GE Industrial Solutions GPS 4848-100 User Manual

Download

Galaxy Power System 4848/100

with 595 Series Rectifiers S1:3 and later

(GPS 4848/100)

H569-434

Note: Refer to User's Guide Issue 8 for

595 Series Rectifiers prior to S1:3.

User’s Guide Select Code 167-792-155 Comcode 107933384 Issue 10 February 2008

Galaxy Power System 4848/100

with 595 Series Rectifiers S1:3 and later

(GPS 4848/100)

H569-434

Notice:

The information, specifications, and procedures in this manual are subject to change without notice. Lineage Power assumes no responsibility for any errors that may appear in this document.

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

1 Introduction

GPS 4848/100 1-1

Overview 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

Architecture 2-2

Introduction 2-2 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 Pushbutton Controls 3-3 Test Jacks 3-3

Issue 10 February 2008 Table of Contents - 1

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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

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

Function 7-1

2 - Table of Contents Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 9-7 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 11-7 Replacing the Rectifier Fan Assemblies 11-9

Testing 11-11

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

Replacement Parts 11-12

System 11-12 Millennium Controller Circuit Boards 11-13

Additional Ordering Information 11-13

Documentation 11-13 Software 11-13

Issue 10 February 2008 Table of Contents - 3

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 DC Distribution 12-9 Low Voltage Load Disconnect 12-10

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

14 Product Warranty

4 - Table of Contents Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

List of Figures

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

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

Figure 2-2: Distributed Architecture 2-3

Figure 2-3: Distributed Architecture Initial and

Growth Cabinets 2-4

Figure 2-4: Centralized Architecture 2-5

Figure 2-5: Centralized Architecture Initial and

Growth 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 G20/220/320 (ED83142-30 G3)

208/240V AC Input Circuit Breaker Panel 5-1

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

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

Figure 5-3: H569-434 G22 (ED83142-30 G2)

480V AC Input Circuit Breaker Panel 5-2

Figure 5-4: H569-434 G24/25/26/27/128/129/130/131/

224/226 (ED83142-30 G5) 208/240/480V AC input Terminal Strip Panel 5-3

Figure 5-5: H569-434 G70 (ED83142-30 G10)

480V 65kAIC AC Input Circuit Breaker Panel 5-3

Figure 5-6: H569-434 G71 (ED83142-30 G11)

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

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

Issue 10 February 2008 List of Figures - 1

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Figure 6-3: H569-434 G32 (ED83143-31 G30)

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

400A DC Distribution Panel 7-1

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 7-2

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 7-3

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 7-4

Figure 7-8: HH569-434 G59 (ED83143-31 G56)

2-Position Fuse Distribution Panel 7-5

Figure 7-9: H569-434 G60/61/65/66 (ED83143-31 G71)

600A DC Distribution Panel 7-5

Figure 7-10: H569-434 G67 (ED83143-31 G22)

600A DC Distribution Panel 7-6

Figure 7-11: H569-434 G68 (ED83143-31 G21)

1200A DC Distribution Panel 7-6

2 - List of Figures Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Figure 7-12: H569-434 G96 (ED83143-31 G15)

510A DC Distribution Panel 7-7

Figure 7-13: H569-434 G97 (ED83143-31 G16)

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

Figure 7-14: H569-434 G54 (ED83143-31 G54)

5-Position DC Distribution Panel 7-8

Figure 7-15: H569-434 G58 (ED83143-31 G58)

6-Position GMT DC Distribution Panel 7-8

Figure 11-1: Installing a Rectifier in a Rectifier Shelf 11-5

Figure 11-2: Fan Replacement 11-9

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 Connection 12-8

Figure 12-7: DC Distribution Panel 12-9

Figure 12-8: Low Voltage Load Disconnect Contactor

Control Switches 12-10

Issue 10 February 2008 List of Figures - 3

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

List of Tables

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

Table 9-B: 595 Series Rectifier Specifications - S1:3 and later 9-4

Table 9-C: Rectifier Display Messages and LEDs 9-6

Table 9-D: AC Panels 9-7

Table 9-E: Battery Connection Panels 9-7

Table 9-F: DC Distribution Panels 9-8

Table 11-A: GPS 4848/100 Replacement Parts 11-12

Table 11-B: Galaxy Millennium Controller Circuit Boards 11-13

Table 11-C: Product Documentation 11-13

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 10 February 2008 List of Tables - 1

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

1 Introduction

GPS 4848/100

Overview The Galaxy Power System (GPS) 4848/100 was developed to support

-48 volt telecommunications powering solutions in worldwide markets. The GPS 4848/100 combines 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 10,000-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 10,000A.

Notes The Galaxy SCF Controller is no longer available in the GPS 4848/100.

For information about systems with SCF controllers, see Issue 5 of this manual.

GPS 4848/100 supports 595LT series rectifiers, one per shelf. See GPS 4848/100 with Dual Rectifier Shelf User's Guide for Specifications of 595LT series rectifiers.

This document includes 595 series rectifiers S1:3 and later. For information about systems with 595 Series Rectifiers prior to S1:3, see Issue 8 of this manual.

Issue 10 February 2008 Introduction 1 - 1

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Galaxy

GPS 4848/100, continued

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

Controller.

Battery Connection Panel

AC Panel

BLJ3 Terminal Board

BIC

Galaxy Millennium Controller

DC Distribution

ESD

RAP

T S T

WRIS GROUNDING

INT O P

595 Series 200A Rectifier

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

1 - 2 Introduction Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 house

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

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

Issue 10 February 2008 Introduction 1 - 3

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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.

AC Input

Rectifiers

AC Input

Power

Chg Bus

(-)

Return

Bus

(+)

DC Distribution

LVLD

Control

Board

LVL D

Battery Distribution

LVBD

Control

Board

Battery

LVB D

Shunt

To 48 Volt Loads

DISCHG RTN

48V Returns

BAT BUS

Battery (-)

CHG RTN

Battery (+)

GND

Sense/Control

Connections

Controller

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

Issue 10 February 2008 System Description 2 - 1

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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.

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: a distributed architecture or a centralized architecture.

2 - 2 System Description Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 current. While the batteries are providing the system load power, the individual shunt 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.

Battery String

Battery Shunt

To Loads

Control

and

Monitor

Figure 2-2: Distributed Architecture

Issue 10 February 2008 System Description 2 - 3

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Galaxy

Architecture, continued

Galaxy

ESD

R T S

ST I

D N

U O

POIN

Initial Cabinet Growth Cabinet

Figure 2-3: Distributed Architecture Initial and Growth Cabinets

2 - 4 System Description Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 initial and growth cabinets. Rectifiers, dc distribution panels, and batteries are cabled to external busbars where a single system shunt is provided to measure total system current. The initial cabinet contains ac distribution, rectifiers, the controller, and termination points for the system interconnect cables. Growth cabinets contain ac distribution, rectifiers, and cable termination points. A separate cabinet provides load distribution and protection facilities and may include load disconnect/reconnect contactors.

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.

Charge Bus Charge Return Bus Discharge Return Bus

Plant

Shunt

Battery Strings

Control

and

Monitor

Figure 2-4: Centralized Architecture

Loads

Issue 10 February 2008 System Description 2 - 5

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Galaxy

Architecture, continued

Galaxy

D S

A R T

S ST I

G N

D N U

POIN

Initial Cabinet Growth Cabinet

Figure 2-5: Centralized Architecture Initial and Growth Cabinets

2 - 6 System Description Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 G70 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 H569-434 for availability.

Through bottom of cabinet Through bottom of cabinet

Through bottom of cabinet Through top of cabinet

Through top of cabinet Through bottom of cabinet

Battery and DC Load Leads

AC Battery and DC Load

AC Input

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

Battery and DC Load Leads

AC Input

Battery and DC Load Leads

Figure 2-6: Non-Traditional Cabling Arrangements

Issue 10 February 2008 System Description 2 - 7

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 10 February 2008 Galaxy Millennium Controller 3 - 1

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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.

Lamp

Test

Plant Voltage

Menu Enter Adjust

Help Escape

CRIT

BATT

MAJ

DIST

MIN

RECT

NORM

AC RM

COM

CTRL

Figure 3-1: Galaxy Millennium Controller Front Panel

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

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.

3 - 2 Galaxy Millennium Controller Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

User Interface and Display, continued

LEDs Two rows of LEDs show the source and severity of various alarms. An

alarm may light two LEDs: one alarm LED and one status LED. More than one alarm LED may be on at the same time. In this case, the status LED will be that of the most severe active alarm.

The first row of seven LEDs indicates the source of the alarm: BD, battery on discharge; BATT, battery; DIST, distribution; RECT, rectifier; AC, ac power supply; RM, remote monitoring; and CTRL, controller.

The second row includes five LEDs. The first four LEDs indicate the severity of the reported alarms: CRIT, critical; MAJ, major; MIN, minor; and NORM, normal. Another LED, labeled COM, will be illuminated when the internal modem is in use.

Pushbutton Controls

A pushbutton labeled LAMP TEST tests the controller’s circuit pack LEDs and front panel LEDs. It will also test the indicators of serially connected rectifiers.

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.

Test Jacks A pair of test jacks allows direct measurement of the dc bus sense

voltage being monitored.

Issue 10 February 2008 Galaxy Millennium Controller 3 - 3

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

4 Rectifiers

595 Series

Overview Two 200-ampere rectifiers are available for the GPS 4848/100 system:

595A Series and 595B Series. The 595A Series operates from 3-phase ac service with a phase-to-phase voltage within the range of 320-530Vac. The 595B Series operates from 3-phase ac service with a phase-to-phase voltage within the range of 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 rectifier’s ID using the ON/STBY switch to allow the controller to learn the rectifier’s physical location for alarm reporting.

Issue 10 February 2008 Rectifiers 4 - 1

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Front Panel Display

Power Switch This three-position switch has two active states:

• 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 and lights when the unit is in current limit.

• The FAN ALM 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, press the Lamp Test button

on the controller.

Illustration

CURRENT

STBY ALM LIM FAN ALM EQL

OFF

200A/48V

Figure 4-1: Rectifier Front Panel

4 - 2 Rectifiers Issue 10 February 2008

Features

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 through 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 110% of rated output), the current limit circuit overrides the voltage regulating signal and safely limits 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

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 three 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.

Issue 10 February 2008 Rectifiers 4 - 3

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 will 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 applied to the rectifiers.

4 - 4 Rectifiers Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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.

Figure 5-1: H569-434 G20/220/320 (ED83142-30 G3)

208/240V AC Input Circuit Breaker Panel

Issue 10 February 2008 AC Input Panels 5 - 1

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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

208/240/480V AC Input Circuit Breaker Panel

Figure 5-3: H569-434 G22 (ED83142-30 G2)

480V AC Input Circuit Breaker Panel

5 - 2 AC Input Panels Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Figure 5-4: H569-434 G24/25/26/27/128/129/130/131/224/226

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

Figure 5-5: H569-434 G70 (ED83142-30 G10) 480V 65kAIC AC Input Circuit Breaker Panel

Issue 10 February 2008 AC Input Panels 5 - 3

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Figure 5-6: H569-434 G71 (ED83142-30 G11) 480V 65kAIC AC Input Circuit Breaker Panel

5 - 4 AC Input Panels Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 panel.

Illustrations The battery connection panels are illustrated in Figures 6-1 through 6-8.

Issue 10 February 2008 Battery Connection Panels 6 - 1

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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

Two 1000A Shunts

Connects to Charge Return Bus

9" REF (229mm)

Two 500A Contactors

Contactor Control Cards

1200A Contactor

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

Battery Connection Panel

1500A Shunt

Connects to Charge Return Bu

6" REF (152mm)

Contactor Control Card

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

Battery Connection Panel

6 - 2 Battery Connection Panels Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Terminal Card

Alarm Card

(2) NH3 Fuse Holders

Figure 6-3: H569-434 G32 (ED83143-31 G30)

Battery Connection Panel

Two 600A Shunts

Connects to Charge Return Bus

9" REF (229mm)

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

Battery Connection Panel

Issue 10 February 2008 Battery Connection Panels 6 - 3

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

600A Shunt

Alarm/Terminal Card

(1) NH3 Fuse Holder

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

Battery Connection Panel

Alarm/Terminal Card

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

M10 Connections

Connects to Charge Return Bus

6" REF (152mm)

15" REF (381mm)

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

(3) 1000A Shunts

(3) 600A Fuses

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

Battery (OLE) Connection Panel

6 - 4 Battery Connection Panels Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Alarm Cards

H569-434

G80

G81

G82

Contactor Control Card

Includes:

1 G31 1 G43 1 G31 2 G43

1 G31 3 G43 (shown)

1200A Contactor

ED83143-31 G31

1200A Contactor

ED83143-31 G43

Two NH3 DIN Fuses Two 600A Shunts

Connect to Charge Return Bus

24" REF (610mm)

Connect to Charge Return Bus

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

Battery Connection Panel

Issue 10 February 2008 Battery Connection Panels 6 - 5

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Terminal Card

800A Contactor

12" REF (152mm)

Connects to Charge Return Bus

Alarm Card

Shunts (Provided with circuit breakers)

6 Circuit Breaker Positions (Circuit breakers ordered separately)

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

Battery Connection Panel

6 - 6 Battery Connection Panels Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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.

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

Alarm/Terminal Card

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

Connects to Charge Return Bus

6" REF (152mm)

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

400A DC Distribution Panel

Issue 10 February 2008 DC Distribution Panels 7 - 1

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Alarm/Terminal Card

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

Connects to Charge Return Bus

9" REF (229mm)

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

400A DC Distribution Panel

Alarm/Terminal Card

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

Connects to Charge Return Bus

6" REF (152mm)

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

600A DC Distribution Panel

7 - 2 DC Distribution Panels Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Terminal Card

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

Connects to Charge Return Bus

12" REF (305mm)

Alarm Card

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

1200A DC Distribution Panel

Terminal Card

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

9" REF (229mm)

Alarm Card

Connects to Charge Return Bus

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

1000A DC Distribution Panel

Issue 10 February 2008 DC Distribution Panels 7 - 3

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Alarm/Terminal Card

10 Medium U.S. Fuse Holders

Connects to Charge Return Bus

6" REF (152mm)

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

600A DC Distribution Panel

2 600A Shunts

2 U.S. Large Fuse Holders

9" REF (229mm)

Alarm/Terminal Card

Connects to Charge Return Bus

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

1000A DC Distribution Panel

7 - 4 DC Distribution Panels Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Figure 7-8: HH569-434 G59 (ED83143-31 G56)

2-Position Fuse Distribution Panel

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

10 Positions for DIN Circuit Breakers (80-125A)

Alarm Cards

or DIN Fuse Holders (14 x 51mm fuses, 1-50A)

Connects to Charge Return Bus

6" REF (152mm)

Figure 7-9: H569-434 G60/61/65/66 (ED83143-31 G71)

600A DC Distribution Panel

Issue 10 February 2008 DC Distribution Panels 7 - 5

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Alarm/Terminal Card

8 NH00 Fuse Holders

Connects to Charge Return Bus

6" REF (152mm)

Figure 7-10: H569-434 G67 (ED83143-31 G22)

600A DC Distribution Panel

Alarm/Terminal Card

2 NH2 Fuse Holders

Connects to Charge Return Bus

6" REF (152mm)

Figure 7-11: H569-434 G68 (ED83143-31 G21)

1200A DC Distribution Panel

7 - 6 DC Distribution Panels Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Alarm/Terminal Card

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

Connects to Charge Return Bus

6" REF (152mm)

Figure 7-12: H569-434 G96 (ED83143-31 G15)

510A DC Distribution Panel

Alarm/Terminal Card

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

Connects to Charge Return Bus

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

Figure 7-13: H569-434 G97 (ED83143-31 G16) 14-Position, and H569-434 G98

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

Issue 10 February 2008 DC Distribution Panels 7 - 7

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Alarm/Terminal Card

300A Shunt (in back of panel) per Position

5 Large TPL-B Fuse Positions

Connects to Charge Return Bus

9" REF

(229mm)

Maximum Panel Capacity

1125A 800A with LVLD

Figure 7-14: H569-434 G54 (ED83143-31 G54) 5-Position DC Distribution Panel

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

6 GMT Fuse Positions

Maximum Panel Ampacity

15A per G58 Panel

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

Figure 7-15: H569-434 G58 (ED83143-31 G58) 6-Position GMT DC Distribution Panel

7 - 8 DC Distribution Panels Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 10 February 2008 Circuit Boards 8 - 1

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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)

-44Vdc to -58Vdc

10,000A

Centralized bus bars available to 5,200A

Nominal Input Voltage (595A3 Rectifier)

Nominal Input Voltage (595B3 Rectifier)

Input Voltage Range per phase (595A3 Rectifier)

Input Voltage Range per phase (595B3 Rectifier)

Input Frequency Range 47 Hz - 63 Hz System Efficiency (including ac and

dc cables) Regulation (line and load range with

controller) AC Ripple <100mVrms Output Noise <2mV psophometric Electromagnetic Immunity 10V/meter over 20 MHz - 2000 MHz

380-480Vac, 3-wire plus ground

200-240Vac, 3-wire plus ground

320Vac - 530Vac

176Vac - 254Vac

>88%

± 0.5%

Issue 10 February 2008 Specifications 9 - 1

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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

Maximum Input Current, per cabinet 120 amperes per phase, 3-wire Heat Release, per cabinet

(54Vdc 24Adc)

Per Rectifier 4 Rectifiers 6 Rectifiers 7 Rectifiers 8 Rectifiers

1,030W (3,520 BTU/hr) 1,180W (4,050 BTU/hr) 4,120W (14,100 BTU/hr) 4,720W (16,120 BTU/hr) 6,180W (21,100 BTU/hr) 7,080W (24,170 BTU/hr) 7,210W (24,600 BTU/hr) 8,260W (28,200 BTU/hr) 8,240W (28,100 BTU/hr) 9,440W (32,200 BTU/hr)

595A/LTA 595B/LTB

Operating Temperature 0°C to 40°C Operating Relative Humidity 5% - 95%

Units Per Initial Cabinet

Rectifiers 0 - 6 Controller 1 Battery Disconnect Modules 1 - 3 DC Distribution 1 - 6

(maximum of 5 with battery disconnect)

Units Per Growth Cabinet

Rectifiers 0 - 6 Battery Disconnect Modules 0 - 1 DC Distribution 1 - 6

(maximum of 5 with battery disconnect)

9 - 2 Specifications Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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/CSA4950)

• 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 B – EN55022 (CISPR 22) Radiated/Conducted

Emission, Class B

• Immunity – IEC/EN 61000-4-2 ESD levels 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) – 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

Issue 10 February 2008 Specifications 9 - 3

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Rectifiers

Table 9-B: 595 Series Rectifier Specifications - S1:3 and later

See Issue 8 for pre S1:3 specifications.

Electrical

Output Voltage 52Vdc typical

Equalize Voltage 65Vdc typical

Output Voltage Adjustment 44-58Vdc float/boost

58-65Vdc equalize mode

Regulation (with controller) ±0.5%

High Voltage Shutdown (selected by controller)

Backup High Voltage Shutdown Float/boost 59-60Vdc (59.5Vdc nominal)

Thermal Alarm

Ripple 100mVrms

Noise <2mV psophometric

Permanent Overload 220Adc

Current Limit Set Point 60Adc - 220Adc

Nominal Input Voltage 595A3 Rectifier 380-480Vac, 3-wire plus ground

Nominal Input Voltage 595B3 Rectifier 200-240Vac, 3-wire plus ground

Input Voltage Range

Input Current

Specified

Rated Maximum 30A 50A

Typical Maxumum 23.7A at 320Vac 44.1A at 176Vac

Typical Maximum

Rectifiers A3 / B3

S1:2 and prior

Frequency Range

Power Factor

Total Harmonic Distortion

Float/boost 44-60Vdc (56Vdc default) Equalize 44-67Vdc (65Vdc default)

Equalize 65.5-66.5Vdc (66Vdc nominal)

595A3 105°C

595B3 103°C

Internal rectifier component temperature

(60Adc - 100Adc in equalize)

595A3 Rectifier 595B3 Rectifier

320Vac - 530Vac 176Vac - 254Vac

595A3 Rectifier 595B3 Rectifier

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

16.2A at 480Vac 38.8A at 200Vac

20.4A at 380Vac 37.3A at 208Vac

24.9A at 320Vac 45.3A at 176Vac

16.6A at 480Vac 39.9A at 200Vac

21.0A at 380Vac 38.3A at 208Vac

32.3A at 240Vac

33.2A at 240Vac

47 - 63 Hz >0.98 @ 50% to 100% load <5% @ 50% to 100% load

9 - 4 Specifications Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Table 9-B: 595 Series Rectifier Specifications - S1:3 and later

See Issue 8 for pre S1:3 specifications. (Continued)

AC Surge Protection: It is important that ac surges reaching rectifiers do not exceed the

capacity of the rectifier internal surge protection. Protection must be provided external to the GPS system, if necessary, to limit surge energy reaching the rectifiers. Site surge protection must be coordinated with rectifier internal surge protection and must clamp at a lower voltage than the rectifier internal protection. The internal protection voltage and current characteristics of the rectifiers are as follows:

595A3

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

595B3

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

Physical

Width 445 mm (17.5 in) rear of unit Height 210 mm (8.25 in) rear of unit Depth 470 mm (18.2 in) overall, less connector Weight 27 kg (<59 lbs)

Environmental

Efficiency > 92% @ 100Adc - 220Adc output current Storage Temperature -40°C - +85°C Storage Relative Humidity 5% - 90% Altitude -50 to 4000 meters (Note: For altitudes above

1500 meters, derate the temperature by 0.656° Celsius per 100 meters.)

Audible Noise < 60dBA at room temperature, mounted in cabinet Heat Release: 54Vdc, 160A 54Vdc, 200A

Per Rectifier 854W [2915 BTU/hr] 1068W [3645.7 BTU/hr]

Issue 10 February 2008 Specifications 9 - 5

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Table 9-B: 595 Series Rectifier Specifications - S1:3 and later

See Issue 8 for pre S1:3 specifications. (Continued)

Standards Compliance

Safety • UL Recognized (US and Canada) and VDE

• UL1950, EN60950/IEC950, and CSA 234/950 (tested for SELV output)

Electromagnetic Compliance: Emission and Immunity

• EN55022 (CISPR22) Radiated/conducted emission, Class B meets FCC Part 15 Class B

• 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

CE Marking CE marked per European Union Council

directives: Low-voltage Directive (73/23/EEC) as amended by CE Marking Directive (93/68/EEC)

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 Over Temperature Shutdown tA ALM Output Under Voltage Shutdown LO ALM High Voltage Shutdown HO ALM

ICS

IP5

Internal Failure

IP6 IP7

SEN

FSE

InF

ALM

9 - 6 Specifications Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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

Distribution Only Panels, no ac

- None 28

- None 29

Battery Connection Panels

Table 9-E: Battery Connection Panels

Fuse or

Circuit Breaker

No Battery Panel

Panels without Fuses or Circuit Breakers

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

LVB D Shunt ED83143-31

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

H569-434

GPS4848/100

None 33

1,500A 30 32

Off Line Equalize Panels

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

3 x 1,000A 61 38

Issue 10 February 2008 Specifications 9 - 7

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 - 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 do not include return bus.

Height

(in.)

LVL D Shunt

600A, 50mV

1 / fuse

600A, 50mV

1 / fuse

300A, 50mV

1 / fuse

300A, 50mV

1 / fuse

ED83143-31

Group

55 53, 53A

55 57, 57A

54 54, 54A

54 54B, 54C

42, 42A, 106, 106A, 107, 107A, 108, 108A, 109, 109A

48, 48A, 110, 110A, 111, 111A, 112, 112A, 113, 113A

43, 43A, 101, 101A, 102, 102A, 103, 103A, 104, 104A

H569-434

GPS 4848/100 Group

9 - 8 Specifications Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 10 February 2008 Safety 10 - 1

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 10 February 2008 Maintenance and Replacement 11 - 1

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 positions in a cabinet below the top installed rectifier may cause excessive temperature in the remaining rectifiers. If a rectifier below the top rectifier is removed, it must be replaced immediately or the vacated position must be occupied by a Rectifier Shelf Cover (848680211).

If a spare rectifier or Rectifier Shelf Cover is not available, a rectifier from the top position must be relocated to occupy the vacant position.

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 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 thermal alarm. The 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.

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 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Replacement Procedures

Installing or

Replacing a Rectifier

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.

Caution

Rectifier is heavy (59 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.

Caution

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

Lift Straight Up

Continued on next page.

Issue 10 February 2008 Maintenance and Replacement 11 - 3

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Replacement Procedures, continued

Installing or Replacing a Rectifier, continued

Step Action

Turn ac circuit breaker OFF.

Place rectifier power switch in STBY.

Verify that rectifier matches the ac input voltage of the

system.

DO NOT INSTALL 595B RECTIFIERS INTO

380/400/480Vac systems; they will will be damaged.

Continued on next page.

11 - 4 Maintenance and Replacement Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Installing or Replacing a Rectifier, continued

Step Action

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 position and working upward.

c. Remove the label over the locking screw access window.

Using a 5mm (3/16") Allen-head “T” wrench, turn the locking screw clockwise to secure the rectifier to the shelf.

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.

Rectifier Shelf in Cabinet

Rectifier

Insertion Tool

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

Continued on next page.

Issue 10 February 2008 Maintenance and Replacement 11 - 5

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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.

Ve r if y :

• Green LED is illuminated.

• No alarms are illuminated.

Set rectifier ID number (choose appropriate procedure):

For 595A2, 595A3, 595B2, and 595B3:

Note: If the rectifier ID goes above 24, then it is a 595A2/A3 or 595B2/ B3 rectifier. Otherwise, it is a 595A or 595B.

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.

For 595A and 595B rectifiers:

a. Depress and hold rectifier power switch in UP position for 5 seconds;

the displayed number will begin to blink.

b. Depress and release switch until desired number is reached.

c. When the desired number is reached, continue to hold switch until

display stops blinking. The new ID number is now set. Note: Abandoning this process before the display stops blinking will default the rectifier to the last number set.

Follow Steps 3-6 to install remaining rectifiers. Follow Steps 7-11 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.

11 - 6 Maintenance and Replacement Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Replacement Procedures, continued

Removing a

Rectifier

Removing a Rectifier

Step Action

Set power switch to STBY.

Turn OFF ac circuit breakers.

Turn OFF output circuit breaker on rectifier.

Wait 5 minutes to allow capacitors to discharge.

Using a 5mm Allen-head “T” wrench, slowly turn the locking

screw counterclockwise to release the rectifier from the shelf.

Slowly slide rectifier from shelf.

Caution

Rectifier is heavy (59 pounds). Use two people to lift and move rectifiers.

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

If the rectifier is not going to be replaced immediately, retire the

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

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

Rectifier ID of the removed rectifier. Press Enter to clear the alarm.

Continued on next page.

Issue 10 February 2008 Maintenance and Replacement 11 - 7

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Replacement Procedures, continued

Removing a Rectifier, continued

Step Action

If the removed rectifier is below the top rectifier in its cabinet, it

must be replaced immediately or the vacated position must be occupied by a Rectifier Shelf Cover 848680211.

If a spare rectifier or Rectifier Shelf Cover is not available, a rectifier from the top position must be relocated to occupy the vacant position.

Temporarily relocated rectifiers retain their rectifier ID and require no configuration changes for alarm free operation.

Follow rectifier removal and installation procedures to relocate a rectifier.

11 - 8 Maintenance and Replacement Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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.

Loosen the front cover (white) by removing 6 screws (2 top, 4 bottom).

Allow the front end of the rectifier to overhang the working surface. To remove bottom screws, turn the rectifier on its side, or work below the table surface.

Caution

Never tilt the front of the unit to gain access to the bottom screws. This will result in damage to the rear connector.

Fan Screws (4 each fan)

Fan Cable Connectors

Figure 11-2: Fan Replacement

Continued on next page.

Issue 10 February 2008 Maintenance and Replacement 11 - 9

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Replacement Procedures, continued

Replacing the Rectifier Fan Assemblies, continued

Step Action

Remove the 4 fan screws attaching the fan to be replaced to

the chassis, and carefully unplug the fan connector. The fan connector is keyed and can be loosened by inserting a screwdriver into the slotted side of the connector and gently prying the fan-side connector loose.

Place the new fan in position and torque screws to 10 in-lb.

Replace the front cover.

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 - 10 Maintenance and Replacement Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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

guidelines for new installations.

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 the AC and MIN alarm LEDs illuminate, the rectifier displays ACF, and the controller alarms screen indicates RECTIFIER FAIL : Gmm.

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

OPTIONAL: Simulate a load circuit breaker alarm by shorting the alarm contacts on the circuit breakers or inserting an operated alarm fuse. For ED83143-31 G1, G2, or G5 add a jumper from the hot bus to the FAJ input signal on the associated BNL1 (P4-1) or BNL7 (P5-6) alarm card. Verify that the DIST and MAJ alarm LEDs illuminate and the controller alarms screen indicates EXTERNAL FUSE MAJOR.

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 10 February 2008 Maintenance and Replacement 11 - 11

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 .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

108588625 BIC8 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

108972238 595LTA, 220 ampere rectifier

108979246 595LTB, 220 ampere rectifier

848693586 Fan

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 - 12 Maintenance and Replacement Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 Remote Peripheral Monitoring System Product Manual

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. To download from our web site, go to http://www.lineagepower.com, click “Downloads” and click on the appropriate EasyView download button.

Description

Issue 10 February 2008 Maintenance and Replacement 11 - 13

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 10 February 2008 Troubleshooting Preparations 12 - 1

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Galaxy

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.).

Cabinet Alarm Light

Galaxy Millennium Controller

ESD

A STSTR I

D N U

O GR

POIN

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

12 - 2 Troubleshooting Preparations Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 Table 13-F.

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.

Issue 10 February 2008 Troubleshooting Preparations 12 - 3

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 12-7

12-8

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, the green

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 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Reference Figures, continued

Millennium Controller, continued

Galaxy Millennium Controller

Alarm Status

Critical

Major

Minor

Normal

Battery on Discharge

Equipment Status

AC System

Battery

Controller

Distribution

Rectifier

Remote Modules

Figure 12-2: Millennium Controller Display

Controller Fuses

F1 F2 F3 F4 F5

Escape Help

Enter

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

BSL Alarm Termination Board

GMT

Fuses

1 1/3A

BSM Modem Board

BSH Basic Controller Board

Basic LEDs

BSJ Intelligent Controller Board

Intelligent LEDs

BSW Data Switch Board (mounting location)

Figure 12-3: Millennium Controller Fuses and Circuit Boards

Issue 10 February 2008 Troubleshooting Preparations 12 - 5

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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.

CURRENT

STBY ALM LIM FANAL M EQL

OFF

200A/48V

CURRENT

STBY

Status Indicators

ALM LIM FAN ALM EQL

200A/48V

Figure 12-4: Rectifier Display

OFF

12 - 6 Troubleshooting Preparations Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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.

CONTACTOR DRIVE BOARD

BOTH SWITCHES DOWN FORCES CONTACTOR OPEN

CONTACTOR OPEN

CONTACTOR OPEN INITIATED

DOWN FORCES

CONTACTOR CLOSED

REMOTE CONTROL ENABLED

Red Light

Yellow Light

Green Light

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

Figure 12-5: Low Voltage Battery Disconnect Contactor

Control Switches

Issue 10 February 2008 Troubleshooting Preparations 12 - 7

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

WARNING

Reference Figures, continued

AC Input

123 4

1234

RECTIFIER RECTIFIER RECTIFIER RECTIFIER

HIGHVOLTAGE BEHIND COVER.

RISKOF SEVERE INJURY OR DEATH.

TURNOFF AC AT BRANCH CIRCUIT

BOX.KEEP COVER IN PLACE TO AVOID

ELECTRICAL HAZARD.

AC Circuit Breakers for Rectifiers

Back of Rectifier

Data Pins for

123 4

DC Output

Communication

Ground

Plugs into Mating Connector on Shelf

AC Input

ABC

Rectifier

595A 595B

Phase Voltage Range

320Vac - 530Vac 176Vac - 254Vac

AC Input

Phase 1 Phase 2 Phase 3

Measure between:

A and B B and C C and A

Figure 12-6: AC Input Panel and Rectifier Connection

12 - 8 Troubleshooting Preparations Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Reference Figures, continued

DC Distribution

Alarm/Terminal Card

Connects to Negative Charge Bus

Connects to Charge Return Bus

Alarm LED

Figure 12-7: DC Distribution Panel

Issue 10 February 2008 Troubleshooting Preparations 12 - 9

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 12-8.

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.

Control switch mounted on right side of cabinet.

GREEN LIGHT

REMOTE CONTROL ENABLED

UP POSITION FORCES CONTACTOR CLOSED

REMOTE CONTROL OVERRIDE SWITCH

Green Light

YELLOW LIGHT ONLY

CONTROLLER SIGNAL ERROR DETECTED

RED AND YELLOW LIGHT

CONTROLLER SIGNAL OPENED CONTACTOR

LOAD DISCONNECT FEATURE IS NOT

FOR USE IN BATTERYLESS SYSTEMS

Yellow Light

Red Light

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

Figure 12-8: Low Voltage Load Disconnect Contactor

Control Switches

12 - 10 Troubleshooting Preparations Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 10 February 2008 Troubleshooting Millennium Systems 13 - 1

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

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 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 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

Internal Failure

LS, CS, IP5, IP6, IP7,

SEN, FSE, InF

LED

Illuminated

ALM

13 - 2 Troubleshooting Millennium Systems Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Millennium

The Millennium display is illustrated below.

Controller Display

AC Alarm LED

Table 13-A: AC Alarms

Controller

LED

AC MIN AC Fail ACF on

Controller

Alarm Status

Millennium

Controller Display

(See Figure 12-6)

Other

Indication(s)

rectifier display

Possible Problem(s) Possible Solution(s)

Rectifier is not receiving ac power:

•AC input circuit

•AC input voltage is

•Internal rectifier

breaker has operated.

out of range.

failure

1. Verify that ac circuit breaker is closed; close circuit breaker if operated.

2. If the problem is not corrected, replace the rectifier.

AC MIN Engine Transfer

Timeout

AC MIN Phase Alarm PF on

Issue 10 February 2008 Troubleshooting Millennium Systems 13 - 3

Engine may have alarm.

rectifier display

Remote engine or connection to engine has failed.

Phase failure:

•Rectifier high voltage shutdown

•External phase imbalance or failure

•Internal rectifier failure

Call technical support.

1. Toggle the ON/STBY switch into the STBY position and then back into the ON position.

2. If the problem is not corrected, replace the rectifier.

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

BATT Alarm LED

Table 13-B: Battery Alarms

(See Figure 12-5)

Controller

LED

BATT CRIT Very Low Voltage -- Occurs in an

Controller

Alarm

Status

Millennium

Controller Display

Other

Indication(s)

Possible Problem(s) Possible Solution(s)

operating system following an extended commercial ac power outage, during which the batteries are providing power for the system and the system voltage is approaching the user-defined low limit.

1. If commercial ac power is present but the system voltage remains low, call technical support.

2. Investigate other alarms that may be present (rectifier-related alarms and the AC Fail alarm may also occur during the fault condition).

BATT*

*Alarm must be configured to turn on the BATT LED; not a factory default.

BATT*

*Alarm must be configured to turn on the BATT LED; not a factory default.

BATT MIN Open String Alarm LED

BATT MIN Low Reserve Time -- Controller has

MAJ Contactor 1 Open Red LED on

contactor drive board is lit.

MAJ Contactor 1 Fail -- Contactor or drive

on battery fuse panel is lit.

Contactor is open:

•Open has been initiated by controller.

•Open has been initiated manually.

board has failed.

Battery fuse has operated.

calculated that batteries are low.

1. Follow instructions on the label adjacent to the contactor drive board (see Figure 12-5).

2. If the problem is not corrected, call technical support.

Call technical support.

Replace the operated fuse.

Call technical support.

13 - 4 Troubleshooting Millennium Systems Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

CTRL Alarm LED

Table 13-C: Controller Alarms

(See Figures 12-2 and 12-3)

Controller

LED

CTRL MAJ Controller Fail -- •BSH failure→

Controller

Alarm

Status

Millennium

Controller Display

Other

Indication(s)

Possible Problem(s) Possible Solution(s)

•BSJ failure

•Option board failure

•Display failure

•BIC failure

Check the BSH board to see if the green LED is extinguished and the yellow LED is lit. If so, perform the following steps:

1. Press the SW200 reset switch on the top of the BSH board. If all diagnostics pass, it is possible that some type of “one time” abnormality occurred to cause the failure.

2. If the diagnostics did not pass, or if the problem recurs, unplug all the optional circuit board cables, then press the reset switch on the top of the BSH board again. If all the diagnostics pass, install optional circuit board cables one at a time, verifying operation after each.

3. If the diagnostics did not pass, replace the BSH board and verify the failure is resolved. If so, reinstall the optional circuit boards and cables one at a time.

4. If the problem is not corrected, call technical support.

Issue 10 February 2008 Troubleshooting Millennium Systems 13 - 5

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Table 13-C: Controller Alarms (Continued)

(See Figures 12-2 and 12-3)

Controller

LED

CTRL MAJ Controller Fail -- •BSH failure

Controller

Alarm

Status

Millennium

Controller Display

Other

Indication(s)

Possible Problem(s) Possible Solution(s)

•BSJ failure→

•Option board failure

•Display failure

•BIC failure

Check the BSJ board to see if the green LED is extinguished and the yellow LED is lit. If so, perform the following steps:

1. Press the SW201 reset switch on the top of the BSJ board. (This circuit has an automatic restart, which will try three times to restart the microprocessor.)

2. If the diagnostics did not pass, or if the problem recurs, remove all the optional circuit board cables, then press the reset switch on the top of the BSJ board again. If all the diagnostics pass, install optional circuit board cables one at a time, verifying operation after each.

3. If the diagnostics did not pass, replace the BSJ board and verify the failure is resolved. If so, reinstall the optional circuit boards and cables one at a time.

4. If the problem is not corrected, call technical support.

13 - 6 Troubleshooting Millennium Systems Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Table 13-C: Controller Alarms (Continued)

(See Figures 12-2 and 12-3)

Controller

LED

CTRL MAJ Controller Fail -- •BSH failure

Controller

Alarm

Status

Millennium

Controller Display

Other

Indication(s)

Possible Problem(s) Possible Solution(s)

•BSJ failure

•Option board failure→

•Display failure

•BIC failure

Check the option boards (modem and data switch) to see if the green LED is extinguished and the yellow LED is lit. If so, perform the following steps:

1. Press the SW201 reset switch on the top of the BSJ board. (This circuit has an automatic restart, which will try three times to restart the microprocessor.) If the BSJ is not present, press the reset switch on the top of the BSH board.

2. If the diagnostics did not pass, or if the problem recurs, replace the failed option board.

CTRL MAJ Controller Fail -- •BSH failure

•BSJ failure

•Option board failure

•Display failure→

•BIC failure

If the front panel LCD module, LEDs, or switches fail, perform the following steps:

1. Verify that the ribbon cable from the BSH board to the display is not cut, abraded, or otherwise mangled. Replace the cable if damaged.

2. Press SW200 to reset the BSH board.

3. If the LCD module is still not operating, replace the LCD module; if the switches and LEDs are still not operating, replace the BSH board.

Issue 10 February 2008 Troubleshooting Millennium Systems 13 - 7

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Table 13-C: Controller Alarms (Continued)

(See Figures 12-2 and 12-3)

Controller

LED

CTRL MAJ Controller Fail -- •BSH failure

Controller

Alarm

Status

Millennium

Controller Display

Other

Indication(s)

Possible Problem(s) Possible Solution(s)

•BSJ failure

•Option board failure

•Display failure

•BIC failure→

1. Strap K1, K2, K3 on BLJ from “C” to “R” prior to replacing BIC. See Figure 8-2.

2. Replace BIC.

CTRL MAJ Circuit Pack Fail -- See “Controller

Fail”.

CTRL MAJ Controller Fuse -- Fuse has operated. Replace the controller fuse

CTRL MAJ Alarm Battery

Supply Fuse

CTRL MAJ Remote Peripheral

Fuse

CTRL MAJ Sense/Control

Fuse

CTRL MAJ Bay Interface ID

Conflict

CTRL MAJ Major

Communication Fail Alarm

-- Fuse has operated. Replace the controller fuse

-- Two or more bay interface cards (BICs) have the same ID number.

Blinking ALM LED on rectifiers

red LED on BIC

Loss of communication with controller:

•Defective

interface from BIC or multiple rectifiers to controller

•Internal failure of

controller, BIC, or multiple rectifiers

See “Controller Fail”.

labeled F2 (intelligent power).

labeled F5 (alarm battery supply).

labeled F1 (option power).

labeled F4 (voltage sense).

Following instructions printed on the label over the BIC, adjust the DIP switches to change the ID number.

1. Verify that the controller is powered and operating correctly.

2. If there are no controller alarms, replace the equipment that has lost communication.

3. If the problem is not corrected, call technical support.

13 - 8 Troubleshooting Millennium Systems Issue 10 February 2008

Controller

LED

CTRL MIN Minor

Controller

Alarm

Status

Controller Display

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Table 13-C: Controller Alarms (Continued)

(See Figures 12-2 and 12-3)

Millennium

Communication Fail Alarm

Other

Indication(s)

Blinking ALM LED on rectifier

Possible Problem(s) Possible Solution(s)

Loss of communication with controller:

•Defective interface from rectifier to controller

•Internal controller or rectifier failure

1. Verify that the controller is powered and operating correctly.

2. If there are no controller alarms, replace the equipment that has lost communication.

3. If the problem is not corrected, call technical support.

CTRL MIN Self Fail Test -- See “Controller

Fail”.

CTRL MIN Thermal Probe

Failure

-- Battery thermal probe has failed.

DIST Alarm LED

Table 13-D: Distribution Alarms

(See Figures 12-7 and 12-8)

Controller

LED

DIST MAJ External Fuse

DIST*

*Alarm must be configured to turn on the DIST LED; not a factory default.

Controller

Alarm

Statu s

MAJ Contactor 2 (or 3)

Millennium

Controller Display

Major

Open

Other

Indication(s)

Alarm LED on dc distribution panel is lit.

Red LED on contactor drive board is lit.

Possible

Problem(s)

DC load fuse or circuit breaker has operated.

Contactor is open:

•Open has been initiated by controller.

•Open has been initiated manually.

See “Controller Fail”.

Call technical support.

Possible Solution(s)

Replace fuse or reset circuit breaker.

1. Follow instructions on the label adjacent to the contactor drive board (see Figure 12-8).

2. If the problem is not corrected, call technical support.

DIST*

*Alarm must be configured to turn on the DIST LED; not a factory default.

Issue 10 February 2008 Troubleshooting Millennium Systems 13 - 9

MAJ Contactor 2 (or 3)

Fail

-- Contactor or drive board has failed.

Call technical support.

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

RECT Alarm LED

Table 13-E: Rectifier Related Alarms

(See Figures 12-4 and 12-6)

Controller

LED

RECT MAJ ID Not Configured None None Rectifier ID

Controller

Alarm

Statu s

Millennium

Controller Display

Rectifier

LED

Rectifier

Display

Problem(s)

number has not been set.

Possible

Possible Solution(s)

Set rectifier ID using procedure in Section 11, “Installing or Replacing a Rectifier.”

RECT MAJ ID Conflict None None Two or more

rectifiers have the same ID number.

RECT MAJ Multiple Rectifier

Fail

RECT MAJ High Voltage

Alarm

RECT MIN Rectifier Fail ALM HO High output

ALM None More than one

rectifier has an ALM LED lit.

ALM HO •Lightning has

struck system.

•Internal rectifier failure

voltage:

•Rectifier high voltage shutdown

•Internal rectifier failure

See above.

See alarms listed below.

1. Toggle the ON/ STBY switch into the STBY position and then back into the ON position.

2. If the problem is not corrected, replace the rectifier.

1. Verify the configurable HV thresholds in the controller.

2. Toggle the ON/ STBY switch into the STBY position and then back into the ON position.

3. If the problem is not corrected, replace the rectifier.

13 - 10 Troubleshooting Millennium Systems Issue 10 February 2008

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Table 13-E: Rectifier Related Alarms (Continued)

(See Figures 12-4 and 12-6)

Controller

LED

RECT MIN Rectifier Fail ALM TA Thermal alarm:

Controller

Alarm

Statu s

Millennium

Controller Display

Rectifier

LED

Rectifier

Display

Possible

Problem(s)

•Excessive ambient temperature

•Internal rectifier failure

Possible Solution(s)

1. Verify that there is no obstruction of the fan inlet.

2. Toggle the ON/ STBY switch into the STBY position and then back into the ON position.

3. If the problem is not corrected, replace the rectifier.

RECT MIN Rectifier Fail ALM CB Circuit breaker

alarm:

•DC output circuit breaker open

•Internal rectifier failure

1. Toggle the ON/ STBY switch into the STBY position; toggle the DC output circuit breaker into the OFF position and then into the ON position. Return the ON/STBY switch to the ON position.

2. If the problem is not corrected, replace the rectifier.

Issue 10 February 2008 Troubleshooting Millennium Systems 13 - 11

Galaxy Power System 4848/100 with 595 Series Rectifiers S1:3 and later

Table 13-E: Rectifier Related Alarms (Continued)

(See Figures 12-4 and 12-6)

Controller

LED

RECT MIN Rectifier Fail ALM ICS

Controller

Alarm

Statu s

Millennium

Controller Display

Rectifier

LED

Rectifier

Display

IP5

IP6

IP7

InF

FSE

Possible

Problem(s)

Internal rectifier failure

Possible Solution(s)

1. Place the ac circuit breaker for the rectifier in the OFF position.

2. Remove the rectifier from the shelf.

3. Wait for 30 seconds or until all front panel display LEDs have extinguished.

4. Replace the rectifier.

5. Return the ac breaker to the ON position.

6. Place the rectifier ON/STBY switch into the ON position.

7. If the problem is not corrected, replace the rectifier.

RECT MIN Rectifier Fail ALM LO Low output

voltage:

•Excessive output current

•Internal rectifier failure

1. Toggle the ON/ STBY switch into the STBY position and then back into the ON position.

2. If the problem is not corrected, replace the rectifier.

13 - 12 Troubleshooting Millennium Systems Issue 10 February 2008

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 was developed to support

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

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 rows of LEDs show the source and severity of various alarms. An

Pushbutton Controls

Test Jacks A pair of test jacks allows direct measurement of the dc bus sense

4 Rectifiers

595 Series

Overview Two 200-ampere rectifiers are available for the GPS 4848/100 system:

Front Panel Display

Power Switch This three-position switch has two active states:

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, press the Lamp Test button

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

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 6-8.

7 DC Distribution Panels

Overview

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

8 Circuit Boards

Overview

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

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