panel

None 33

Panels without Fuses or Circuit Breakers

1,500A 30 32

3,000A 30A 32A 2,000A 3,000A 36 39 1,200A 1,500A 31 31 2 x 500A 2 x 600A 32 30

Panels with Fuses or Circuit Breakers

2 x NH3 fuse 2 x 600A 41 34 1 x NH3 fuse 600A 42 35 2 x NH3 fuse 1,200A 2 x 600A 43 with 31 80 4 x NH3 fuse 1,200A 4 x 600A 2 x 43 with 31 81 6 x NH3 fuse 1,200A 6 x 600A 3 x 43with 31 82 6 x breaker poles 63 86 6 x breaker poles 800A 64 87

Off Line Equalize Panels

1,200A 3 x 1,000A 60 37

3 x 1,000A 61 38

H569-434

GPS4848/100

Issue 5 September 2011 Specifications 9 - 7

Galaxy Power System 4848/100 with Dual Rectifier Shelf

DC Distribution Panels

Table 9-F: DC Distribution Panels

Fuse or CB Pos

CB Clip-on / Fuse Small - TPA 14 6 11 40, 40A, 50, 50A CB Clip-on / Fuse Small - TPA 14 6 Y 11 45, 45A, 55, 55A CB Clip-on / Fuse Small - TPA 22 9 12 41, 41A, 51, 51A CB Clip-on / Fuse Small - TPA 22 9 Y 12 46, 46A, 56, 56A

CB Large – Bolt-in 3 6 CB size, 25mV 2

CB Large – Bolt-in 3 6 Y CB size, 25mV 2 47, 47A

CB Large – Bolt-in 5 9 CB size, 25mV 5

CB Large – Bolt-in 5 9 Y CB size, 25mV 5 48B, 48C

CB Large – Bolt-in 6 12 CB size, 25mV 1

CB Large – Bolt-in 6 12 Y CB size, 25mV 1 43B, 43C CB Bullet 10 6 15 96, 96A CB Bullet 10 6 Y 15 96B, 96C CB Bullet 14 6 16 97, 97A CB Bullet 14 6 Y 16 97B, 97C CB Bullet 22 9 17 98, 98A CB Bullet 22 9 Y 17 98B, 98C Fuse Medium - TPS 10 6 53 52, 52A Fuse Medium - TPS 10 6 Y 53 52B, 52C

Fuse Large 2 6

Fuse Large - TPL 2 9

Fuse Large - TPL 2 9 Y

Fuse Large - TPL-B 5 9

Fuse Large - TPL-B 5 9 Y

CB DIN Small 14 6 71/171 60, 60A CB DIN Small 14 6 Y 71/171 60B, 60C CB DIN Large 10 6 71/171 61, 61A CB DIN Large 10 6 Y 71/171 61B, 61C Fuse DIN 10 x 38mm 14 6 71/171 65, 65A Fuse DIN 10 x 38mm 14 6 Y 71/171 65B, 65C Fuse DIN 14 x 51mm 10 6 71/171 66, 66A Fuse DIN 14 x 51mm 10 6 Y 71/171 66B, 66C Fuse DIN NH00 8 6 22 67, 67A Fuse DIN NH00 8 6 Y 22 67B, 67C Fuse DIN NH2 2 6 21 68, 68A Fuse DIN NH2 2 6 Y 21 68B, 68C Small Fuse, 6-GMT 6 0 58 58 Blank Panel - 3 JD 93 Blank Panel - 6 JA 90 Blank Panel - 9 JB 91 Blank Panel - 12 JC 92

1. Groups with B suffix or no suffix include return bus. Groups with A or C suffix and Blank Panels

Height

LVL D Shunt

(in.)

do not include return bus.

1500A, 50mV

1 / fuse

600A, 50mV

1 / fuse

600A, 50mV

1 / fuse

300A, 50mV

1 / fuse

300A, 50mV

1 / fuse

ED83143-31

Group

42, 42A, 106, 106A, 107, 107A, 108,

48, 48A, 110, 110A, 111, 1

43, 43A, 101, 101A, 102, 102A, 103,

56, 56A 59, 59A

55 53, 53A

55 57, 57A

54 54, 54A

54 54B, 54C

11A, 112, 112A, 113, 113A

H569-434

GPS 4848/100 Group

108A, 109, 109A

103A, 104, 104A

9 - 8 Specifications Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

10 Safety

Please read and follow all safety instructions and warnings before servicing the GPS 4848/100. Reference the Safety section of the GPS Installation Guide and individual module product manuals for safety statements specific to the modules.

Issue 5 September 2011 Safety 10 - 1

Galaxy Power System 4848/100 with Dual Rectifier Shelf

11 Maintenance and Replacement

Requirements

System With the exception of the battery, 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 Section 9 of this product manual.

Refer to Table 11-A for system replacement parts.

Batteries The batteries must be maintained as directed by the battery

manufacturer’s requirements.

Controller For replacement circuit packs for the Galaxy Millennium Controller,

refer to Table 11-B.

Issue 5 September 2011 Maintenance and Replacement 11 - 1

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Requirements, continued

Rectifier With the exception of a fan failure, rectifiers are repaired by

replacement.

Refer to “Installing or Replacing a Rectifier” and “Removing a Rectifier” in this section.

Vacant Rectifier Positions

Rectifier Fan Assembly

Vacant rectifier position below or beside the top installed rectifier in this cabinet may cause over-heating of the installed rectifiers. Immediately install a replacement rectifier or a Rectifier Shelf Cover / Air Dam into the vacated position.

Rectifier Shelf Cover (848680211)

Air Dam (CC848809178)

The expected life of the rectifier fans at 25°C (77°F) is approximately

seven years. The fans in the rectifiers may be replaced in the field.

Two approaches can be taken to fan maintenance:

• The first approach is to replace the two fans on a routine basis every six to seven years; this ensures that the fans do not fail in the field under normal operating conditions. This approach is appropriate when there are no remote alarm facilities at the site.

• The second approach, assuming one has remote alarm capability, is to wait until the fans fail. The rectifier will safely shut down and issue both a fail alarm and a fan alarm. The two fans can then be replaced. Since it is likely that all the rectifiers in that installation are of roughly the same age, all rectifier fans at that site should be replaced at that time.

Covers both left and right rectifier positions

Covers the left or right rectifier position

The approach used depends on the location and manning of the site as well as the monitoring of alarms used at the site.

Refer to “Replacing the Rectifier Fan Assemblies” in this section.

11 - 2 Maintenance and Replacement Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Lift Straight Up

ABC12345678

Model:595LTA

480V

48V

RECTIFIER

KZO41234567

SX:X

220A/48V

STBY

ALM

LIM

FAN ALM

BST

Replacement Procedures

Installing or

Replacing a

ier

Rectif

Stop!

Be sure rectifier is set to STBY and ac breakers on

cabinet are OFF!

Installing or Replacing a Rectifier

Step Action

Unpack the rectifier from shipping container.

Rectifier is heavy (47.5 pounds). Use two people to lift and move rectifiers.

Remove rectifier by lifting the unit in a vertical direction

from the packing container. See figure below.

Do not rest rectifier on faceplate or rear chassis; damage to faceplate and/or rear busbars will occur, rendering the unit unusable.

Caution

Continued on next page.

Issue 5 September 2011 Maintenance and Replacement 11 - 3

Galaxy Power System 4848/100 with Dual Rectifier Shelf

REMOVE BEFORE ADDING SECOND RECTIFIER

ABC12345678

Model:595LTA

480V

48V

RECTIFIER

KZO41234567

SX:X

220A/48V

STBY

ALM

LIM FAN

ALM

FAN ALM

BST

Rectifier Shelf in Cabinet

Remove connector cover to install a rectifier into position 2

Rectifier Position 1

Insertion Tool

Replacement Procedures, continued

Installing or Replacing a Rectifier, continued

Step Action

Turn ac circuit breaker OFF.

Place rectifier power switch in STBY.

Install the rectifier. See Figure 11-1.

a. Verify that the output circuit breaker is OFF and that

the rectifier power switch is in the “Standby” position.

b. Slide the unit slowly onto the shelf until it contacts the rear

connector.



Note: Install rectifiers, starting at the bottom left position and working to the right, and then upward.

Caution

Verify that the rectifier chassis slides rearward evenly on the left and right sides as the locking screw is turned. DO NOT USE EXCESSIVE FORCE DURING THIS PROCEDURE! If the rectifier-to-shelf mating process appears to bind, back the unit out and start over. Avoid stripping the threads of the locking screw by stopping when the rearward progress of the rectifier ceases.

Figure 11-1: Installing a Rectifier in a Rectifier Shelf

Continued on next page.

11 - 4 Maintenance and Replacement Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Replacement Procedures, continued

Installing or Replacing a Rectifier, continued

Step Action

Turn ON output circuit breaker.

Turn ON ac circuit breaker.

Turn rectifier power switch to ON position.

Verify:

• Green LED is illuminated.

• No alarms are illuminated.

Set rectifier ID number as follows:

a. Depress rectifier power switch in UP position; rectifier ID

is displayed.

b. Hold rectifier power switch in UP position for 5 seconds;

the display number will begin to blink.

c. Release the switch.

d. Depress and hold the switch for 3 seconds to rapidly

advance the ID.

e. Depress and release repeatedly until the desired ID is

reached.

f. Leave switch un-pressed for 10 seconds to save the ID

number.

Follow Steps 3-5 to install remaining rectifiers. Follow Steps 6-10 to set remaining ID numbers.

Verify that the system voltage reads 52.08V or desired float voltage.

Test replaced rectifiers using the “Testing Additional Alarms After Replacement of Rectifiers” procedure in this section.

Issue 5 September 2011 Maintenance and Replacement 11 - 5

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Replacement Procedures, continued

Removing a

Rectifier

Step Action

Set power switch to STBY.

Turn OFF ac circuit breakers.

Turn OFF output circuit breaker on rectifier.

Removing a Rectifier

Wait 5 minutes to allow capacitors to discharge.

Using a 5mm Allen-head “T” wrench, sl screw counterclockwise to release the rectifier from the shelf.

Slowly slide rectifier from shelf.

Caution

Rectifier is heavy (37 pounds). 

Do not rest rectifier on faceplate or r faceplate and/or rear busbars will occur, rendering the unit unusable.

If the rectifier is not going to active CMA (Communications Fail - Minor) against that rectifier ID by using the following path on the Configuration menu on the front display of the plant controller:

Menu -> CONFIG -> RECT MNGR (Basic Controller) or Menu -> CONFIG -> RECT MNGR -> RECT OPER (Intel

troller)

Con Move to the Field RMOVE RECT and use the (+) key to input

the Rectifier ID alarm.

If the removal of the rectifier results in a vacant rectifier position cabinet, it must be replaced immediately or the vacated position must be occupied by a Rectifier Shelf Cover or Air Dam.

below or beside the top installed rectifier in this

of the removed rectifier. Press Enter to clear the

be replaced immediately, retire the

owly turn the locking

ear chassis; damage to

Rectifier Shelf Cover Covers both left and ri (848680211) positions

Air Dam Covers the left or right rectifier

CC848809178) position

(

11 - 6 Maintenance and Replacement Issue 5 September 2011

ght rectifier

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Fan Cable Clamps

Fans

Fan Connectors

Fan Screws

Faceplate Screws

Faceplate

Replacement Procedures, continued

Replacing the

Rectifier Fan Assemblies

Step Action

Replacing the Rectifier Fan Assemblies

Follow instructions in the “Removing a Rectifier” procedure in this section. Refer to Figure 11-1.

Place rectifier on a flat surface at a comfortable working height.

Allow the front end of the rectifier to overhang the working surface.

Remove 4 faceplate screws (2 on each side).

Turn the rectifier onto its side.

Caution

Carefully position the faceplate as shown in Figure 11-2.

Caution

Avoid excessive force on cables connected to the faceplate.

Figure 11-2: Rectifier Fan Replacement

Continued on next page.

Issue 5 September 2011 Maintenance and Replacement 11 - 7

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Replacement Procedures, continued

Replacing the Rectifier Fan Assemblies, continued

Step Action

Remove the fan cable clamps.

Carefully unplug the fan connectors (2). Fan connectors are

keyed and can be loosened by inserting a screwdriver into the slotted side of the connector and gently prying the fan-side connector loose.

Remove the fans by removing the fan screws (8).

Install the new fans in position as shown in Figure 11-2 by

installing the fan screws (8).

Position the fan cables as shown in Figure 11-2.

Replace the fan cable clamps.

Caution

Place faceplate ground wire terminal under fan cable

clamp as shown in Figure 11-2.

Replace the faceplate by installing the faceplate screws (4).

Install the rectifier, following the “Installing or Replacing a

Rectifier” procedure in this section.

Test replaced rectifiers using the “Testing Additional Alarms

After Replacement of Rectifiers” procedure in this section.

11 - 8 Maintenance and Replacement Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Test in g Note: Consult the GPS Installation Guide for complete testing

guidelines for new installations. Alarm LEDs refer to the controller unless otherwise noted.

Testing Additional Alarms After Replacing Rectifiers

Alarm operation may be verified while the system operates at float voltage.

Testing Additional Alarms After Replacing Rectifiers

Step Action

Turn OFF the ac circuit breaker of replaced rectifier. Verify that AC and MIN alarm LEDs illuminate, the rectifier displays ACF, and the controller alarms screen indicates AC FAIL: Gmm .

Turn ON the ac circuit breaker of the replaced rectifier. Verify that the rectifier starts and the alarms retire.

Turn OFF the DC Output CB at the bottom left of the rectifier. Verify that the Rectifier and Minor alarm LEDs illuminate, the rectifier displays Cb, and the controller alarms screen indicates RECTIFIER FAIL: Gmm.

Turn ON the DC Output CB of the rectifier. Verify that the rectifier picks up load similar to others in the system and that the alarms retire.

Testing Rectifiers and Load Share in Bay Expansions

Testing Rectifiers and Load Share in Bay Extensions

Step Action

Turn all rectifiers to STBY.

Connect a resistive load box (proper voltage) to the system’s positive and negative bus bars.

Verify that the system load is less than 50 amperes.

Increase the system load to 200 amperes.

Turn ON all the rectifiers; after approximately 60 seconds, verify that the load is divided equally among all the rectifiers (within 2 amperes).

Reduce the system load. Verify that the rectifiers continue to share the load.

Remove system load.

Issue 5 September 2011 Maintenance and Replacement 11 - 9

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Replacement Parts

System Table 11-A provides a list of replacement parts for GPS 4848/100.

Table 11-A: GPS 4848/100 Replacement Parts

Ordering Comcode Description

Cabinet

406204230 3 ampere alarm fuse

402328926 0.18 ampere alarm fuse

406530725 1-1/3 ampere alarm fuse

405673161 1/2 ampere panel alarm fuse (WP90247 L3)

406420273 GMT fuse puller tool

848262622 BLJ3 terminal board

408229318 Wire insertion tool

848703419 BIC9 bay interface card

107900169 EBV2 load disconnect board

107604076 BJN1 battery disconnect board

407226786 Lens cover, red

407227172 Cabinet alarm lamp, 48V

Rectifier and Rectifier Shelf

108979238 595LTA, 220 ampere rectifier

108990405 595LTB, 220 ampere rectifier

848693586 Fan (2 Required)

901181834 Insulated Allen-head wrench

Distribution

405673161 1/2 ampere alarm fuse

Galaxy Millennium Controller

406677880 Battery TL5101 for BSJ

406530725 1-1/3 ampere fuse (GMT)

406204230 3 ampere fuse (GMT)

11 - 10 Maintenance and Replacement Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Replacement Parts, continued

Millennium Controller Circuit Boards

Table 11-B lists the spare parts of the Galaxy Millennium Controller.

Table 11-B: Galaxy Millennium Controller Circuit Boards

Ordering Comcode

108029679 Display board (BSK1)

108029687 Alarm wire wrap board (BSL1)

848194551 Insulation displacement alarm board (BSL2)

108029653 Basic control board (BSH1)

847950912 LCD module assembly display board

108029661 Intelligent control board (BSJ1)

108851338 Modem board (BSM5)

108163601 Data switch board (BSW1)

108340100 Gateway board (EBW1)

Additional Ordering Information

Description

Documentation Table 11-C lists documentation associated with the GPS 4848/100.

Table 11-C: Product Documentation

Document

Number

H569-434 GPS 4848/100 Ordering Guide

167-792-157 GPS Installation Guide

167-792-180 Galaxy Millennium Controller Product Manual

167-790-063

193-104-105 EasyView Software Product Manual

193-104-106 Galaxy Gateway Product Manual

Software EasyView software is a Windows-compatible communications package

designed specifically for use with Galaxy controllers. Download EasyView software from http://www.lineagepower.com. Click “Downloads” and click on the appropriate EasyView download button.

Remote Peripheral Monitoring System Product Manual

Description

Issue 5 September 2011 Maintenance and Replacement 11 - 11

Galaxy Power System 4848/100 with Dual Rectifier Shelf

11 - 12 Maintenance and Replacement Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

11 - 14 Maintenance and Replacement Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

12 Troubleshooting Preparations

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 GPS 4848/100.

Warning

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.

Too ls The following tools are necessary in order to troubleshoot the GPS

4848/100:

• 3/16-inch (5 mm) Allen-head wrench

• Insulated hand tools

• Calibrated digital voltmeter (DVM)  (0.05% accuracy on dc scale)

•ESD wrist strap

Issue 5 September 2011 Troubleshooting Preparations 12 - 1

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Galaxy Millennium Controller

Cabinet Alarm Light

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 location as a first and fundamental step in diagnosing and correcting the problem.

For all trouble conditions, proceed as follows:

Cabinet Alarm 1. Locate the system controller. The controller is typically located in

the cabinet identified as BAY ONE. Because a trouble condition exists, the red alarm on the top of the cabinet will be illuminated. See Figure 12-1.).

Figure 12-1: Location of Cabinet Alarm Light and Controller

12 - 2 Troubleshooting Preparations Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Troubleshooting Procedure, continued

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

and status LEDs will be illuminated. The controller default screen indicates system voltage and current, the system mode (i.e., FLOAT or EQUALIZE), and the number of alarms and/or warnings present.

If the screen is blank, but alarm and status LEDs are illuminated, call technical support. 



If the entire panel is blank, check the F3 basic power fuse (Figure 12-3). Verify that the controller is getting power. If not, replace fuse. If the display is still blank, call technical support.

Alarms Menu 3. 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.

Troubleshooting Tab le s

Identifying Problems

4. Based on the information presented by the alarm LEDs, select the appropriate table from the list below:

Section 13, Troubleshooting Millennium Systems

Alarm LED Ta bl e

AC 13-A, AC Alarms BATT 13-B, Battery Alarms BD 13-F, Miscellaneous Alarms CTRL 13-C, Controller Alarms DIST 13-D, Distribution Alarms RECT 13-E, Rectifier Related Alarms No LED* 13-F, Miscellaneous Alarms *If an alarm condition exists, but no alarm LED is lit, refer to T

5. Once the appropriate table is identified, use the status LEDs and the alarm menu data to identify the specific problem that is causing the alarm.

able 13-F.

Issue 5 September 2011 Troubleshooting Preparations 12 - 3

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Reference Figures

Figure Numbers and Titles

Millennium Controller

The following figures are provided for reference while performing the troubleshooting procedure:

Figure No. Title

12-1 12-2 12-3 12-4

12-5

12-6 12-8

12-9

Basic Controller

BSH (microprocessor board): After power up, or after a reset, the

green and yellow LEDs will both be lit while self diagnostics are in progress (which will take about 10 seconds). If all diagnostics pass, the yellow LED will extinguish and the green LED will remain lit. If a failure is detected during diagnostics, the green LED will extinguish and the yellow LED will remain lit.

Location of Cabinet Alarm Light and Controller Millennium Controller Display Millennium Controller Fuses and Circuit Boards Rectifier Display Low Voltage Battery Disconnect Contactor

Control Switches AC Input Panel and Rectifier Connection DC Distribution Panel Low Voltage Load Disconnect Contactor

Control Switches

If a failure occurs during normal operation, the green LED will extinguish and the yellow LED will light.

Intelligent Controller

BSJ (microprocessor board): After power up, or after a reset

and yellow LEDs will both be lit while self diagnostics are in progress (which will take about 30 seconds). If all diagnostics pass, the yellow LED will extinguish and the green LED will remain lit. If a failure is detected during diagnostics, the green LED will extinguish and the yellow LED will remain lit. If a terminal is attached to the local port during diagnostics, the diagnostic messages will show which test failed.

If a failure occurs during normal operation, the green LED will extinguish and the yellow LED will light.

12 - 4 Troubleshooting Preparations Issue 5 September 2011

, the green

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Galaxy Millennium Controller

Alarm Status

Critical

Escape Help

Enter

Equipment Status

AC System

Battery

Controller

Distribution

Rectifier Remote

Modules

Major

Minor

Normal

Battery on Discharge

BSM Modem Board

Intelligent LEDs

Basic LEDs

BSH Basic Controller Board

BSJ Intelligent Controller Board

BSL Alarm Termination Board

BSW Data Switch Board (mounting location)

Controller Fuses

F1 - Peripheral Monitor Power F2 - Intelligent Power F3 - Basic Power F4 - Voltage Sense F5 - Alarm Battery Supply

F1 F2 F3 F4 F5

GMT

Fuses

1 1/3A

Reference Figures, continued

Millennium Controller, continued

Figure 12-2: Millennium Controller Display

Issue 5 September 2011 Troubleshooting Preparations 12 - 5

Figure 12-3: Millennium Controller Fuses and Circuit Boards

Galaxy Power System 4848/100 with Dual Rectifier Shelf

StatusIndicators

ABC12345678

Model:595LTA

480V 48V

RECTIFIER

KZO41234567 SX:X

220A/48V

STBY

ALM LIM FAN

ALM

BST

ALM FAN

ALM

LIM BST

Reference Figures, continued

Rectifier During normal operation, the rectifier’s green ON LED will be lit and

the display will show the rectifier’s output current.

Figure 12-4: Rectifier Display

12 - 6 Troubleshooting Preparations Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Red Light Yellow Light

Green Light

CONTACTOR DRIVE BOARD

BOTH SWITCHES DOWN FORCES CONTACTOR OPEN

CONTACTOR OPEN

CONTACTOR OPEN INITIATED

DOWN FORCES

CONTACTOR CLOSED

REMOTE CONTROL ENABLED

Note: All switches should be in the up position for normal operation.

Reference Figures, continued

Low Voltage Battery Disconnect

The low voltage battery disconnect (LVBD) feature consists of a contactor, circuitry on the BJN board, and associated wiring. Control of the contactor is dictated by the BJN contactor control board and the controller.

Issue 5 September 2011 Troubleshooting Preparations 12 - 7

Figure 12-5: Low Voltage Battery Disconnect

Contactor Control Switches

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Reference Figures, continued

AC Input

Figure 12-6: AC Input Panel and Rectifier Positions, 6 Rectifiers

12 - 8 Troubleshooting Preparations Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Reference Figures, continued

AC Input

Figure 12-7: AC Input Panel and Rectifier Positions, 12 Rectifiers

Issue 5 September 2011 Troubleshooting Preparations 12 - 9

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Connects to Negative Charge Bus

Alarm LED

Alarm/Terminal Card

Connects to Charge Return Bus

Reference Figures, continued

DC Distribution

Figure 12-8: DC Distribution Panel

12 - 10 Troubleshooting Preparations Issue 5 September 2011

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Note: Switch should be in the down position for normal operation.

Red Light

Yellow Light

Green Light

UP POSITION FORCES CONTACTOR CLOSED

REMOTE CONTROL ENABLED

CONTROLLER SIGNAL ERROR DETECTED

CONTROLLER SIGNAL OPENED CONTACTOR

GREEN LIGHT

YELLOW LIGHT ONLY

RED AND YELLOW LIGHT

LOAD DISCONNECT FEATURE IS NOT FOR USE IN BATTERYLESSSYSTEMS

REMOTE CONTROL OVERRIDE SWITCH

Control switch mounted on right side of cabinet.

Reference Figures, continued

Low Voltage Load Disconnect

The EBV low voltage load disconnect (LVLD) contactor control board is mounted on the right side of the cabinet, as shown in Figure 12-9.

The manual contactor control switch (SW300) is not meant to be used to permanently override the LVLD function. It is only to be used temporarily while servicing or testing the equipment.

Figure 12-9: Low Voltage Load Disconnect Contactor

Control Switches

Issue 5 September 2011 Troubleshooting Preparations 12 - 11

Galaxy Power System 4848/100 with Dual Rectifier Shelf

13 Troubleshooting Millennium

Systems

Introduction

In This Section This section provides information for locating and interpreting visual

indicators to help identify problems.

Preparation Read Section 12, Troubleshooting Preparations, thoroughly before

proceeding.

Technical Assistance

When visual indicators do not identify a defective part, notify Lineage Power Technical Support.

Issue 5 September 2011 Troubleshooting Millennium Systems 13 - 1

Galaxy Power System 4848/100 with Dual Rectifier Shelf

Troubleshooting Tables

Organization The tables in this section are organized alphabetically by Alarm LED,

then grouped according to the status of the alarm: Critical (CRIT), Major (MAJ), or Minor (MIN).

Table Reference Use the reference below to locate the Alarm LED and corresponding

table.

Controller Alarm LED Tabl e

AC 13-A, AC Alarms BATT 13-B, Battery Alarms BD 13-F, Miscellaneous Alarms CTRL 13-C, Controller Alarms DIST 13-D, Distribution Alarms RECT 13-E, Rectifier Related Alarms RM 13-F, Miscellaneous Alarms No LED* 13-F, Miscellaneous Alarms *If an alarm condition exists, but no alarm LED is lit, refer to

Table 13-F.

Rectifier Display Messages and LEDs

State Display Message LED Illuminated

Normal Current On Output Limited Current LIM Manual Standby Blank STBY Remote Standby

(Shu

tdown) Output Breaker Open CB ALM Interlock Open ILC ALM AC Fail ACF None Phase Fail PF None OverTemperature

Shut

down

Output Under Voltage Shut

down High Voltage Shutdown HO ALM Internal Failure LS, ICS, IP5, IP6, IP7,

tr STBY

tA ALM

LO ALM

N, FSE, InF

ALM

13 - 2 Troubleshooting Millennium Systems Issue 5 September 2011

GE Industrial Solutions GPS 4848-100 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

List of Figures

List of Tables

1 Introduction

GPS 4848/100

Overview The Galaxy Power System (GPS) 4848/100 provides -48 volt

Related Documentation

Illustration Figure 1-1 is an isometric view of the GPS 4848/100 with a Millennium

Safety •UL1 Listed (US and Canada): UL Subject 1801 with applicable

CE Marking • CE marked per European Union Council Directives:

Telcordia • GR-63 and GR-1089 NEBS (including Level 3 testing)

Customer Service Contacts

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

Customer Training Lineage Power offers customer training on many Power Systems

Downloads and Software

2 System Description

Overview

Block Diagram Figure 2-1 shows a basic block diagram of the Galaxy Power System

System Components

Bonding Network The GPS 4848/100 system is suitable for installation as part of a

Facility The GPS 4848/100 system is suitable for installation in Network

Architecture

Introduction For the GPS 4848/100 system, the basic system components, i.e., ac

Distributed In this system each cabinet contains ac distribution, dc distribution

Centralized Figure 2-4 shows GPS 4848/100 components configured in a

Standard Standard cabinets are designed so that ac, battery, and dc load cables are

Non-Traditional Any of the battery panels and dc load panels (shown in Sections 6 and

3 Galaxy Millennium Controller

Overview

Mounting Location The Galaxy Millennium Controller mounts inside the front door with the

Circuit Boards The Galaxy Millennium Controller is equipped with a Basic control

Reference Material

Controller Product Manual

RPM System Product Manual

User Interface and Display

Front Panel The control panel displays alarm and status indicators and provides test

Default Display The default display shows basic plant status. The controller returns to

LEDs Two columns of LEDs show the severity and source of active alarms.

Pushbutton Controls

Test Jacks A pair of test jacks allows direct measurement of the system voltage

595 Series

Overview Four rectifiers are available for the GPS 4848/100 system with dual

Rectifiers

Front Panel Display

Power Switch This three-position switch has two functions:

Status Indicators In addition to the ON and STBY LEDs, four other LEDs on the

Current Display This display indicates the current of the rectifier. Upon specific

Lamp Test To test the LEDs on the rectifier front panel, use the Lamp Test feature

Illustration

Features

Output Voltage Adjustment

Output Current “Walk-in”

Electronic Current Limit

Selective High Voltage Shutdown (SHVSD)

Backup High Voltage Shutdown (BHVSD)

Restart Upon shutdown, the rectifier will attempt to restart. The rectifier will try

Output Circuit Breaker

Fan Alarm and Control

Thermal Alarm The rectifier senses the internal operating temperature and will issue a

Controller Communications Alarm

Autonomous Operation of the Rectifier

Connectorized The rectifiers provide the controller with a full complement of status and

“Forced” Load Sharing

5 AC Input Panels

Overview

AC Service The ac input panel provides the facility to terminate the 3-phase ac

Illustrations Circuit breaker panels are shown in Figures 5-1 through 5-4, 5-8, and

6 Battery Connection Panels

Overview

Introduction Batteries are connected to the GPS 4848/100 cabinets based on the

Distributed Architecture

Centralized Architecture

Illustrations The battery connection panels are illustrated in Figures 6-1 through 6-9.

7 DC Distribution Panels

Overview

Function A variety of dc distribution panels are available featuring large or small