GE Industrial Solutions H5692448 User Manual

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Critical Power

Installation Guide

H5692448 Power Systems

Infinity M1 (NE-M)

with

Galaxy Millennium™ II Controller

or

Galaxy Pulsar™ Plus Controller

and Eco Capability

Pulsar Plus Controller

Millennium II Controller

equipped

equipped

Issue 6 and later of this manual cover all NE-M systems, replacing CC848845333 NE-M with Millennium II Installation Guide.

Issue 5 and earlier of this manual covered only NE-M with Pulsar Plus.

1 Trademark of General Electric Company

Service and Assistance - +1 877 546 3243 or +1 972 244 9288

PE.TechSupport@ge.com

© 2013 General Electric Company. All rights reserved.

www.gecriticalpower.com

CC848815325

Issue 06 May 2013

1

NE-M Installation Guide

H5692448

Table of Contents

 

Table of Contents............................................................................................................................................................................................................................

2

Table of Figures................................................................................................................................................................................................................................

3

Table of Tables..................................................................................................................................................................................................................................

4

Introduction........................................................................................................................................................................................................................................

5

Reference Documents ........................................................................................................................................................................................................

5

Customer Service Contacts..............................................................................................................................................................................................

5

On-Line Power Systems Product Manuals and Software ................................................................................................................................

5

Product Description .......................................................................................................................................................................................................................

6

Components.............................................................................................................................................................................................................................

9

Installation ........................................................................................................................................................................................................................................

16

Preparation .............................................................................................................................................................................................................................

16

Safety................................................................................................................................................................................................................................

16

Installation Tools.........................................................................................................................................................................................................

16

Equipment Identification........................................................................................................................................................................................

16

Anchor Frame........................................................................................................................................................................................................................

16

Floor Mounted Frame ..............................................................................................................................................................................................

16

Battery or Battery Stand Mounted Frame ....................................................................................................................................................

18

Sub-frame Mounted Systems:.............................................................................................................................................................................

18

Ground Frame .......................................................................................................................................................................................................................

19

Floor Mounted Frame ..............................................................................................................................................................................................

19

Battery or Battery Stand Mounted Frame ....................................................................................................................................................

20

Connect Central Office Ground (COG).......................................................................................................................................................................

20

Install PV/AC Partition Kit – NE-M Eco systems only .........................................................................................................................................

21

Connect Input Power .........................................................................................................................................................................................................

23

Install Battery Trays............................................................................................................................................................................................................

26

Install Batteries .....................................................................................................................................................................................................................

27

Tray Mounted Batteries...........................................................................................................................................................................................

27

External Batteries.......................................................................................................................................................................................................

28

Connect Batteries................................................................................................................................................................................................................

29

Tray Mounted Batteries...........................................................................................................................................................................................

29

External Battery Connection ................................................................................................................................................................................

33

Connect Battery Probes..........................................................................................................................................................................................

34

Verify Battery Bus Voltage and Polarity...................................................................................................................................................................

34

Connect Load Wiring .........................................................................................................................................................................................................

35

Verify Installation .................................................................................................................................................................................................................

38

Install Controller ...................................................................................................................................................................................................................

39

Install Pulsar Plus........................................................................................................................................................................................................

39

Install Millennium II....................................................................................................................................................................................................

46

Install BSM6 Modem .................................................................................................................................................................................................

50

Install Optional Controller Peripherals ............................................................................................................................................................

50

Install Rectifiers/Converters...........................................................................................................................................................................................

50

Install Rectifiers ...........................................................................................................................................................................................................

52

Verify Rectifier Positions .........................................................................................................................................................................................

53

Install Converters .......................................................................................................................................................................................................

54

Install Battery Voltage Temp (VT)-Probes ...............................................................................................................................................................

54

Install Aux Display (NE830A) Alarm Cable (Optional).........................................................................................................................................

54

Configure Controller – Minimum .................................................................................................................................................................................

56

Configure Pulsar Controller...................................................................................................................................................................................

56

Configure Millennium II Controller.....................................................................................................................................................................

58

Acceptance Testing .....................................................................................................................................................................................................................

60

Troubleshooting.............................................................................................................................................................................................................................

63

System.......................................................................................................................................................................................................................................

63

Rectifiers/Converters .........................................................................................................................................................................................................

70

Voltage Temp (VT)-Probes...............................................................................................................................................................................................

71

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Specifications and Application...............................................................................................................................................................................................

72

Safety...................................................................................................................................................................................................................................................

73

Special Installation Notes................................................................................................................................................................................................

74

Deutsch............................................................................................................................................................................................................................

74

Español ............................................................................................................................................................................................................................

75

Revision History..............................................................................................................................................................................................................................

76

Table of Figures

 

Figure 1 Block Diagram ...............................................................................................................................................................................................................

8

Figure 2 NE-M Components ......................................................................................................................................................................................................

9

Figure 3 Frame - Full-Height ..................................................................................................................................................................................................

10

Figure 4 Frame - Half Height .................................................................................................................................................................................................

10

Figure 5 Sub-frame .....................................................................................................................................................................................................................

10

Figure 6 Pulsar Front Panel.....................................................................................................................................................................................................

11

Figure 7 Millennium II Controller Front Panel................................................................................................................................................................

11

Figure 8 NE830 Display.............................................................................................................................................................................................................

12

Figure 9 Rectifier and Converter Type Badge ...............................................................................................................................................................

12

Figure 10 Power Input Panel..................................................................................................................................................................................................

14

Figure 11 Battery Stand............................................................................................................................................................................................................

14

Figure 12 DC Distribution Bullet & Bolt-In .......................................................................................................................................................................

15

Figure 13 DC Distribution - Bullet ........................................................................................................................................................................................

15

Figure 14 Frame Mount Template.......................................................................................................................................................................................

17

Figure 15 Battery Stand Mount ............................................................................................................................................................................................

18

Figure 16 Mount Sub-Frame..................................................................................................................................................................................................

19

Figure 17 Ground Frame..........................................................................................................................................................................................................

19

Figure 18 Ground Short Frame.............................................................................................................................................................................................

20

Figure 19 CO Ground Landing...............................................................................................................................................................................................

20

Figure 20 Eco Input Panel........................................................................................................................................................................................................

21

Figure 21 Input Panel Screws................................................................................................................................................................................................

21

Figure 22 Partition Labels........................................................................................................................................................................................................

22

Figure 23 Partition Insert ........................................................................................................................................................................................................

22

Figure 24 Label Input Panel....................................................................................................................................................................................................

23

Figure 25 Label Input Panel Cover......................................................................................................................................................................................

23

Figure 26 Input Power Terminal Block Positions .........................................................................................................................................................

23

Figure 27 Rectifier and Shelf Numbering ........................................................................................................................................................................

24

Figure 28 Rectifier Dual Feed Jumper Positions – ac feeds only ........................................................................................................................

24

Figure 29 Input Conduit Locations......................................................................................................................................................................................

24

Figure 30 Input Jumper Dividers..........................................................................................................................................................................................

25

Figure 31 AC Bridging Jumper ..............................................................................................................................................................................................

25

Figure 32 Input Panel Sections .............................................................................................................................................................................................

25

Figure 33 Battery Trays.............................................................................................................................................................................................................

26

Figure 34 Batteries in Tray – 48V.........................................................................................................................................................................................

27

Figure 35 Place Batteries .........................................................................................................................................................................................................

28

Figure 36 Battery Inter-Cell Bus Bars ................................................................................................................................................................................

28

Figure 37 Battery Disconnect Switch ................................................................................................................................................................................

29

Figure 38 Batt Disconnect Switch Input Bus .................................................................................................................................................................

29

Figure 39 Battery Cable -48V.................................................................................................................................................................................................

29

Figure 40 Battery Cable +24V................................................................................................................................................................................................

30

Figure 41 Battery Return Cable -48V.................................................................................................................................................................................

30

Figure 42 Battery Return Cable +24V................................................................................................................................................................................

30

Figure 43 Anderson Battery Connector ...........................................................................................................................................................................

31

Figure 44 Battery Connections - Anderson....................................................................................................................................................................

31

Figure 45 Battery Cable Direct -48V ..................................................................................................................................................................................

32

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Figure 46 Battery Cable Direct +24V .................................................................................................................................................................................

32

Figure 47 Battery Return Cable Direct -48V...................................................................................................................................................................

32

Figure 48 Battery Return Cable Direct +24V..................................................................................................................................................................

33

Figure 49 External Battery Shunt Panel ...........................................................................................................................................................................

33

Figure 50 External Battery Shunt Panel Lug Adapters.............................................................................................................................................

33

Figure 51 External Shunt Panel Battery Connections...............................................................................................................................................

34

Figure 52 Battery Bus Connections....................................................................................................................................................................................

34

Figure 53 Battery Bus Labels .................................................................................................................................................................................................

35

Figure 54 Distribution Assignment Record Label........................................................................................................................................................

35

Figure 55 Vertical Bullet Distribution Panel....................................................................................................................................................................

36

Figure 56 GMT Fuse Module...................................................................................................................................................................................................

36

Figure 57 Bolt-In Breakers.......................................................................................................................................................................................................

38

Figure 58 Rectifier Positions ...................................................................................................................................................................................................

39

Figure 59 ESD Grounding Connector.................................................................................................................................................................................

40

Figure 60 Alarm Relay Jumpers – Pulsar Plus...............................................................................................................................................................

40

Figure 61 Alarm Relay Jumper Positions - Pulsar Plus.............................................................................................................................................

41

Figure 62 1-Wire Jumper - Pulsar Plus.............................................................................................................................................................................

42

Figure 63 Controller Connections........................................................................................................................................................................................

42

Figure 64 Local Port - Pulsar Plus........................................................................................................................................................................................

46

Figure 65 ESD Grounding Connector.................................................................................................................................................................................

46

Figure 66 Millennium II Circuit Card - Field.....................................................................................................................................................................

47

Figure 67 Controller Connections........................................................................................................................................................................................

47

Figure 68 Alarm Connections Millennium II ...................................................................................................................................................................

49

Figure 69 LAN Connection - Millennium II.......................................................................................................................................................................

50

Figure 70 Insert Rectifier ..........................................................................................................................................................................................................

50

Figure 71 Open Rectifier Door...............................................................................................................................................................................................

51

Figure 72 Close Rectifier Door...............................................................................................................................................................................................

51

Figure 73 Open Rectifier Door...............................................................................................................................................................................................

51

Figure 74 Remove Rectifier.....................................................................................................................................................................................................

51

Figure 75 Inventory Screen.....................................................................................................................................................................................................

53

Figure 76 Main Screen - web .................................................................................................................................................................................................

54

Figure 77 NE830 Alarm Cable Connector .......................................................................................................................................................................

55

Figure 78 Front Panel - Pulsar Plus Controller..............................................................................................................................................................

56

Figure 79 Front Panel - Millennium II Controller ..........................................................................................................................................................

58

Figure 80 Rectifier Face Plate................................................................................................................................................................................................

70

Table of Tables

 

Table 1 Rectifiers and Converters .......................................................................................................................................................................................

13

Table 2 Conduit Size - Input Feed........................................................................................................................................................................................

26

Table 3 Alarm Defaults – Standard Pulsar Plus............................................................................................................................................................

41

Table 4 Analog Interface Connector Signals – Pulsar Plus ....................................................................................................................................

43

Table 5 Auxiliary Input Connector Signals - Pulsar Plus ..........................................................................................................................................

44

Table 6 Alarm Signals - Pulsar Plus ....................................................................................................................................................................................

45

Table 7 Power and Sense Signals - Millennium II........................................................................................................................................................

48

Table 8 Power Connections - NE830 .................................................................................................................................................................................

55

Table 9 Alarm Connections - NE830 ..................................................................................................................................................................................

55

Table 10 Push Buttons - Millennium II...............................................................................................................................................................................

58

Table 11 Rectifier/Converter LEDs ......................................................................................................................................................................................

70

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Introduction

This manual is intended as a guide in assisting equipment understanding, installation, testing, and troubleshooting. For additional assistance contact Customer Service or access additional information on-line.

Reference Documents

Document Title

Infinity M Product Line Brochure – Specifications and Ordering Guide H5692448-AD NE System, 24V and/or 48V Assembly Drawing

CC848815341 Galaxy Pulsar Plus2 Family Product Manual 108994645 Galaxy Millennium II3 Installation and User’s Guide

Customer Service Contacts

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

Services provided include initiating the spare parts procurement process, ordering documents, product warranty administration, and providing other product and service information.

GE Energy phones are staffed from 7:00 am to 5:00 pm USA Central Time Zone (GMT -6), Monday through Friday, on normal business days. At other times, this number is still available, but for emergencies only.

Calling from

Phone Number

• United States, Canada, Puerto Rico, and the US Virgin

+1 877 546 3243

Islands

 

• All other countries

+1 972 244 9288

 

Or

 

USADCC4 + 877 546 3243

Or contact your local field support center or your sales representative to discuss your specific needs.

On-Line Power Systems Product Manuals and Software

Product manuals, product line brochures, and software are available on-line. Software includes Easy View and SNMP MIB.

www.gecriticalpower.com

2Referred to as “Pulsar Plus” throughout this document.

3Referred to as “Millennium II” throughout this document.

4The USA direct country code for the country where the call is originating

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Product Description

Infinity M (NE-M) is available in multiple system arrangements - Figure 1.

Refer to the Infinity M Product Line Brochure for detail description.

Single or Dual Output Voltage

Primary DC Voltage

Secondary DC Voltage

(Battery and Rectifiers)

(dc/dc Converters)

24V

none

24V

48V

48V

none

48V

24V

Battery Connections

Direct connection to NE-M system bus

Through battery maintenance switches or circuit breakers located at the battery

Through a Low Voltage Battery Disconnect (LVBD)

DC Distribution

DC Voltage: Primary only or Primary and Secondary

Low Voltage Load Disconnect (LVLD) (Primary DC Voltage option)

Selectable distribution options

Universal Power Shelf

Accepts rectifiers or converters interchangeably in any power slot

Can be installed with no AC connected, making it a converter only shelf

AC Feeds

Front accessible terminal blocks

One or two rectifier positions per feed

The controller monitors and controls system operation.

Controller

Pulsar Plus

• Eco features included

Millennium II

Framework

84 inch, 72inch, or 42 inch frame

Sub-frame - mount in customer provided 23 inch frame

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Eco Capable Systems - Pulsar Plus only

Eco capable systems (Eco systems) add support for multiple power inputs of multiple types, including PV (photo voltaic or solar) arrays.

Power Input

PV (photo voltaic or solar) arrays

AC generators

AC mains Rectifiers

NE Eco Rectifiers5

Input - AC or DC (PV or solar) input

MPPT (Maximum Power Point Tracking) maximizes power harvested from PV arrays

Recommended for all rectifier positions in Eco systems

Controller

Pulsar Plus

• Eco features included (PV, Gen Set, etc.)

5REQUIRED – Eco rectifiers in all DC (PV or solar) powered rectifier positions. RECOMMENDED – Eco rectifiers in all Eco system rectifier positions.

NOT RECOMMENDED – non-Eco rectifiers in Eco systems.

Non Eco rectifiers will not function properly when powered by DC (PV or solar) input in Eco systems.

Use of non-Eco rectifiers in Eco systems increases the risk of improperly filling all system rectifier positions. Non Eco rectifiers may be installed in AC powered rectifier positions of Eco systems.

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GE Industrial Solutions H5692448 User Manual

NE-M Installation Guide

H5692448

Figure 1 Block Diagram

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Components

Frameworks:

Full-Height Frame

Half-Height Frame

Sub-frame

with frame mounting brackets

Pulsar Plus or Millennium II controller

NE830 Redundant Voltage Monitor

NE-Series Rectifiers and Converters

Front accessible AC terminal blocks

Battery Options and Monitoring:

Battery Trays with Disconnect Breakers or Anderson PowerPole® disconnects

LVBD Contactors

Thermal/Voltage Probes

External Ambient Temperature Probes

Battery Shunt

dc distribution options:

Bullet terminal breakers up to 250A

Bolt-in KS22012 breakers up to 600A

TPS fuses up to 70A

GMT fuses up to 15A

LVLD Contactor

AC Input

Terminals, DC

Output

Distribution,

and Battery

Connections

 

NE830

Pulsar Plus

Voltage

Display

Controller

 

 

 

NE Series

Rectifiers

Figure 2 NE-M Components

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H5692448

 

Frameworks

 

 

 

 

 

 

 

 

 

 

 

Framework

 

Description

 

 

 

 

Floor Mount

 

 

 

Full-Height –

84” - 44RU equipment space

 

 

 

72” - 38RU equipment space

 

 

 

Heavy Duty

 

 

 

• 1200 lb zone 4

 

 

 

 

 

 

 

 

• 1800 lb zone 2

 

 

Figure 3 Frame -

 

 

 

 

 

Full-Height

 

 

 

 

 

 

 

 

 

 

 

 

• Mounted on top of floor-mounted batteries or battery stand

 

 

 

Half-Height

42” Half-Height (21RU equipment space)

 

 

 

 

• Supports systems with up to seven universal shelves

 

 

Figure 4 Frame -

 

 

 

 

 

Half Height

 

 

 

 

 

 

 

 

 

 

 

 

• Mounting Brackets for shipping NE-M for field installation in a

 

 

 

Sub-frame

 

customer provided 23” framework

 

 

 

 

36.75” (21RU) High

 

 

Figure 5 Sub-frame

 

 

 

 

 

 

 

 

 

 

 

 

Kick Plates for

15” depth

 

 

 

Full Height

 

 

 

24” depth

 

 

 

Framework

 

 

 

 

 

 

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Controller – Pulsar Plus

Plant Status LEDs

Plant Voltage and

Load Current

RS-232 and LAN

Ports for PC

Web Pages

Voltage Test Jacks

Plant Mode

 

Menu Navigation

 

 

 

 

Figure 6 Pulsar Front Panel

Local or remote viewing and configuration of system parameters, alarm thresholds, and userdefinable alarm inputs and relays

LVBD and LVLD Low Voltage Disconnect contactor control and monitoring

dc Distribution monitoring

• Extensive rectifier/converter Monitoring and Control • Standard and Programmable Alarms

Advanced Battery Management to maximize and manage battery health

Emergency Power Off (EPO) to meet local emergency services code requirements

System voltage and current monitoring

Extensive Voltage, Current, Temperature, and Binary Input monitoring

Standard and programmable Office Alarm relays

Digital communications to all system devices

See the Pulsar Plus Controller Family Product Manual for further detail.

Controller – Millennium II

Number of Alarms

Plant Voltage and Load

Date and Time

and Warnings

Current

 

 

 

 

Plant Status LEDs

Voltage Test Jacks

Plant Mode

Menu Navigation

RS-232 and LAN Ports

 

 

 

 

for PC Web Pages

 

 

 

 

Figure 7 Millennium II Controller Front Panel

Local or remote viewing and configuration of system parameters, alarm thresholds, and userdefinable alarm inputs and relays

LVBD and LVLD Low Voltage Disconnect contactor control and monitoring

dc Distribution monitoring

• Extensive rectifier/converter Monitoring and Control • Standard and Programmable Alarms

Advanced Battery Management to maximize and manage battery health

Emergency Power Off (EPO) to meet local emergency services code requirements

System voltage and current monitoring

Extensive Voltage, Current, Temperature, and Binary Input monitoring

Standard and programmable Office Alarm relays

Digital communications to all system devices

Remote Peripheral Modules (RPMs)

See the Galaxy Millennium II Installation and User’s Guide for further detail.

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Aux Display - NE830A (Optional)

The Aux Display is a voltage monitor that alarms when the voltage of the power system is out of the normal operating range. It is mounted on the door of the distribution box.

 

• Fully independent of the main system controller

 

• Displays one or two system voltages and battery state:

 

• Single voltage systems, -48V, +24V

 

• Dual voltage systems, -48V and +24V with common return

 

• The display and LED color indicates battery charge state and wiring errors:

 

Green display

= batteries are not discharging

 

Red display = batteries are discharging

 

Amber display

= wiring error

 

• A Battery on Discharge alarm relay with form-C contacts is provided

 

• Can be panel, wall or frame rail mounted within 150 ft of the power system

Figure 8 NE830 Display

 

 

 

 

 

 

 

Rectifiers and Converters

NE-Series rectifiers and converters are hot-pluggable for quick, simple, plug-and-play installation without tools.

 

Type Badge

 

Figure 9 Rectifier and Converter Type Badge

NE Eco Rectifiers

 

Input

AC or DC (PV or solar)

Compatibility

All Infinity Rectifier Positions

Eco Feature

MPPT (Maximum Power Point Tracking) maximizes power harvested from PV arrays

NE Non-Eco Rectifiers

Input

AC only

Compatibility

All AC powered Infinity Rectifier Positions6

6 Non Eco rectifiers will not function properly when powered by DC (PV or solar) input in Eco systems.

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H5692448

 

 

 

 

 

 

 

 

 

 

Table 1 Rectifiers and Converters

 

 

 

 

Rectifier/Converter

Input

Output

Eco Compatible

 

 

Eco Rectifier

 

ac 110/208/220/240 Vac

 

 

 

 

 

NE050ECO48ATEZ

dc 60Vdc (+/-30V)

48V, 50A

Yes7

 

 

 

to 310Vdc (+/-150)

 

 

 

 

 

 

 

 

blue

 

11A max

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Eco Rectifier

 

ac 110/208/220/240 Vac

 

 

 

 

 

NE100ECO24TEZ

dc 60Vdc (+/-30V)

24V, 100A8

Yes7

 

 

 

to 310Vdc (+/-150)

 

 

 

 

 

 

 

 

orange

 

11A max

 

 

 

 

 

 

 

 

 

 

Converter

NE040DC48ATEZ

 

48V, 40A

Yes

 

 

 

24 Vdc

 

 

 

 

 

 

 

 

blue

NE030DC48A

48V, 30A

Yes

 

 

 

 

 

 

 

 

 

 

 

Converter

 

 

 

 

 

 

 

NE075DC24A

48 Vdc

24V, 75A

Yes

 

 

orange

 

 

 

 

 

 

 

 

 

 

 

 

 

Rectifier

NE075AC48ATEZ

110/208/220/240 Vac

48V, 75A9

 

 

 

 

NE050AC48ATEZ

110/208/220/240 Vac

48V, 50A

AC Only10

 

 

blue

NE050AC48A11

208/220/240 Vac

 

 

 

 

 

 

 

Rectifier

NE100AC24ATEZ

110/208/220/240 Vac

 

 

 

 

 

 

AC Only10

 

 

 

 

 

24V, 100A

 

 

orange

NE100AC24A11

208/220/240 Vac

 

 

 

 

 

 

 

 

 

 

 

 

 

NE850 Slot Filler

 

 

 

 

7REQUIRED – Eco rectifiers in all DC (PV or solar) powered rectifier positions. RECOMMENDED – Eco rectifiers in all Eco system rectifier positions.

NOT RECOMMENDED – non-Eco rectifiers in Eco systems.

Non Eco rectifiers will not function properly when powered by DC (PV or solar) input in Eco systems.

Use of non-Eco rectifiers in Eco systems increases the risk of improperly filling all system rectifier positions. Non Eco rectifiers may be installed in AC powered rectifier positions of Eco systems.

844A with 120Vac input

922A with 120Vac input

10NOT RECOMMENDED for use in Eco systems - Non Eco rectifiers will not function properly when powered by DC (PV or solar) input in Eco systems.

Use of non-Eco rectifiers in Eco systems increases the risk of improperly filling system rectifier positions.

11Non-TEZ rectifiers are no longer orderable and have lower efficiency than TEZ rectifiers

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Power Input Panel

Power Input

Terminal blocks in a front access panel at the bottom of the distribution box.

Conduit Ground

Terminal Blocks Accept 24-

¼-20 x 0.75” or

6 AWG wire.

 

0.625” Studs

Straps provided to

 

feed rectifier pairs.

 

Knockouts

 

each side:

 

(2)

1” and

 

(2)

1-1/2”

Figure 10 Power Input Panel

Battery Options and Monitoring Features

Battery Options

• Designed for operation with GE flooded, VRLA and Durathon™ Sodium batteries, as well as other vendors’ batteries.

• Battery trays are available for 100Ahr to 170Ahr batteries with Anderson PowerPole® connectors or circuit breaker disconnects.

• Half-height and third-height systems can be mounted on floor-mounted VRLA strings or on GE Universal Battery Stands.

 

Battery Monitoring Features

 

• Open String (OS) Alarms

 

• Emergency Power Off (EPO) for disconnecting batteries from the system

 

• Temperature/voltage probes (up to 16) used in Battery Management options

 

 

• Slope Thermal Compensation – High and Low Temperature

 

 

• Battery High Temp Disconnect

 

 

• Mid-String Voltage Monitoring

 

Battery Discharge Test

 

Battery Shunt

Figure 11 Battery Stand

Low Voltage Battery Disconnect/Reconnect Contactor (LVDB)

 

 

with Emergency Power Off (EPO)

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dc Distribution and Battery Termination

 

 

 

 

 

 

 

Configuration

Features

 

 

 

 

 

Door Mounted Controller

(12) pair Battery and Return bus landings for battery cables

LVBD Contactor

(80) Bullet Distribution positions arranged for:

Bullet terminal breakers to 250A

TPS fuse holders for fuses to 70A

GMT Fuse Module - (6) position

(8) KS22012 circuit breaker positions

LVLD Contactor

Up to 8 Universal Power Shelves

Figure 12 DC Distribution Bullet & Bolt-In

Figure 13 DC Distribution - Bullet

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Installation

Follow all site engineering instructions. This section is provided only as a guide.

Preparation

Safety

Read and follow all safety statements, warnings, and precautions in the Safety section of this manual and manuals of all other equipment before installing, maintaining or repairing the equipment.

Installation Tools

You will need the following tools.

Wire cutters and strippers

Heat shrink gun

5/16-inch (8 mm) hex driver

Digital meter with an accuracy of ±0.02%

Screw drivers (flat-blade and Phillips)

ESD wrist strap

24 or 48V test load

Calibrated clamp-on dc current meter (0.1 ADC sensitivity)

Torque wrench

Socket wrenches:

7/16” and 9/16” - cable connections

19 mm - anchor bolts

12" extension for socket

Masonry drill kit as required

Compression for installation of various compression lugs

Protective canvas

Insulating rubber mat

Standard insulated installation tools, screwdrivers, etc.

Controller Manual

Galaxy Pulsar Plus Family Product Manual or

Galaxy Millennium II Installation and User’s Guide

Windows-based personal computer laptop (PC) and cable to connect the PC communications port to the local port of the controller or a CAT5 LAN cable. (Optional. See the controller manual for more information).

Equipment Identification

Identify the equipment you have received. Follow procedural steps which match the equipment being installed.

Anchor Frame

Ventilation space is required to the rear of the equipment: 4” to solid surface, 6” to heat producing surface.

Floor Mounted Frame

Using the 847135688 Floor Anchor Kit (recommended):

Anchor Type (Hilti)

Wrench

Torque

 

 

720 in-lb

(4) 12 mm Cap Bolts

19 mm

60 ft-lb

 

 

82 Nm

Note: For systems with tray mounted batteries at sites requiring Seismic Zone 4 rating, (2) 847135688 kits are required to provide (8) floor anchors.

Note: If using Equivalent Floor Anchors, make sure the floor anchors are rated for this application.

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Step

Action

 

Figure 14 Frame Mount Template

6 ft and 7ft Frames

CAUTION: Health Hazard

Follow safe floor drilling procedures to prevent possible asbestos exposure.

1Drill anchor holes.

2Place frame and install floor anchors according to manufacturer requirements.

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Battery or Battery Stand Mounted Frame

 

 

 

 

 

 

 

Step

Action

 

Verify that battery or battery stand is positioned to provide adequate ventilation space to the rear of the equipment: 4” to solid surface, 6” to heat producing surface (shown in the floor mounted frame figure below)

Place and secure frame to battery or battery stand per instructions provided with the battery stand or adapter.

Minimum Distance to Surface 7.5" to Solid Surface

9.5" to Heat Producing Surface

1

Figure 15 Battery Stand Mount

Sub-frame Mounted Systems:

Sub-frame mounted systems can be mounted in any standard 23” equipment mounting rack or frame with EIA-310 standard 1-3/4” rack spaces or 1” standard rack spaces. The brackets are 36.75” (21U) tall. Comcode CC848819607 kit provides two brackets and 20 12-24 mounting screws.

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Step

Action

 

Verify that the rack is positioned to provide adequate ventilation space to the rear of the equipment: 4” to solid surface, 6” to heat producing surface.

Distance required to rear of mounting rails: 16.5” to solid surface, 18.5” to heat producing surface.

Position the sub-frame system in the rack as desired.

Secure the sub-frame system into the rack with at least (12) frame mounting screws, 6 screws per side.

Torque to 35 in-lb – 5/16 socket.

1

Figure 16 Mount Sub-Frame

Ground Frame

Floor Mounted Frame

Select a Frame Ground landing on the top of the frame and clean.

Step

Action

Use either of two frame ground lug landing locations.

 

Secure Frame Ground connection with provided

 

hardware:

 

(2)

¼-20 x ¾” HH Bolt

 

(2)

¼-inch lock washer

1

(2)

¼-inch flat washer

 

 

 

If required by local code or practice, treat with an

 

oxidation inhibitor such as NO-OX.

 

Torque to 65 in-lb - 7/16” socket.

Note: Lug landings are 1/4” on 5/8”and 1” centers.

Figure 17 Ground Frame

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NE-M Installation Guide

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Battery or Battery Stand Mounted Frame

If required by local code or practice, battery or battery stand mounted frames may be grounded to the frame or chassis of the other equipment. Select a Frame Ground landing at the side of the frame and clean.

Step

 

 

 

Action

 

 

 

Secure Frame Ground connection with provided

 

 

 

 

hardware:

 

 

 

(2)

¼-20 x ¾” HH Bolt

 

 

 

(2)

¼-inch lock washer

 

 

1

(2)

¼-inch flat washer

 

 

 

 

 

 

 

 

 

If required by local code or practice, treat with an

 

 

 

 

oxidation inhibitor such as NO-OX.

 

 

 

 

Torque to 65 in-lb - 7/16” socket.

Note: Lug landings are 1/4” on 5/8” centers.

 

 

 

 

 

 

 

 

 

Figure 18 Ground Short Frame

 

 

 

 

 

 

Connect Central Office Ground (COG)

 

 

 

 

 

 

 

Step

 

 

 

Action

 

Secure COG connection with provided hardware:

(2) 3/8-16 nut

(2) 3/8-inch lock washer

(2) 3/8-inch flat washer

1

If required by local code or practice, treat with an oxidation inhibitor such as NO-OX.

Torque to 240 in-lb - 9/16” socket.

Figure 19 CO Ground Landing

Note: Lug landings are 3/8” on 1” centers.

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NE-M Installation Guide

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Install PV/AC Partition Kit – NE-M Eco systems only

This section applies only to NE-M Eco systems

NE-M Eco systems power some rectifiers from PV (photo voltaic or solar array) and others from ac, typically a generator. Each terminal block powering rectifiers can be connected to either PV or ac, but not both.

The PV/AC Partition Kit (150028727) divides the Input panel into separate input sections for PV and AC fed terminal blocks.

The position of the partition is site specific. Follow all site engineering instructions. This position indicated in this section is only an example.

 

 

Figure 20 Eco Input Panel

 

 

 

 

 

 

CAUTION: Personal injury and Equipment Damage

 

 

 

PV Disconnect Panel with disconnects rated at 300Vdc on each PV conductor is required for use

 

 

 

with Solar Arrays (PV sources).

 

 

 

 

 

 

Step

Action

 

1 Remove the Input Panel cover (4 captive screws).

Figure 21 Input Panel Screws

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Step

Action

 

Apply labels onto PV/AC Partition as shown.

2• Place “PV WIRING” label on the left (PV) side of partition.

Place the “AC WIRING” label on the right (AC) side of partition.

Figure 22 Partition Labels

Make space for the PV/AC Partition - Separate DIN rail Terminal Blocks to make space for the PV/AC Partition.

3

Loosen screws securing all DIN spacer blocks to the left of the Partition location specified in the site engineering instructions.

4Slide Terminal Blocks and spacer to the left of the Partition location to the left to allow installation of the PV/AC Partition.

Figure 23 Partition Insert

Install PV/AC Partition in the location specified in the site

5engineering instructions.

Snap the Partition onto the DIN rail.

Slide the loosened Terminal Blocks and spacer block to the right

6snugly against the Partition.

The Partition lower edge will be under the Terminal Block on its left.

7Tighten screws securing all DIN spacer blocks s to the left of the Partition.

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Step

Action

 

Apply labels to the Input Panel chassis.

8• Place “PV Wiring” label on the left (PV) side of partition.

Place the “AC Wiring” label on the right (AC) side of partition.

Figure 24 Label Input Panel

9 Replace the Input Panel cover and secure fasteners.

Apply 2 labels to Input Panel cover in any available space.

10• Warning label

• Max Power-Point label

Figure 25 Label Input Panel Cover

Connect Input Power

WARNING: Shock Hazard

Disconnect all input branch circuits prior to making input connections to the system. When connecting to any source, ensure compliance to all local and national wiring rules.

CAUTION: Equipment Damage

PV inputs must be current limited to 11A maximum.

Terminal Block are arranged to allow addition of shelves (to the bottom) and terminal blocks (from the inside out). Example shown is for 4-shelf system; up to 6 shelves are allowed.

Figure 26 Input Power Terminal Block Positions

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