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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H5692448 |
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.
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, 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.
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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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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Figure 1 Block Diagram
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•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
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NE830 |
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Pulsar Plus |
Voltage |
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Display |
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Controller |
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NE Series
Rectifiers
Figure 2 NE-M Components
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Frameworks |
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Framework |
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Description |
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Floor Mount |
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Full-Height – |
• |
84” - 44RU equipment space |
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72” - 38RU equipment space |
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Heavy Duty |
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• 1200 lb zone 4 |
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• 1800 lb zone 2 |
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Figure 3 Frame - |
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Full-Height |
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• Mounted on top of floor-mounted batteries or battery stand |
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Half-Height |
• |
42” Half-Height (21RU equipment space) |
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• Supports systems with up to seven universal shelves |
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Figure 4 Frame - |
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Half Height |
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• Mounting Brackets for shipping NE-M for field installation in a |
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Sub-frame |
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customer provided 23” framework |
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36.75” (21RU) High |
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Figure 5 Sub-frame |
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Kick Plates for |
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15” depth |
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Full Height |
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24” depth |
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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 |
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Menu Navigation |
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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 |
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and Warnings |
Current |
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Plant Status LEDs |
Voltage Test Jacks |
Plant Mode |
Menu Navigation |
RS-232 and LAN Ports |
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for PC Web Pages |
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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.
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• Fully independent of the main system controller |
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• Displays one or two system voltages and battery state: |
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• Single voltage systems, -48V, +24V |
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• Dual voltage systems, -48V and +24V with common return |
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• The display and LED color indicates battery charge state and wiring errors: |
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Green display |
= batteries are not discharging |
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• |
Red display = batteries are discharging |
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• |
Amber display |
= wiring error |
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• A Battery on Discharge alarm relay with form-C contacts is provided |
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• Can be panel, wall or frame rail mounted within 150 ft of the power system |
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Figure 8 NE830 Display |
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Rectifiers and Converters
NE-Series rectifiers and converters are hot-pluggable for quick, simple, plug-and-play installation without tools.
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Type Badge |
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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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Table 1 Rectifiers and Converters |
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Rectifier/Converter |
Input |
Output |
Eco Compatible |
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Eco Rectifier |
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ac 110/208/220/240 Vac |
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NE050ECO48ATEZ |
dc 60Vdc (+/-30V) |
48V, 50A |
Yes7 |
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to 310Vdc (+/-150) |
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blue |
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11A max |
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Eco Rectifier |
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ac 110/208/220/240 Vac |
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NE100ECO24TEZ |
dc 60Vdc (+/-30V) |
24V, 100A8 |
Yes7 |
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to 310Vdc (+/-150) |
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orange |
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11A max |
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Converter |
NE040DC48ATEZ |
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48V, 40A |
Yes |
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24 Vdc |
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blue |
NE030DC48A |
48V, 30A |
Yes |
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Converter |
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NE075DC24A |
48 Vdc |
24V, 75A |
Yes |
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orange |
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Rectifier |
NE075AC48ATEZ |
110/208/220/240 Vac |
48V, 75A9 |
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NE050AC48ATEZ |
110/208/220/240 Vac |
48V, 50A |
AC Only10 |
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blue |
NE050AC48A11 |
208/220/240 Vac |
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Rectifier |
NE100AC24ATEZ |
110/208/220/240 Vac |
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AC Only10 |
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24V, 100A |
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orange |
NE100AC24A11 |
208/220/240 Vac |
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NE850 Slot Filler |
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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- |
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¼-20 x 0.75” or |
6 AWG wire. |
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0.625” Studs |
Straps provided to |
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feed rectifier pairs. |
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Knockouts |
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each side: |
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(2) |
1” and |
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(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.
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Battery Monitoring Features |
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• Open String (OS) Alarms |
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• Emergency Power Off (EPO) for disconnecting batteries from the system |
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• Temperature/voltage probes (up to 16) used in Battery Management options |
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• Slope Thermal Compensation – High and Low Temperature |
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• Battery High Temp Disconnect |
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• Mid-String Voltage Monitoring |
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Battery Discharge Test |
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Battery Shunt |
Figure 11 Battery Stand |
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Low Voltage Battery Disconnect/Reconnect Contactor (LVDB) |
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with Emergency Power Off (EPO) |
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dc Distribution and Battery Termination |
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Configuration |
Features |
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•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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Follow all site engineering instructions. This section is provided only as a guide.
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.
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).
Identify the equipment you have received. Follow procedural steps which match the equipment being installed.
Ventilation space is required to the rear of the equipment: 4” to solid surface, 6” to heat producing surface.
Using the 847135688 Floor Anchor Kit (recommended):
Anchor Type (Hilti) |
Wrench |
Torque |
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720 in-lb |
(4) 12 mm Cap Bolts |
19 mm |
60 ft-lb |
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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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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 |
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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
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Figure 15 Battery Stand Mount
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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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.
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Figure 16 Mount Sub-Frame
Select a Frame Ground landing on the top of the frame and clean.
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Use either of two frame ground lug landing locations.
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Secure Frame Ground connection with provided |
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hardware: |
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(2) |
¼-20 x ¾” HH Bolt |
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(2) |
¼-inch lock washer |
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¼-inch flat washer |
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If required by local code or practice, treat with an |
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oxidation inhibitor such as NO-OX. |
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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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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.
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Secure Frame Ground connection with provided |
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hardware: |
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(2) |
¼-20 x ¾” HH Bolt |
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(2) |
¼-inch lock washer |
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1 |
(2) |
¼-inch flat washer |
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If required by local code or practice, treat with an |
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oxidation inhibitor such as NO-OX. |
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Torque to 65 in-lb - 7/16” socket. |
Note: Lug landings are 1/4” on 5/8” centers. |
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Figure 18 Ground Short Frame |
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Connect Central Office Ground (COG) |
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Action |
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Secure COG connection with provided hardware:
(2) 3/8-16 nut
(2) 3/8-inch lock washer
(2) 3/8-inch flat washer
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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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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.
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Figure 20 Eco Input Panel |
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CAUTION: Personal injury and Equipment Damage |
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PV Disconnect Panel with disconnects rated at 300Vdc on each PV conductor is required for use |
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with Solar Arrays (PV sources). |
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1 Remove the Input Panel cover (4 captive screws).
Figure 21 Input Panel Screws
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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.
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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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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
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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