GE Industrial Solutions J85501P-1 User Manual

Basic Installation and User’s Guide for the Millennium II Controller J85501P-1

Product Manual Select Code 167-792-181 Comcode 108994645 Issue 3 January 2008

Notice:

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

Basic Installation and User’s Guide for the Millennium II Controller

1 Introduction.................................................................................................................... 4

Millennium II.................................................................................................................. 4

Customer Service Contacts............................................................................................. 5

2 Product Description....................................................................................................... 6

Overview......................................................................................................................... 6

Feature Summary............................................................................................................ 6

General Specifications .................................................................................................. 11

Hardware....................................................................................................................... 12

3 Safety............................................................................................................................. 15

Safety Statements.......................................................................................................... 15

Warning Statements and Safety Symbols..................................................................... 17

Precautions.................................................................................................................... 18

Special Installation Notes ............................................................................................. 19

4 New Installations.......................................................................................................... 21

Controller Connections ................................................................................................. 23

Installing Circuit Packs................................................................................................. 24

Thermal Probes ............................................................................................................. 28

USB Interface................................................................................................................ 29

Wiring Alarm Outputs .................................................................................................. 29

Wiring Alarm and Control Inputs................................................................................. 32

Fuses ............................................................................................................................. 35

Front Panel Display....................................................................................................... 35

Controller Defaults........................................................................................................ 39

Controller Display Menu Maps .................................................................................... 46

5 Acceptance Testing ...................................................................................................... 58

Introduction................................................................................................................... 58

Tools and Test Equipment ............................................................................................ 58

Test Precautions............................................................................................................ 58

Test Sequences.............................................................................................................. 59

6 Controller Retrofits ..................................................................................................... 67

Millennium Basic Controller Retrofit........................................................................... 67

Millennium Intelligent Controller Retrofit ................................................................... 85

7 Troubleshooting ......................................................................................................... 104

Controller Circuit Pack ............................................................................................... 104

Option Cards ............................................................................................................... 104

Controller Alarm Descriptions.................................................................................... 104

Clear Events................................................................................................................ 110

Uninstall Devices........................................................................................................ 111

8 Spare Parts ................................................................................................................. 112

9 Product Warranty...................................................................................................... 113

Revision History............................................................................................................ 115

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

1 Introduction

Millennium II

The J85501P-1 Galaxy Millennium II controller is the next generation full-featured power system controller from Lineage Power. It provides control, monitoring, and alarm monitoring functions over a multi-drop serial interface that interconnects system rectifiers, converters, Bay Interface Cards (BICs), and other serial devices. It utilizes robust RS-485 serial busses that support the Galaxy Protocol (GP) to communicate to these devices. The Millennium II has a plethora of I/O and monitoring options. It can monitor and control battery plants containing up to 64 Galaxy serial rectifiers, up to 16 serial converters, and up to 32 BICs. A maximum combination of 85 GP nodes can be directly managed on the rectifier serial bus. The Millennium II performs many functions described more thoroughly in following sections. Following is a high level view.

• Alarm Detection, Identification, and Reporting

• System and Component Status

• System and Feature Configuration

• System Alarm Thresholds

• Battery Management (Slope Thermal Compensation/Recharge Current Limit)

• Battery discharge testing

• Reserve Time Prediction

• Selective high/low voltage shutdown

• Float/Boost Mode Control

• Low Voltage Disconnect Management

• Remote Access Control And Multiple Level Password Security

• Control and Operations

• History

• Statistics

This controller replaces the existing +24V and -48V versions of the Millennium controller with a single unit. While becoming easier to use, the Millennium II adds additional functionality to the comprehensive feature set now provided by the existing Millennium. The Millennium II is separate Independent (Basic), Intelligent, and network interface circuit packs of the existing Millennium controller have been integrated into a single standard board offering with the Millennium II. This eliminates the need to manage multiple boards for features as well as plant voltage. Intelligent functionality with remote 10/100 Base-T network access capability to display power system operating status and available information via the world wide web (internet) or your enterprise network (intranet) using standard browsers such as Microsoft Internet Explorer® or Netscape® Navigator is now the standard offering.

Issue 3 January 2008

Lineage Power’s new flagship controller product. The

Basic Installation and User’s Guide for the Millennium II Controller

Not only are the software features of the Millennium all contained in the Millennium II, the new controller is physically backwards compatible for field upgrades and replacements. The Millennium II can also be used as an upgrade to the door mounted Galaxy Vector controller When performed, this installation adds newer and more available technologies to the power system. The old Millennium chassis is replaced with the new Millennium II chassis shown in the figure following. All existing and future GPS cabinet systems remain supported by the Millennium II.

Figure 1-1:Galaxy Millennium II Controller

Customer Service Contacts

Customer Service, Technical Support, and Warranty Service

For customers in the United States, Canada, Puerto Rico, and the US Virgin Islands, call 1-800-THE-1PWR (1-800-843-1797). This number is staffed from 7:00 am to 5:00 pm Central Time (zone 6), Monday through Friday, on normal business days. At other times this number is still available, but for emergencies only. Services provided through this contact include initiating the spare parts procurement process, ordering documents, product warranty administration, and providing other product and service information.

For other customers worldwide the 800 number may be accessed after first dialing the AT&T Direct country code for the country where the call is originating, or you may contact your local field support center or your sales representative to discuss your specific needs.

Customer Training

Lineage Power offers customer training on many Power Systems products. For

information call 1-972-284-2163. This number is answered from 8:00 a.m. until 4:30 p.m., Central Time Zone (Zone 6), Monday through Friday.

On-Line Power Systems Product Manuals and Software

Power Systems on-line product manuals and software are available on-line. Software includes Easy View and SNMP MIB.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

2 Product Description

Overview

The Millennium II has been designed to be a complete power system monitor and controller with a variety of alarming and remote access capabilities that complies with all relevant regulatory requirements, respectively. It is the nerve center of the battery plant that utilizes serial monitored and controlled rectifiers, converters, and system peripherals. It monitors and controls the plant rectifiers, distribution, and batteries. It can also monitor and control peripheral power equipment, including standby generators, converter plants, and inverters.

The Millennium II monitors and control battery plants containing up to 64 Galaxy serial rectifiers, up to 16 serial converters, and up to 32 Bay Interface Cards (BICs). A maximum combination of 85 GP nodes can be directly managed on the rectifier RS485 serial bus. The following table contains the Lineage Power rectifiers that can interface with the Galaxy Millennium II:

Table 2-A: Rectifiers That May Be Used With Millennium II

Model Vdc Current

570A -48V 100A 595A, 595B,

595C, 595LTA, 595LTB

596A / 596D -48V 50A / 100A 596B +24V 100A / 125A 596F +24V 100A NP +24V / -

CPS6000 QS86X -48V 7.5A – 50A AC3000 -48V 60A

-48V 200A/220A

24A – 50A

48V

Feature Summary

The Millennium II has combined and enhanced its Millennium predecessor’s Basic, Intelligent, and Network functionality into its standard offering. This controller unit supports the features available in the Millennium II.

Lineage Power‘s most extensive controller feature set. Following is a summary of

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Standard System Features

Monitoring and control of up to 85 RS485 serial connected devices

Alarms

• Maximum of 64 serial switchmode rectifiers

• Maximum of 32 Bay Interface Cards (BICs)

• Maximum of 16 serial converters

• Standard and custom User Defined system

alarms

• Alarm test

• Alarm cut-off

• Multiple-level alarm severity: Critical, Major,

Minor, Warning, and Record-Only

Rectifiers

• Automatic rectifier restart

• Reserve engine transfer

• High Voltage Shutdown

• Energy management

• Remote rectifier (on/off) control

• Automatic rectifier sequence control

• N + X redundancy check

• Digital voltage regulation and rectifier load

Contactor/Disconnect Control

• Low Voltage Load

• Low Voltage Battery

Interfaces

• Enhanced Front Panel Display

• Local PC Port

• Modem

• LAN (Gateway Card)

• X.25/TL1

Peripheral Monitoring and Control

• Up to 512 monitoring channels

• On board generic voltage channel

• On board 4-20mA transducer interface

Maintenance Tools

• User Programmable Alarms

• History

• Statistics

• Diagnostics

• Derived Channels

• Inventory Management

• Configuration Backup/Restore

Memory

• Non-Volatile

• Battery Backed

• Remote and Local Software Upgrade

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Enhanced Front Panel User Interface

Cabinet door mounted LCD

• Front access without opening the cabinet door

• 8-line by 40-character (240 x 64) backlit

display with digital contrast adjust

Menu Driven User Interface

• Re-designed user friendly menu driven LCD with similar push-button membrane switch interface

• Menu structure similar to other Lineage Power

controllers

Audible Alarm Buzzer

• Integrated on display assembly

• May be Enabled/Disabled

LEDs

• 12 individual user configurable status LEDs: Critical, Major, Minor, Normal, AC System, Battery, Controller, Distribution, Rectifier, Remote Modules, Modem, and Battery On Discharge

Test Jacks Local Port

• Used to verify displayed system bus voltage

• DB-9 RS232 system port for local terminal

access or event log printing

• ANSI T1.317 serial access

• EasyView Windows-based software for

configuration and reporting

• Ground referenced

Compatibility

• Backwards compatible to existing Millennium

Remote Access And Features

Integrated 10/100Base-T Ethernet Network capability

Optional Modem access

Issue 3 January 2008

• Supports TCP/IP Version 5, SNMP Version 2c, SMTP, TL1, DHCP, Telnet, FTP

• Standard and custom web pages for standard browsers (HTTP)

• Compatible to Galaxy Manager

• Standard shielded RJ-45 interface referenced

to chassis

• Remote access via internal BSM5 Modem option (56k bps Modem)

• Remote access capability via external Modem

• Callback security

Basic Installation and User’s Guide for the Millennium II Controller

Optional BSW Dataswitch

TL1

Easy View PC User Interface

Security

Battery Management

Slope Thermal Compensation (STC)

Recharge Current Limit Reserve Time Prediction

Battery Discharge Testing

Float/Boost Mode Control

Temperature Disconnect Emergency Power Off

• Connections to 3 standard RS232 devices for pass-through and alarm management

• BSN extension to provide 3 additional RS232 serial connections

• Configurable RS-232/485 port for remote via TL1/X.25

• Windows-based software, for configuration and reporting through local terminal or

• Modem connections

• Multiple password-protected security levels

• Dip Switches

• Enhanced Security Features enable or disable

many controller features

• High temperature compensation

• Low temperature compensation

• Step temperature

• STC Enable/Disable

• Low temperature Enable/Disable

• mV/°C adjustments

• Control rechargerate for batteries

• Supports a variety of batteries

• Use configurable Low Reserve Time Alarm

• Integrated “At Rate Calculator” for estimation

purposes

• Manual

• Periodic

• Plant Battery Test (PBT) input driven

• Battery Discharge trace data

• Manual Timed Boost- Locally T1.317 and

remotely initiated

• External Timed Boost

• Battery Thermal Protect module Boost (BTP)

• Auto Boost terminated by time or current

• Manual front panel Boost

• Programmable high temperature

• User programmable

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Integrated Monitoring Inputs/Outputs

System Voltage and Current monitoring System Shunts

• Maximum of 2 (more with BICs and RPMs)

• Battery or Load

• Battery or Return Side

4-20 mA

• Single channel

• Input

0-5 Vdc

• Single Channel

• Input

• Selectable resistors for: 5, 30 and 60 Vdc

ranges

Temperature Probe

• 4 Channels

• 1 – 10/30k Thermal Probe Inputs

• 3 – 10k Thermal Probe Inputs

Binary Inputs

• 22 Inputs

• Engine signal inputs

• Battery test inputs

• External Float/Boost control

• 2 User programmable

Remote Peripheral Monitoring

• Integrated serial bus

• Maximum 300 M serial bus

• 512 channels

• Transducer interface

• Battery, Shunt monitoring

• Channels can be programmed for custom

alarms

Integrated Outputs

Traditional Office Alarms 19 Form C alarm outputs

2 User programmable relay outputs

Alarm Battery Supply

Issue 3 January 2008

• 1.3A Fused

Basic Installation and User’s Guide for the Millennium II Controller

General Specifications

Basic Millennium II specifications are summarized in table 2-B. Consult service center for other details.

Table 2-B: General Millennium II Controller Specifications

General Specifications

Input Voltage Range ±24 Vdc, -48 Vdc (Range: 18-60V) Maximum Input Power 36W depending upon options Operating Temperature Range -40 to 75 °C (-40 to 167 °F) Storage Temperature Range -40 to 85 °C (-40 to 185 °F) Physical Specifications 9.24 in. H, 20.76 in. W, 2.14 in. D Display 8-line by 40-character backlit LCD Cabinet Mounting Requirements Door mounted

Input/Outputs Specifications

Form C Alarm Output Contact Ratings 60VDC at 0.5A Plant Voltage Measurement

Accuracy

0 to 50 °C (±.05% of full scale + 1

count)

-40 to 85 °C (±0.1% of full scale + 1 count)

Resolution

Plant Current Measurement (Up to 2 shunts)

Accuracy

Resolution

Temperature Measurement

Accuracy

Thermistor temperature

One-Wire Serial probes

Resolution

4-20mA Input Monitor

Accuracy Resolution

General (0-5V) Input

Accuracy

48V Systems: ±40 mV 24V Systems: ±25 mV 48V Systems: ±70 mV 24V Systems: ±40 mV

0.01V

0 to +50 °C : ±0.5% of full scale

-40 to +85 °C: ±1.25% of full scale 1A

-5 to +55 °C: ±2°C

-40 to +85 °C: ±3°C

-5 to +55 °C: ±1°C (next release)

-40 to +85 °C: ±3°C

0.1°C

±100µA ±10.0µA

0 to +50 °C: ±0.5% of full scale

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Resolution

Safety And Standards Specifications Electrostatic Discharge IEC 801-2 level 2, 4, 5 Radiated Emissions FCC Class B, CISPR 22 level B Safety UL Unlisted Component as Part of GPS Power

NEBs Level 3 Tested and Complaint with Galaxy Power

It should also be noted that the Millennium II is suitable for use in power plants with or without batteries. In batteryless plants, the loss of ac power causes an immediate loss of dc power to the controller and the activation of all office alarm relays. When ac power is restored, plant rectifiers will return to their last specified voltage set point, and the controller will automatically return to its last configuration.

-40 to +85 °C: ±1.0% of full scale

0.01VDC

System

Systems

Hardware

Chassis

The Galaxy Millennium II, like its Millennium predecessor, is low-profile enclosure mounted on the inside front cabinet door of a Galaxy Power System (GPS) plant. See Figure 2-1, and 2-2. This arrangement occupies no space within the frame mounting racks, thus allowing additional room for other plant equipment. The unit is pre-installed in the factory for all applicable GPS configurations. However, it has been designed to be backwards compatible to existing Millennium to allow field replacements or upgrades. It is composed of two main components: a rust resistant metal enclosure and a clear plastic cover. The metal enclosure interfaces with the cabinet door and provides appropriate cable routing entrances to the circuit pack it secures. A maintenance friendly clear plastic cover is used to protect the enclosed circuit packs. This cover also provides clear and quick visibility to individual circuit pack alarm status indicators and all wiring connections without removing a cover allowing quick board integrity and connectivity checks without removing cover.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Figure 2-1: Controller Dimensions

Figure 2-2: Millennium Mounted on Cabinet Door

Controller Circuit Packs

MCR1 and MCR2

The core of the Galaxy Millennium II controller consists of a matched pair of surface mount technology circuit packs, MCR1 and MCR2. These circuit cards are attached and secured together at the factory. See Figure 2-3. The MCR1 is the larger of the two boards and contains all the external input/output interfaces, local and remote user interface circuitry, measurement circuits, real time clock, wide input range power converter, and connections for the MCR2. The MCR2 contains the main 32-Bit 66MHz microprocessor

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

with 16Mbytes of Flash memory and 8Mbytes of RAM. It also contains the hardware for the Ethernet control. Factory calibration values for the analog circuits located on the MCR1 are stored in memory on the MCR2.

Figure 2-3: MCR1 and MCR2 Boards

Figure 2-4: Millennium II Primary Interfaces

Figure 2-4 illustrates all of the primary interfaces located on the MCR1 for the Millennium II controller.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

3 Safety

Safety Statements

Please read and follow all safety instructions and warnings before installing, maintaining, or repairing the Millennium II controller:

• The CE Mark demonstrates compliance with the European Union Council

Directives for Low Voltage and EMC.

• The Millennium II platform is Underwriters Laboratories (UL) recognized per

Subject Letter 1801, DC Power Distribution Centers for Telecommunications Equipment.

• Install only in restricted access areas (dedicated equipment rooms, equipment

closets, or the like) in accordance with articles 110-16, 110-17, and 110-18 of the U.S. National Electric Code (NEC), ANSI/NFPA No. 70, and pursuant to applicable local codes.

• This equipment is to be used in controlled environments (an area where the

humidity is maintained at levels that cannot cause condensation on the equipment, the contaminating dust is controlled, and the steady-state ambient temperature is within the range specified).

• This equipment has been evaluated for continuous use in ambient temperature from

-40°C to 75°C.

• This equipment must not be installed over combustible surfaces.

• For installations in the United States, Listed compression connectors are to be used

to terminate Listed field-wired conductors where required. For all installations, the appropriate connector is to be applied only to the correct size conductor as specified by the connector manufacturer, using only the connector manufacturer’s recommended tooling or tooling approved for that connector.

• If the proper connector for the country of installation is not provided, obtain

appropriate connectors and follow manufacturer’s and all local requirements for proper connections. All national and local rules and regulations should be followed when making field connections.

• All input and output connections comply with SELV requirements.

• Insulation on field-wired conductors should be rated no less than 90° Celsius. Wire

conductor size should be sized per electrical codes for 90° Celsius wire, and based on the ampacity of the associated protection device. Wiring internal to enclosed equipment cabinets should be rated at 105° Celsius (minimum).

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

• Torque or secure electrical connections to the values specified on labels or in the

product documentation.

• Alarm contacts on the office alarm connector are not fused within the controller;

therefore, current limiting protection for these contacts must be provided by external circuits. Maximum ratings for alarm connections are 60Vdc and 0.5 amperes. Exceeding these maximum ratings could result in fire or damage to the unit.

• In enclosed equipment cabinets, the Millennium II mounting framework must be

connected directly to the cabinet ac service ground bus. For applications in huts, vaults, and central offices, the Millennium II mounting framework must be connected to the system integrated ground grid.

• Installing fuses not specified for use in controller may result in equipment damage.

Use only replacement parts listed in this manual and on the equipment drawings.

• The telecom-type (e.g., GMT type) fuses can produce sparks during interruption or

clearing of a fault on a high energy circuit. Use only fuses provided with safety caps for this type of circuit. Installing telecom-type fuses not equipped with safety caps may result in injury to service personnel.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Warning Statements and Safety Symbols

The symbols may sometimes be accompanied by some type of statement; e.g., “Hazardous voltage/energy inside, or Risk of injury. This unit must be accessed only by qualified personnel.” Signal words as described below may also be used to indicate the level of hazard.

Indicates the presence of a hazard that will cause death or severe personal

DANGER

WARNING

CAUTION

injury if the hazard is not avoided.

Indicates the presence of a hazard that can cause death or severe personal injury if the hazard is not avoided.

Indicates the presence of a hazard that will or can cause minor personal injury or property damage if the hazard is not avoided.

This symbol identifies the need to refer to the equipment instructions for important information.

These symbols (or equivalent) are used to identify the presence of hazardous ac mains voltage.

This symbol is used to identify the presence of hazardous ac or dc voltages. It may also be used to warn of hazardous energy levels.

One of these two symbols (or equivalent) may be used to identify the presence of rectifier and battery voltages. The symbol may sometimes be accompanied by some type of statement, for example: “Battery voltage present. Risk of injury due to high current. Avoid contacting conductors with uninsulated metal objects. Follow safety precautions.”

One of these two symbols may be used to identify the presence of a hot surface. It may also be accompanied by a statement explaining the hazard. A symbol like this with a lightning bolt through the hand also means that the part is or could be at hazardous voltage levels.

This symbol is used to identify the protective safety earth ground for the equipment.

This symbol is used to identify other bonding points within the equipment.

Issue 3 January 2008

This symbol is used to identify the need for safety glasses and may sometimes be accompanied by some type of statement, for example: “Fuses can cause arcing and sparks. Risk of eye injury. Always wear safety glasses.”

Basic Installation and User’s Guide for the Millennium II Controller

Precautions

When working on or using this type of equipment, the following precautions should be noted:

• This unit must be installed, serviced, and operated only by skilled and qualified

personnel who have the necessary knowledge and practical experience with electrical equipment and who understand the hazards that can arise when working on this type of equipment.

• The equipment could be powered by multiple ac inputs. Ensure that the appropriate

circuit protection device for each ac input being serviced is disconnected before servicing the equipment. Do not disconnect permanent bonding provisions unless all ac inputs are disconnected.

• Batteries may be connected in parallel with the output of the rectifiers. Turning off

the rectifiers will not necessarily remove power from the bus. Make sure the battery power is also disconnected and/or follow safety procedures while working on any equipment that contains hazardous energy/voltage.

• Hazardous energy and voltages are present in the unit and on the interface cables

that can shock or cause serious injury. Follow all safety warnings and practices when servicing this equipment. When equipped with ringer modules, hazardous voltages will be present on the ringer output connectors.

In addition to proper job training and safety procedures, the following are some basic precautions that should always be used:

• Use only properly insulated tools.

• Remove all metallic objects (key chains, glasses, rings, watches, or other jewelry).

• Wear safety glasses. Fuses can produce sparks. High energy levels on buses and

distribution components can produce severe arcing.

• Test circuits before touching.

• Lock out and tag circuit breakers/fuses when possible to prevent accidental turn on.

• Be aware of potential hazards before servicing equipment.

• Identify exposed hazardous electrical potentials on connectors, wiring, etc. (note the

condition of these circuits, especially wiring).

• Use care when removing or replacing covers; avoid contacting circuits.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Special Installation Notes

Deutsch

Installationsanleitung

Eingangsspannung ( Voltage ) : 2x AC 120/200-240V V Eingangsstrom ( Current ) : QS801A, max 45A, QS800A, max 30A Eingangsleistung ( Watts ) : Nennfrequenz ( Frequency ) : 50 / 60 Hz

Seriennummer ( Assembly No. ):--

Modellnummer (Modell No. ) : QS801A, QS 800A

Abmessungen sind nur zur Referenz : 150mm x 22.5mm x 77.5mm ( Dimensions are for reference only )

Max. Umgebungstemperatur : max. 75 deg. C ( Max. Operation temperatur )

Achtung: Für kontinuierlichen Feuerschutz sollte die Sicherung nur mit einer des gleichen Types ersetzt werden. Sicherungswert : ( Warning : For continued protection against fire replace with same type and rating of fuse )

Das System ist ein Gerät der Schutzklasse I / Überspannungs Kategorie II ( Power Supply is a Class I equipment / overvlotage category II )

Ausgangsspannungen und –stöme: DC 58 V / SELV ( Output Voltage and Current )

--Das Gerät darf nur in Räumen mit beschränktem Zutritt aufgestellt werden. ( Nur ausgebildetes Personal )

--Nur für Aufstellung auf Boden oder einer anderen brennbaren Oberfläche geeignet.

--Das Gerät hat keinen eigenen Ausschalter, es muß daher mit einem Ein- und Ausschalter im Versorgungskreis versehen sein.

--Das Gerät ist für den Einbau in IT- Geräte in einem Rahmen bestimmt (siehe weitere Anleitung)

--Beim Einbau des Gerätes ist daraf zu achten das alle Anforderungen gemäß EN60950 eingehalten werden.

ACHTUNG: HOHER ABLEITSTROM VOR ANSCHLUSS AN DEN VERSORGUNGSSTROMKREIS UNBEDINGT ERDUNGSVERBINDUNG HERSTELLEN

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Espanol

Notas especiales para instalaciones en países de habla hispana

• Instrucciones de instalación

(Installation Instructions)

• Voltaje (Voltage):

Vea tabla 2-A

• Corriente (Current):

Vea tabla 2-A

• Frecuencia (Frequency):

50/60Hz

• Voltaje y corriente de salida (Output Voltage and Current):

Vea tabla 2-A

• Temperatura IREa de operación (Maximum Operation Temperature):

75°C (167°F)

• Sin cabina contra incendios, suelo no combustible

(No IRE enclosure, non-combustible floor)

• Evaluado en EN60950

(Evaluated to EN60950)

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

4 New Installations

The Millennium II is factory pre-installed and pre-configured with industry standard defaults for thresholds and feature operability in GPS cabinet applications. In addition, customer specific default controller settings may be available upon request. This section provides:

Preparation and Precautions

Procedures for the proper addition of optional packs

Input and output wiring to the controller and the installation and wiring of optional features

Controller default configuration information such as alarm severity and description, system voltage, shunt information

Controller configuration information

Preparation

The following Installation procedures should be performed AFTER:

But BEFORE:

Precautions

Observe ESD protection while installing circuit packs. Wear grounded antistatic wrist straps when handling all circuit packs. The wrist strap must contact the skin and is not to be worn over clothing. Never hand a circuit pack from a grounded to a non-grounded person or vice-versa.

• All the equipment frames (initial and supplemental bays, free- standing rectifiers, etc.) are anchored in place.

• The battery stands have been erected and the batteries installed.

• The overhead cable racks have been installed and the power

cables have been run and terminated.

• The plant’s charge and discharge bus bar assemblies have been installed.

• Connecting the batteries to the plant charge and discharge bus bars or turning up the plant rectifiers.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Safety

Action Verified

Always consider personal safety before beginning any procedure. Review the Safety section. Be aware of the presence of unfused battery potential in the vicinity of the controller. Use only insulated tools. Make sure the system is properly grounded per the National Electrical Code and local building codes. Remove all metal jewelry before beginning the installation.

Installation Materials

Item Verified

Wire cutters and strippers 18 to 22 AWG wire Jewelers screwdriver (Flat and Phillips) Small needle nose pliers Digital meter, +/- 0.02% Screw Drivers (flat-blade and Phillips) ESD wrist strap Wire-wrap tool or Amp alarm punch-down tool

Issue 3 January 2008

Figure 4-1: Millennium II

Basic Installation and User’s Guide for the Millennium II Controller

Controller Connections

Figure 4-2: Millennium II Controller Connections

Table 4-A: Millennium II Interface Reference

Interface

Reference Description

P13

P14

P15

P201

P202

P205

TB1

TB2

J10

Connectorized interface for large parallel format 8x40 LCD assembly 10/100 Base-T LAN/Ethernet interface Connectorized interface for 10K/30K thermistor probe options or 210E Connectorized input for input power, monitoring of two shunts, plant sense voltage, and

Major Fuse alarm (Same connection as on the Millennium) RJ45 receptacle for ground referenced Auxiliary RS485 circuit and One-Wire temperature

monitoring devices BSL1-4 circuit pack Interface connector for Input/Output to controller RJ45 receptacle for isolated RS485 system component monitoring and control of rectifiers,

converters, low voltage disconnect contactors, and bay level alarm inputs (Serial Rectifier bus)

Factory test connector (not used in the field) Connectorized interface for future smaller serial format LCD Connectorized interface for future smaller serial format LCD Connectorized interface for optional Modem Ground referenced DB-9 for local RS232 serial port Option board connector Terminal block interface for RS232/RS485 Auxiliary port and Remote Peripheral Module

(RPM) connections Terminal block interface for three additional 10K thermistor probe or 210E connection

options USB interface (reserved for future use)

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Installing Circuit Packs

Figure 4-3: Millennium II Controller Connections

Modem Card

The optional Modem card may require field installation. To do so, perform the following steps:

Step Action

NOTE:

1. Remove the controller front cover.

2. Install the BSM on the 4 standoffs, to left of the controller MCR1 board using

3. Connect the 848091798 cable assembly between the BSM J100 plug and P201

5. Operate the reset switch on the MCR1 board in the lower left corner of the

NOTE:

Installation or replacement of this pack can be done “hot”; power removal is not necessary.

four 845143866 screws.

on the MCR1 board.

Note: This step may be performed at a later time

Install phone line wiring from Connect the existing telephone cable to the RJ11 connector at the top of the board

Connect Tip/Ring conductors to TB1 at the top of the board. NOTE: Tip is TB1 pin 1 (Pin closest to the RJ11 connector) and Ring is Pin 3.

Pin 2 is not used.

MCR1 board. (see Figure 4-3) The Password Reset button is to the LEFT of the serial port connector, and the

Controller Reset is to the right of the serial connector.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Data Switch Card

Step Action

NOTE:

Installation or replacement of this pack can be done “hot”; power removal is not necessary.

2. Install two 407882133 standoffs on the BSJ intelligent board. Screw threads are protruding just below TB1, located at the upper left hand corner of the MCR1 board.

3. Place BSW pack inside the 847950938 insulator.

4. Plug BSW pack into the P205 connector on the BSJ intelligent controller board

5. Secure the BSW board to the standoffs with two 900562208 screws.

NOTE:

To install the Data Switch Extension board, please see the User’s Guide for Millennium II Controller Advanced Features manual.

Alarm Termination Board

Alarm Termination board options provide for wire wrapped or insulation displacement (punch down) terminations. The Alarm Termination Board for a specific application may require field installation. To do so, perform the following steps:

Step Action

1. In the upper right hand corner of the MCR1 board, find the alarm board already installed.

2. Remove the two screws holding the board at the top.

3. Holding the board on both sides, slowly, but firmly, remove the alarm board from the P8 connector.

4. Unpack the new board from its box, carefully observing proper ESD procedures.

5. Connect the alarm board to P8 and press down firmly, until the board is seated.

6. Secure the alarm board at the top using the two screws removed earlier.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Gateway (LAN) Connections

Step Action

NOTE:

The Gateway card has been designed into the MCR1/MCR2 boards and requires no additional circuit packs.

NOTE:

The Gateway has an IEEE 802.3 compliant 10Base-T network interface. Since the cable length required to connect to the network is variable, this cable must be supplied by the user.

1. At the controller, connect one end of the network interface cable to P2. This connector is located at the bottom center of the MCR1 board, and immediately below the MCR2 board.

2. Connect the other end to an IEEE 802.3 compatible network.

3. Configure the Gateway for the network by contacting the customer’s network administrator. Detailed configuration information may be found in the User’s Guide for Millennium II Controller Advanced Features manual.

Rectifier Cabling

Step Action

NOTE:

For new installations, the Millennium II rectifier cabling has been factory wired and installed to the cabinet BIC/BLJ board for alarm and rectifier communication.

NOTE:

For connector integrity, verify that the cable is installed and connected properly.

1. Verify that the rectifier cable is connected to P9, and NOT P7(AUX) cable connector.

2. Verify that the cable connector is properly seated into P9, and that it is not loose.

3. Verify that the rectifier cable terminating on the BIC/BLJ board is connected to P9 and also not loose.

Remote Peripheral Monitoring (RPM)

RPM provides data acquisition capability far beyond that normally available in a power system controller. Monitoring modules available consist of:

• Shunt monitors (6 channels + 1 temperature channel)

• 0-100mV dc Voltage monitors (6 channels + 1 temperature channel)

• 0-3V dc Voltage monitors (6 channels + 1 temperature channel)

• 0-16V dc Voltage monitors (6 channels + 1 temperature channel)

• 0-200V dc Voltage monitors (6 channels + 1 temperature channel)

• Temperature monitor (7 Channels)

• Control Relay module (3 sets of programmable form C relay outputs)

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

The user may connect a maximum of 95 of any combination of these modules serially.

Step Action

NOTE:

The Remote Peripheral Monitoring feature has been designed into the MCR1 board and requires no additional circuit packs. Monitoring and control modules ARE required, based on the application.

NOTE:

This section only describes a single module connection to the controller. Modules MUST BE PROGRAMMED after they have been installed or they may not function properly. Detailed connection and configuration information may be found in the User’s Guide for Millennium II Controller Advanced Features manual.

1. Using the RPM bus cable (comcode 407377704), wrap the cable through the EMI inductor bead twice. Place the bead approximately 3 inches from the end of the cable.

2. Connect the bus cable to:

TB-1 Pin

Assignments

TB-1 Pin

Descriptions

RPM

Conductor

RPM Conductor

Description

Color 6 *6 Blue or White Power/Communications 8 *8 Blue or White Power/Communications

9 or 10 FGND Bare wire Shield

*connections of the bus wire are NOT polarity sensitive.

3. Secure the module connection unit and route the wires through the openfaced bottom of the connection unit.

4. Make the connections to TB2 on the connection unit:

TB-2 Pin

Assignments

RPM

Conductor

RPM Conductor

Description

Color

IN Blue or White Power/Communications

OUT Blue or White Power/Communications

SHIELD Bare wire Shield

*connections of the bus wire are NOT polarity sensitive. * there are 2 IN, and 2 OUT connections. Either one may be used.

5. Locate the control unit. This is the half with circuitry on it.

6. In the lower right hand side of the control unit (inside), are two rotary switches. Set SW-1 (LO) to 1. The module will be recognized as 01 by the controller. Other modules added cannot have the same address or 00 for the address.

7. Carefully attach the control unit to the connection unit using the ribbon connector.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

NOTE:

8. After approximately 1 minute, the green LED on the front of the module will

This connector/cable is not keyed, so be careful to line up the pins properly.

blink once approximately every 5 seconds. Detailed troubleshooting information may be found in the User’s Guide for Millennium II Controller Advanced Features manual.

Thermal Probes

Without thermal probes, many of the controller’s battery management features will not function, or produce erroneous results. Some features requiring thermal inputs are:

• Slope Thermal Compensation

• Reserve Time Prediction

• High Temperature Alarm

• Ambient High and Low Temperature Alarms

• High Temperature Disconnect

Step Action

NOTE:

1. The following table shows the type of probe and connector location on the

The controller supports a number of thermal probe inputs. The type of probe used determines where it is connected on the controller. Detailed thermal probe and battery management information may be found in the User’s Guide for Millennium II Controller Advanced Features manual.

Millennium:

Type of Probe Comcode Controller Connection

Location 10/30K P3 210E Thermal Probe

Mux 1 Wire Temperature

Monitoring Devices Terminal Block

Interface for 3 additional 10k probes or 210E connection

TB2

Pin Description

1 Probe 2 2 Probe 2

RTN 3 Probe 3 4 Probe 3

RTN 5 Probe 4 6 Probe 4

RTN

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

USB Interface

This interface is reserved for future use.

Wiring Alarm Outputs

These external alarms may be wired to customer external office alarms at their destination.

Form-C Alarm Contact Ratings 60Vdc, 0.3A

Conductor Size for terminating on Alarm board

Refer to Table 4-B and 4-C for lead designations and their descriptions for leads terminating on the BSL alarm interface board.

Table 4-B: Controller Alarm Descriptions and Pin Numbers

Number

1 PCRAO 33 MJFR 65 FAN 2 PCRAC 34 MNFR 66 AMN 3 PCRAR 35 MNFC 67 TFLT 4 PCRVR 36 MNFO 68 TBST 5 PCRVC 37 BDO 69 TRTN 6 PCRVO 38 BDC 70 7 PCREO 39 BDR 71 8 PCREC 40 ACFR 72 OS

9 PCRER 41 ACFC 73 TR1 10 PMJAR 42 ACFO 74 TEQ 11 PMJAC 43 RFAO 75 ETR 12 PMJAO 44 RFAC 76 ETRR 13 PMJEO 45 RFAR 77 RO 14 PMJEC 46 HVR 78 ROR 15 PMJER 47 HVC 79 TR2 16 PMJVR 48 HVO 80 TR4 17 PMJVC 49 UR1O 81 18 PMJVO 50 UR1C 82 TBD

Signal

Name

Number

18 – 22AWG (if less than 18AWG, use multi-conductor cable for mechanical integrity)

Signal

Name

Number

Signal Name

PBTR

PBT

RBRPO

now general

I/O-1

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Number

19 PMNAO 51 UR1R 83 USR1PRESENT/

20 PMNAC 52 CTLRR 84 LVD1 21 PMNAR 53 CTLRC 85 TR3 22 PMNVR 54 CTLRO 86 23 PMNVC 55 UR2O 87 24 PMNVO 56 UR2C 88 25

26 - 58 UR3R

27 - 59 UR3C

28 PMNER 60 UR3O

29 PMNEC 61 LVD2 93 ABS 30 PMNEO 62 LVD2R 94 ABS 31 MJFO 63 FAJ 95 DG 32 MJFC 64 AMJ 96 DG

Critical-Audio

Critical-Visual

Critical-External

Power Major-Audio

Power Major –External

Power Major –Visual

Signal

Name

Number

Signal

Name

Number

Signal Name

BTP

now general

I/O-2

4-20mA in

4-20mA Rtn

57 UR2R 89 USR3PRESETN/

BTPFLT

now general I/O-

90 USR3DETECT/

Now VLVR

BTMJ

0-5V in

Now VLVC

0-5V Rtn

Now VLVO

1 PCRAO 2 PCRAC 3 PCRAR 4 PCRVR 5 PCRVC 6 PCRVO 7 PCREO 8 PCREC

9 PCRER 10 PMJAR 11 PMJAC 12 PMJAO 13 PMJEO 14 PMJEC 15 PMJER 16 PMJVR 17 PMJVC 18 PMJVO

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Power Minor-Audio

Power Minor –Visual

Power Minor –External

Major Fuse

Minor Fuse

Battery On Discharge

AC Fail

Rectifier Fail

High Voltage

User Relay 1

Controller Fail

User Relay 2

Very Low Voltage

19 PMNAO 20 PMNAC 21 PMNAR 22 PMNVR 23 PMNVC 24 PMNVO 28 PMNER 29 PMNEC 30 PMNEO 31 MJFO 32 MJFC 33 MJFR 34 MNFR 35 MNFC 36 MNFO 37 BDO 38 BDC 39 BDR 40 ACFR 41 ACFC 42 ACFO 43 RFAO 44 RFAC 45 RFAR 46 HVR 47 HVC 48 HVO 49 UR1O 50 UR1C 51 UR1R 52 CTLRR 53 CTLRC 54 CTLRO 55 UR2O 56 UR2C 57 UR2R 58 VLVR 59 VLVC 60 VLVO

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Wiring Alarm and Control Inputs

In a standard Galaxy Power System configuration, plant level alarms are sent to the controller via the Bay Interface Card through serial data communication. The following alarm inputs are provided for discretionary use in non-standard applications.

Table 4-C: Controller Alarm and Control Inputs

Alarm Pin

Number

Low Voltage 2 Disconnect State Detect 61 LVD2

Fuse Alarm Major 63 FAJ Fuse Alarm Minor 65 FAN

Auxiliary Alarm Major 64 AMJ

Auxiliary Alarm Minor 66 AMN

Timer Float Control 67 TFLT

Timer Boost Control 68 TBST

Plant Battery Test 71 PBT

Open String Detect 72 OS

Transfer Rectifier 1 73 TR1

General Purpose Input 4 74 IN-4 previously TEQ

General Purpose Input -5 (Previously

Engine Transfer)

Reserve Operation 77 RO Transfer Rectifier 2 79 TR2 Transfer Rectifier 4 80 TR4

Reserve Battery-Emergency Power Off 81 RBRPO

General Purpose Input 1 82 IN-1

BTP or General Purpose Input 2 83 IN-2/BTP

Low Voltage 1 Disconnect State Detect 84 LVD1

Transfer Rectifier 3 85 TR3

General Purpose 4-20mA Measuring

Circuit

General Purpose 4-20mA Measuring

Circuit-RTN

BTPFLT or Generic Input 3 89 IN-3/ BTPFLT

Low Voltage 3 Disconnect State Detect

Also

Battery Thermal Protect Major

General Purpose 0-5Vdc Measuring

Circuit

General Purpose 0-5Vdc Measuring

Circuit-RTN

75 IN-5 Previously ETR

87 4-20mA

88 4-20mAR

90 LVD3/ BTMJ

91 0-5V

92 0-5VR

Signal Name

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

BSL-63 FAJ: Fuse Alarm Major

An optional battery potential input, must use an external 1K ohm 2W current limiting resistor at the source. A Fuse Alarm Major is generated when battery potential is received.

BSL-65 FAN: Fuse Alarm Minor

A battery potential input is required, which must use an external 1K ohm, 2W current limiting resistor at the source. A Fuse Alarm Minor is generated when battery potential is received.

BSL-72 OS: Open String Alarm

A battery potential input is required, which must use an external 1K ohm 2W current limiting resistor at the source. This circuit is used to signal Galaxy that a battery string protective device or switch is in the open position. An Open String Alarm is generated when battery potential is received.

BSL-64 AMJ: Aux Major

A battery potential input is required, which must use an external 1K ohm, 2W current limiting resistor at the source. This circuit is used to allow Galaxy to monitor another power device and provide alarms for it. An Aux Major Alarm is generated when battery potential is received.

BSL-66 AMN: Aux Minor

A battery potential input is required, which must use an external 1K ohm, 2W current limiting resistor at the source. This circuit is used to allow Galaxy to monitor another power device and provide alarms for it. An Aux Minor Alarm is generated when battery potential is received.

LVD1: BSL-84 Low Voltage Disconnect Active A battery potential input is required, which must use an external 1K ohm, 2W current limiting resistor at the source if not using standard Lineage Power LVD circuit boards or controller. This circuit is used to inform Galaxy that the monitoring circuit of a Low Voltage Disconnect device has failed. In standard Galaxy Power Systems, the Bay Interface board monitors these alarms and informs the Controller through the serial interface connection.

LVD2/LVD2R: BSL-61/62 Low Voltage Disconnect Active A closure between these points or a ground signal into LVD2/ BSL-61 is used to inform Galaxy that the a Low Voltage Disconnect device has opened. In standard Galaxy Power Systems, the Bay Interface board monitors these alarms and informs the Controller through the serial interface connection.

External Boost Option

A variety of external devices may be used to initiate boost in Galaxy. Wiring is required from positions 67/68/69 on the BSL board for operation of this feature. Providing a contact closure between TBST and TRTN initiates the boost feature. A contact closure between TFLT and TRTN returns the plant to float. Additional information on External Boost can be found in the User’s Guide for Millennium II Controller Advanced Features manual.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Rectifier Sequence Option

The controller is capable of sequencing rectifiers on line after detecting a AC is being provided by emergency generator. Internal Rectifier Sequencing requires external wiring to ETR/ETRR on BSL pin numbers 75/76, and optionally RO/ROR on BSL pin numbers 77/78, in order to function. The controller can also accept ground signals onto TR1 to TR4 on BSL 73/79/ 85/80 from an external device to control the sequencing of plant rectifiers in groups as follows:

Table 4-D: TR leads and Associated Rectifiers

Rectifiers Affected

Signal

TR1 G01, G02, G09, G10, G17, G18, G25, G26, G33, G34, G41, G42, G49, G50,

G57, G58

TR2 G03, G04, G11, G12, G19, G20, G27, G28, G35, G36, G43, G44, G51, G52,

G59, G60

TR3 G05, G06, G13, G14, G21, G22, G29, G30, G37, G38, G45, G46, G53, G54,

G61, G62

TR4 G07, G08, G15, G16, G23, G24, G31, G32, G39, G40, G47, G48, G55, G56,

G63, G64 Additional information on the Rectifier Sequence Options can be found in the User’s Guide for Millennium II Controller Advanced Features manual.

Battery Temperature Option

Slope Thermal Compensation and Battery Reserve Time Prediction features of the controller, require that battery temperature be monitored. If either of these features is to be configured in Galaxy software, a battery temperature input must be connected to P3 temperature probe connector on the Controller board. Three optional cables are used to connect to various battery arrangements:

Cable Assembly Connects to:

848152997 KS20472 round cell thermistor 848152989 ring or paddle type thermistors 848153003 210E Thermal Probe Multiplexer

Refer to User’s Guide for Millennium II Controller Advanced Features manual for additional information on these features.

Alarm Battery Supply Signals

Table 4-E: ABS Pin Numbers

Signal

Pin No.

Name

ABS 93 ABS 94

DG 95 DG 96

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Fused Battery Supply BSL-93, 94 ABS: Alarm Battery Supply

This is an alternate plant voltage source for user alarm systems. This power is fused with a 1-1/3 ampere ABS fuse.

BSL-95,96 DG: Discharge Ground

Plant ground/return source for user alarm systems.

Fuses

Two Fuses, located on the MCR1 board, provide protection for the controller input power and Alarm Battery Supply, used to power alarm panels or other devices requiring the power system voltage at no more than 1.3A.

Figure 4-4: Millennium Controller Fuses

FUSE Description Fuse Size

F1 Controller Input Power 3A F2 Alarm Battery Supply

(ABS)

1.3A

Front Panel Display

LCD

The primary local interface for the Millennium II is an eight-line LCD assembly mounted to the front of the primary GPS cabinet door. This user interface is a panel that includes a backlit LCD module, two sections of status LEDs, system voltage test jacks, and an array of simple push-button controls. This controller supports multiple LCD display assemblies. It is backwards compatible to both existing Millennium LCD assemblies L51 and L50 shown in Figure 4-5. It is also compatible with the enhanced L52 LCD display assembly (see figure 4-6) specifically developed for the Millennium II. This new display

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

assembly is compatible to existing GPS cabinet doors and is functionally backwards compatible to the Millennium. It looks very similar to the L51 option. LCD assembly, but the L52 also provides a built-in audible alarm and digital contrast adjust that are only available when used with the Millennium II controller.

Figure 4-5: Controller Front Panel Displays

Figure 4-6: Detailed Controller Front Panel Display – L51/52

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

LEDs

Depending on the LCD option utilized, the LCD assemblies contain two rows of LEDs at the right side of the interface board or two columns of LEDs at the left side of the interface board as seen in figure 4-5. The segregated sections of LEDs provide an indication of the alarm source (rectifier, battery, distribution, communication, controller, remote modules) and the severity (Critical, Major, Minor, Nominal) of the various alarms. Operation of the status LEDs can be reconfigured via the local or remote controller interfaces.

Push Buttons

A group of push-button keys identified in table 4-F, provides the primary method of locally interacting with the Galaxy Millennium II controller. These keys are used singly or in combination to navigate through the menus and follow industry standard functionality. Following is the general description of all the keys.

Table 4-F: Push-Button Key Functionality

Key Function

Up arrow Use to navigate the menu; press the key to move the

cursor up one line.

Down arrow Use to navigate the menu; press the key to move the

cursor down one line.

Left arrow Use to navigate the menu; press the key to move the

cursor left one field.

Right arrow Use to navigate the menu; press the key to move the

cursor right one field.

ADJUST Plus

Use to adjust (increase) the value of a field.

(+) ADJUST Minus

Use to adjust (decrease) the value of a field.

(-) MENU Press this key any time to bring the MAIN menu on

line.

HELP Press this key to display limited on-line help

information.

ENTER Use this key to save a value that has been changed, or

to select a menu item.

ESCAPE Use this key to abort a change, or to go back to the

immediate higher level menu.

Lamp Test

Use this key to test the display and LEDs

(L50 Only)

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Test Jacks

The Millennium II LCD panel assemblies also provide test jacks to provide the ability of using an external meter to monitor the Plant Voltage as seen in figure 4-7. Voltages to the front panel test jacks are current limited and ESD protected. The controller measures this voltage to regulate the system bus voltage as well as display it as the battery plant bus voltage. The value of this voltage is used for many other controller related features.

Serial (PC) Port

A ground referenced RS-232 local port is provided at the front of the display to allow easy connection to a personal computer or terminal using ANSI T1.317 object oriented command language. Lineage Power’s EasyView is also available to provide a user friendly system interface locally or remotely. See figure 4-6.

Alarm Buzzer

The audible alarm buzzer is located on the front panel display assembly. It can be programmed from the front panel display to operate as follows:

Contrast Adjust

• For L50, L52 Displays: Press the + or – keys and hold until the display changes it’s contrast setting. Once the desired setting is reached, release the button.

• For L51 Displays: Using a small flat head jeweler’s screwdriver, insert it into the small opening at the top of the display assembly (above the UP arrow). Turn clockwise or counter clockwise until the display contrast is set.

Issue 3 January 2008

• Disabled for ALL Alarms

• Audible on PCR

• Audible on PMJ

• Audible on PMN

Basic Installation and User’s Guide for the Millennium II Controller

Controller Defaults

Dip Switch Settings

The Millennium has 8 dip switch positions (SW202) that may be changed. SW202 is located on the MCR1 board, above the MCR2 board. (See figure 4-7)

Figure 4-7: Millennium II Controller Dip Switches

Table 4-G: Millennium II Controller Dip Switch Settings

Switch Position SW202-8 1 Front Panel Configuration ENABLED DISABLED SW202-7 0 Modem/Aux/Local/Gateway/USB/

SW202-6 0 Enhanced Security Mode (See

SW202-5 1 Auxiliary Port Configuration RS-232 RS-485 SW202-4 1 Remote Rectifier in Standby ENABLED DISABLED SW202-3 0 Boost Mode ENABLED DISABLED SW202-2 1 Reserved for Future Use ENABLED DISABLED SW202-1 1 Reserved for Future Use ENABLED DISABLED

Default Description Closed

(1)

ENABLED DISABLED IRDA Port Setting Configuration (Remote Access)

ENABLED DISABLED table 4-H, for features affected

Open (0)

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Table 4-H: Enhanced Remote Security Features The modem and auxiliary ports can be configured for full access and read-only using DIP switch 202-7. Restricted access is also available. This prevents changes ia the modem and auxiliary ports that will affect the state of the plant, even when logged in as a Super-User or Administrator. This enhanced remote security is enabled and disabled with DIP switch SW202-6. The functions and parameters restricted with the enhanced remote security feature are listed in this table.

Enable or disable Rectifier Restart feature Change All Rectifier On Threshold Change Timed Manual Boost Duration Change Boost Current Threshold Change Rectifier Status to “Standby”/ “Vacant” status is prohibited. The change to “On”status is allowed. Change Rectifier Shunt Voltage configuration Change Rectifier Float High Voltage Shutdown Threshold Change Rectifier Boost High Voltage Shutdown Threshold Change Rectifier Float Set Point Change Rectifier Boost Set Point Change Rectifier Boost Current Limit Change Converter Voltage Set-Point Change Converter Low Voltage Disconnect Threshold Change Converter Low Voltage Reconnect Threshold Enable or disable Converter Low Voltage Disconnect feature Change Converter Status to “Standby”/ “Vacant” status is prohibited. The change to “On”status is allowed. Change Battery High Temperature Threshold Enable or disable Battery Current Limit Change Battery Limit Threshold Change Battery Contactor Status to “Open” status is prohibited. The change to “Close” status is allowed. Change Battery Disconnect Threshold Change Battery Reconnect Threshold Change Very Low Voltage Alarm Threshold and Severity Change Multiple Rectifier Fail Alarm Threshold and Severity Change Limited Recharge Current Alarm Threshold and Severity Change Excess Rectifier Drain Alarm Threshold and Severity Change Engine Transfer Timeout Alarm Threshold and Severity Change Reserve Time Low Alarm Threshold and Severity Change Multiple Converter Fail Alarm Threshold and Severity Change Battery On Discharge Alarm Threshold and Severity

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Voltage Threshold Ranges and Default Values

Table 4-I: Voltage Threshold Ranges and Default Values

Low High Default

Very Low Voltage (VLV) 24V 20.00 25.50 23.00 48V 40.00 51.00 46.00 Battery on Discharge (BD) 24V Float 23.00 28.00 25.00 24V Boost 23.00 28.00 25.00 48V Float 46.00 55.00 51.00 48V Boost 46.00 55.00 51.00 High Float Voltage (HFV) 24V Float 24.75 29.75 26.50 24V Boost 25.75 31.75 26.50 48V Float 50.00 60.00 53.00 48V Boost 52.00 60.00 53.00 High Voltage Shutdown Alarm (HV) 24V Float 24.75 29.75 26.8 24V Boost 25.75 31.75 26.8 48V Float 50.00 60.00 53.6 48V Boost 52.00 60.00 53.6 Rectifier On Threshold (ROT) 24V 20.00 25.00 22.00 48V 40.00 51.00 44.00

Controller Alarm Severity, LED and Relay Default Values

Table 4-J:Controller Alarm Severity, LED and Relay Default Values

Symbol Default Designation Default

Severity

Default LED Default

Relay

AAC ACO Active RO None None ABS Alarm Battery Supply Fuse Major CTLR CTLR AMJ Auxiliary Major Major None None AMN Auxiliary Minor Minor None None ATA Alarm Test Active RO None None

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Symbol Default Designation Default

Severity

Default LED Default

Relay

ATB Alarm Test Aborted RO None None ATF Alarm Test Failed Warning None None BBL Memory Backup Battery Low Warning None None BCA Battery Type Conflict Warning None None BDA Battery on Discharge Major BD BD BFA Battery Test Failed Minor BAT None BID Bay Interface ID Conflict Major CTLR CTLR BTA Battery Test Active RO BD BD BTJ Battery Thermal Major Major BAT None BTN Battery Thermal Minor Minor BAT None CCH Configuration Changed RO None None CDFA Converter Distribution Fuse Major RECT MJF CDID Converter ID Conflict Major RECT None CFA Converter Fail Minor RECT None CLC Clock Changed RO None None CMA Minor Communications Failure Minor CTLR None CMFA Multiple Converter Fail Major RECT None CNF1 Contactor 1 Failed Major BAT None CNF2 Contactor 2 Failed Major BAT None CNF3 Contactor 3 Failed Major BAT None CNO1 Contactor 1 Open Major BAT None CNO2 Contactor 2 Open Major BAT None CNO3 Contactor 3 Open Major BAT None COF Queue Overflow Warning None None COR Number Did Not Respond Warning None None CPA Circuit Pack Fail Major CTLR CTLR CRA Controller Fail Major CTLR CTLR DID Rectifier ID Conflict Major RECT None EMD Energy Management Disabled Warning None None EPD Excess Plant Drain Minor RECT None EPO Emergency Power Off Critical BATT None EPR External Password Reset Warning None None ETO Engine Transfer Timeout Minor AC None EXL Excessive Login Attempts Warning None None FAJ External Fuse Major Major DIST MJF FAN External Fuse Minor Minor DIST MNF HCL History Cleared RO None None

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Symbol Default Designation Default

Severity

Default LED Default

Relay

HFV High Float Voltage Minor RECT None HVA High Voltage Major RECT HV LMR Limited Recharge Minor RECT None LVD Low Voltage Disconnect Minor BAT None LVDA Low Voltage Disconnect Fail Minor BAT None MCM Major Communication Fail Minor CTLR None MDF Module Failure Minor RM None MOR Measurement Out Of Range Minor RM None MTC Module Type Conflict Warning None None NNC Number Not Configured Warning None None OSA Open String Minor BAT None PFD Password At Default Warning None None PGI Program Line Invalid Major None None PHT Processor Halt RO None None POR Number Did Not Respond Warning None None RLS1 Redundancy Loss Ninor RECT None RPI Rectifier/Plant Inconsistency Warning None None RTL Reserve Time Low Minor BAT None SNC Shunt Not Configured Warning None None STF Self Test Failed Minor CTLR CTLR TPA Thermal Probe Failure Minor CTLR CTLR URC User Relay Conflict Warning None None VLA Very Low Voltage Critical BAT UR3 VSF Sense/Control Fuse Major CTLR CTLR ZID ID Not Configured Major RECT None

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Table 4-K: Rectifier Alarm Defaults

Symbol Default Designation Default

Severity

Default LED Default

Relay

ACF AC Fail Minor AC ACF CLM Rectifier Current Limit RO None None ERD Excess Rectifier Drain Minor RECT None ETS External Transfer Shutdown Minor RECT None HPA Half Power Minor RECT None LCA Low Current Alarm Minor RECT None LSF Load Share Fuse Minor RECT None MACF Multiple AC Fail Major AC ACF MAN Manual Off Minor RECT None MFA Multiple Rectifier Fail Major RECT RFA MMAN Multiple MAN Alarm Major RECT None PHA Phase Or Low Output Minor AC None RIC Rectifier Incomplete Config Warning None None RFA Rectifier Fail Minor RECT RFA

Default Display

The default display shown in figure 4-8 provides basic system status. The controller returns to this display after approximately three minutes after the last time a key is pressed.

Figure 4-8: Millennium II Controller Default Display

The first line shows:

# of Alarms # of Warnings Date Time

The larger text in the middle of the screen shows:

Plant Voltage Plant Load (Current)

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

The bottom line(s) show: An Hourglass may appear in the lower left hand corner of the screen. This indicates that a configuration change is being saved to non-volatile memory. Audible Alarm Cutoff State(Toggle) (Only shown if an alarm is active) Plant Mode (Default Float)

Screen information is updated approximately every two seconds. The front panel display offers a series of menus that allow the user to:

• Configure

• Control

• View Status

• View History

• View Statistics

• Perform Diagnostics

These menu operations are accomplished by navigating through different screens.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Controller Display Menu Maps

Configuration Menu Map

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Control and Operations Menu Map

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Status Menu Map

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

History Menu Map

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Statistics Menu Map

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Minimum Configuration

Front Panel

The Millennium II controller’s primary user interface is the front panel, which includes a backlit LCD, and an array of pushbutton controls. SW202-8 must be set to ENABLED for changes to be made from the front panel. This section covers only the basic operations that must be performed so that the controller is minimally configured. For more advanced operations, please see the User’s Guide for Millennium II Controller – Advanced Features.

Step Configuration

Attribute to

Menu Path/Action Customer

Value

Change

DATE/TIME

Format

This field allows you to select one of the following date formats: MM/DD/YY, DD/MM/YY, YY/MM/DD, MM/DD/YYYY, DD/MM/YYYY, YYYY/MM/DD. Use the <+> or <-> key to select the desired format and press <ENTER> to save the change.

Month Use this field to change the month; the

possible value is from 1 to 12.

Day Use this field to change the day of the month;

the possible value is from 1 to 31.

Year Use this field to change the year; the possible

value is from 1992 and up.

NOTE:

Please note that the system will validate the

entries before the system date is modified.

TIME

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Format

This field allows you to select one of the following time display formats: 12 or 24 hour. Use the <+> or <-> key to select the desired format and press <ENTER> to save the change.

Time

Allows you to change/set the time.

Daylight

Enables or Disables Daylight Savings.

SYSTEM SHUNT

Type

This selection allows the operator to configure the type of shunt that is connected to the controller. Possible values are LOAD, BATTERY, or NONE. The configuration is determined by the plant architecture. Refer to the GPS Power Plant Product Manual for a description of these architectures.

In a plant using distributed architecture a shunt type of NONE should be selected. In

this arrangement, up to 32 shunts, located between batteries and plant bus bars, can be connected to the Bay Interface Cards in the system bays. The controller reads the shunt currents over the serial data connection. The load current displayed is derived from the total of battery currents and the total of rectifier currents. In a plant using centralized architecture, either LOAD or BATTERY should be selected. A maximum of two shunts of the same amperage can be connected through P6 on the BSH. A shunt type of LOAD means that a load shunt, located between load and plant bus bars, is connected. The load current displayed on the front panel is the sum of the two shunt currents. A shunt type of BATTERY means that a battery shunt located between the batteries and plant bus bars is connected. The load current displayed on the

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

front panel is derived from the total battery current and the total rectifier output current.

Use the <+> or <-> key to change the field values. Press <ENTER> to save the changes.

mV The first item to configure is the Plant

Voltage shunt. Make sure the cursor is on the SHUNT mV field and use the <+> or <-> key to step through the available values (25, 50, 60, 100, 150 mV). Select the one that best suits the application; press the <ENTER> key to save the change.

Move the cursor to the SHUNT I field by using the <UP>/<DOWN>/<LEFT>/<RIGHT> ARROW keys. Use the <+> or <-> key to step through the available values (0-99999). Select the desired value; press <ENTER> to save the change.

ALARM THRESHOLDS

High Voltage

When the plant voltage exceeds this threshold, the plant High Voltage Alarm (HVA) is turned ON, and the controller will send a signal to the rectifiers to shut down in an orderly and timely fashion. This will also light the Major (MJ) LED, and activate the PMJ relay (assuming there is no alarm with CRITICAL severity level active). Move the cursor to the fields and use the <+> or <-> key to adjust the High Voltage shut down alarm for FLOAT mode to the desired level. Press <ENTER> to save the change.

High Voltage Float When the plant voltage exceeds this

threshold, the plant High Float Voltage Alarm (HFV) is turned ON, and this will also light the Minor LED, activate the PMN contact closure (assuming there is no alarm with CRITICAL or MAJOR severity level active).

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

The purpose of this alarm is to indicate that the plant voltage is high probably due to an adjustment in the plant rather than due to a failure. This alarm allows the High Voltage (HV) shutdown threshold to be raised slightly, thus reducing the number of nuisance shutdowns without decreasing the plant reliability. Move the cursor to the fields and use the <+> or <-> key to adjust the High Voltage shut down alarm for FLOAT mode to the desired level (normally less than the HV threshold). Press <ENTER> to save the change.

Battery on

Discharge

If the plant voltage is less than the threshold value, the Battery Discharge alarm is turned ON, this in turn activates the PMJ and BD relay, light the MAJ and BD LEDs. Move the cursor to the fields, and use the <+> or <-> key to adjust the threshold to the desired level. Press <ENTER> to save the change.

Very Low Voltage This alarm threshold is used to indicate that

the system voltage is very low, and that the batteries have discharged to a dangerously low depth. When the plant voltage falls below this level, the Very Low Voltage (VLV) and Power Critical alarm will be generated. Move the cursor to the field and use the <+> or <-> key to adjust the threshold value. Press <ENTER> to save the change.

Rectifiers

Setpoint This value sets the system voltage for all

serial rectifiers. Move the cursor to the field and use the <+> or <-> key to adjust the threshold value. Press <ENTER> to save the change.

HVSD The configuration of this field sets the internal

high voltage shutdown value of all serial

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

rectifiers. Move the cursor to the field and use the <+> or <-> key to adjust the threshold value. Press <ENTER> to save the change.

Batteries

Model The configuration of this field selects the

installed battery type from a list of predefined battery types used in reserve time prediction and enhanced battery test features. Move the cursor to the field and use the <+> or <-> key to adjust the threshold value. Press <ENTER> to save the change.

Strings The configuration of this field selects the

number of battery strings in the system. This parameter is used in reserve time prediction and enhanced battery test features. Move the cursor to the field and use the <+> or <-> key to adjust the threshold value. Press <ENTER> to save the change.

Cells/String The configuration of this field selects the

number of installed cells in the battery strings. This parameter is used in reserve time prediction and enhanced battery test features. Move the cursor to the field and use the <+> or <-> key to adjust the threshold value. Press <ENTER> to save the change.

Type The configuration of this field selects the

batter type, Flooded or Valve Regulated (sealed). This parameter is used in reserve time prediction and enhanced battery test features. Move the cursor to the field and use the <+> or <-> key to adjust the threshold value. Press <ENTER> to save the change.

7. Thermal Comp

Issue 3 January 2008

This feature allows dynamic control of sealed

Basic Installation and User’s Guide for the Millennium II Controller

cell battery voltage as a function of temperature.

Enabled Enables or Disables the Thermal

Compensation Feature. Move the cursor to the field and use the <+> or <-> key to Enable or Disable. Press <ENTER> to save the change.

High Temp

Comp

Volt Step Down

This feature allows the system to compensate for high temperatures. Battery step temperature can be set from 113185F. At this temperature, the system voltage is reduced by 0.17 X # of cells/string.

High Comp Limit Decrease

This sets the maximum temperature for which thermal compensation is active. This sets the slope (mV/degC) for high temperature compensation.

Nominal Temp

This field set the temperature at which no compensation is required. The system voltage is at the setpoint float mode.

Low Temp Comp This feature allows the system to compensate

for low temperatures.

Low T Comp Low Comp Limit Increase

This enables or disables the low temperature compensation feature. This sets the minimum temperature for which thermal compensation is active. This sets the slope (mV/degC) for low temperature compensation.

8. Recharge Current Limit

This feature sets the total amount of current that will be allowed to recharge the batteries.

Limit

The configuration of this field enables or disables the feature.

Limit to

This programmable value sets the maximum amount of recharge current (in Amps) that will be allowed for recharging the batteries. The range is from 10 – 1000A.

9. Contactors Up to three optional LVD devices can be

connected to a Millennium and configured

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

from this screen.

Contactor 1-3

Type

This setting identifies the type of contactor, BATTERY, LOAD or NONE that has been installed in the plant. Be sure that the wiring for the contactor being configured matches the type chosen here. For standard GPS configurations using BIC cards, Contactor 1 is wired to and controls all BATTERY contactors in the plant. Contactors 2 and 3 are wired to and control only LOAD contactors. To toggle between the various contactor types, move the cursor to one of the fields and use the <+> or <-> key to select the desired type. Press <ENTER> to save the change.

Disconnect

This setting configures the plant voltage at which the contactor will disconnect from the bus. Use the <+> or <-> key to adjust the voltage to the desired level. Press <ENTER> to save the change.

Reconnect

This setting configures the plant voltage at which the contactor will reconnect to the bus. To prevent the contactor from re-operating when battery voltage increases due to load removal, a voltage several volts higher than the disconnect voltage is recommended. Use the <+> or <-> key to adjust the voltage to the desired level. Press <ENTER> to save the change.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

5 Acceptance Testing

Introduction

The Galaxy Millennium Controller is tested before it leaves the factory, but many users wish to add some test procedures as part of installation and turn-up. The tests described here will simulate various alarm conditions and verify that the controller functions properly. Follow the steps listed below in the order they are given.

Tools and Test Equipment

Tools and Test Equipment Required for Acceptance Testing

Digital Voltmeter (DVM) with dc accuracy of at least 0.05% Short length of wire or clip lead for jumper Jeweler’s screwdriver

Test Precautions

Follow these steps to test plant alarms when installing the Galaxy Millennium Controller in a new plant. In a new installation, begin the sequence with the rectifiers running with a dummy load on the plant bus bar.

For these tests, it is assumed that:

• All rectifiers are functioning properly.

• Plant batteries have received their original charges and are ready to support a

load.

If you are testing a controller in a live plant:

• Some tests will cause a battery discharge. Insure that plant batteries are capable of supporting the load.

• Alarms will be generated. Notify the appropriate alarm monitoring personnel.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Test Sequences

Lamp Test

This test verifies that All of the LEDs on the front panel of the controller are functioning properly. No alarms are generated from this test.

Step Action

1. From the Default Screen, press the Menu button for the Main Menu.

2. Using the Up/Down Arrows, Scroll to Control/Operations and press Enter.

3. Select Start Lamp Test, and press Enter.

4. Press Enter again to start the test, or Escape to return to the menus.

5. Observations:

• LCD Refreshes

• Front Panel LEDs ALL turn on momentarily and return to normal

• NO alarms are generated from this test

Front Panel Display Meter Calibration

Using a calibrated digital voltmeter, measure the plant voltage from the front panel test jacks. Follow these steps to calibrate the front panel meter display for Voltage and Current readings:

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Step Action for Voltage Calibration

1. Using the Meter Calibration Menus, reset the plant voltage reading by selecting RESET VOLTAGE. Press the Enter key to reset the voltage. This will remove any pre-existing user calibrated values if they exist.

2. Wait at least 5 seconds and press the ESCAPE key.

3. Select CALIBRATE VOLTAGE. Use the Arrows, and UP/DOWN keys to calibrate the system voltage. Press ENTER to save.

NOTE:

The controller will not allow changes greater than +/- 0.5V of the displayed voltage.

4. Press the <ESCAPE> key until the default screen is displayed. Verify that the plant voltage reading now agrees with the calibrated DVM.

NOTE:

The DVM reading will be the one to change since Rectifier Manager will adjust rectifier outputs as necessary per the calibration performed.

Step Action for Current Calibration

NOTE:

The following procedure is applicable only in plants with Load shunts in a plant configured for “Centralized Architecture.”

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

1. Using a calibrated DVM, measure the plant load from the sense connection points on the plant shunt(s).

2. Calculate the plant load, in amperes, as measured by the DVM.

a) Divide the mV DVM reading by the rated shunt mV value b) Multiply this result by the shunt ampere rating

This value is the plant load measured by the DVM, in amperes.

3. Using the Meter Calibration Menus, reset the plant Plant Current reading by selecting RESET LOAD. Press the Enter key to reset the Load. This will remove any pre-existing user calibrated values if they exist.

4. Wait at least 5 seconds and press the ESCAPE key.

5. Select CALIBRATE LOAD. Use the Arrows, and UP/DOWN keys to calibrate the system Load. Press ENTER to save.

NOTE:

The maximum total change is +/-10% of the cuurent load value.

6. Press the <ESCAPE> key until the default screen is displayed. Verify that the plant current reading has been changed.

NOTE:

This operation is performed and verified ONLY if plant load is constant during the calibration procedure. Observation:

• Displayed System load changes to new value.

High Float Voltage Alarm – New Installations

Step Action for Testing the High Float Voltage Alarm NOTE: NOTE:

Clear all controller alarms for this test. The high voltage alarm test is completed by raising the plant voltage above the threshold set for HFV (High Float Voltage) .

NOTE:

Raising the plant voltage on a working system is left to the discretion of the user.

• This test could disrupt power to working equipment.

• If the test is performed, verify that the plant is in FLOAT

mode

• Rectifier voltage has been set to the normal level after completing the test.

1. Using the Voltage Alarms Menu Screens, note High Float Alarm threshold value. _________

2. Using the Float Settings Menu Screens, select Set Point and note the value. ________

NOTE:

The next step WILL RAISE the system voltage.

3. Use the Arrows, and UP/DOWN keys to change the system float voltage setpoint to 0.1V above the High Float Alarm Threshold.. Press ENTER to save.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

4. Observe:

• The plant voltage increases to the set voltage

• Power Minor alarm (PMN) is generated

• RECT and MIN LEDs are illuminated

5. Using the Float Settings Menu Screens, select Set Point.

6. Use the Arrows, and UP/DOWN keys to change the system float voltage setpoint to it’s original value. Press ENTER to save.

7. Observe:

• The plant voltage decreases to the original set voltage

• Power Minor alarm (PMN) retires

• RECT and MIN LEDs are extinguished

High Float Voltage Alarm – Systems with Actual Loads

Step Action for Testing the High Float Voltage Alarm NOTE: NOTE: NOTE:

Clear all controller alarms for this test. The System Voltage WILL NOT change. The high float voltage alarm test is completed by changing the threshold for this condition below the system voltage to make it active.

1. Using the Float Settings Menu Screens, select Set Point and note the value. ________

2. Using the Voltage Alarms Menu Screens, note the High Float Alarm threshold value. _________

3. Use the Arrows, and UP/DOWN keys to change the High Float Alarm Threshold to 0.1V below the System Voltage. Press ENTER to save.

4. Observe:

• Power Minor alarm (PMN) is generated

• RECT and MIN LEDs are illuminated

5. Using the Voltage Alarms Menu Screens, change the High Float Alarm threshold value to it’s original value. Press ENTER to save.

6. Observe:

• Power Minor alarm (PMN) retires

• RECT and MIN LEDs are extinguished

High Voltage Shutdown – New Installations Only

STEP Action for Testing High Voltage Shutdown Alarm

NOTE:

The High Voltage Shutdown Test is recommended only for new installations where a dummy load is available prior to the application of office load, and batteries are connected.

NOTE:

There are three requirements for a serial rectifier to shut down upon a controller initiated High Voltage Alarm.

1. The plant voltage must be above the level set for the High

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Voltage alarm at the VOLTAGE ALARMS menu screen: MENUÆCONFIGUREÆFLOAT SETTINGSÆVOLTAGE ALARMS

2. The rectifier must be delivering a current of at least 10% of its capacity.

3. The rectifier’s current output must be unbalanced by more than 10% from the average output currents of the other rectifiers.

Because item 3 is difficult to achieve in a simulation test of properly functioning serial rectifiers, (even with load share disabled), rectifiers are tested one at a time, rather than as a group. Slightly different test procedures are used for special applications in batteryless plants. Serial rectifiers have their own internal restart circuits which will function 3 times before the rectifier locks itself out and initiates a High Output Rectifier Fail Alarm to the controller. If there is a sufficient interval between restart and a subsequent shutdown the rectifier resets its restart counter. The controller initiates a restart signal a few seconds after the first RFA (HO) alarm is received. After the second RFA (HO) is received, the controller waits 5 minutes before sending one additional restart signal.

1. Verify the Auto Restart is enabled from the front panel menus:

2. Turn off all rectifiers except the rectifier under test by operating their power switches to STBY.

3. Adjust the dummy load to provide 10 to 30% of the rectifier’s output capacity.

4. Using the Voltage Alarms Menu Screens, note High Voltage Alarm threshold value. _________

5. Using the Float Settings Menu Screens, select Set Point and note the value. ________

NOTE:

The next step WILL RAISE the system voltage.

6. Use the Arrows, and UP/DOWN keys to change the system float voltage setpoint to 0.1V above the High Voltage Alarm Threshold.. Press ENTER to save.

7. Controller Observations:

• The plant voltage increases

• Power Major alarm (PMJ) is generated

• RECT and MAJ LEDs are illuminated

Rectifier Observations:

• When the voltage increases to the HV (FLOAT) level the

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

rectifier shuts down.

• The Green ON LED on the rectifier blinks, the ALM LED on the rectifier is not lit.

• After 5-6 seconds the rectifier initiates its own restart signal again raising the plant voltage.

• The rectifier will shutdown and restart two additional times.

• Upon the third shutdown, the rectifier’s ALM LED lights and the rectifier’s display indicates “HO”.

• The controller receives the RFA signal from the rectifier and initiates a restart signal 5-6 seconds later.

• The rectifier restarts again raising plant voltage.

• The rectifier shuts down and restarts 3 additional times.

• During these shutdowns the Green ON LED on the

rectifier blinks and the ALM LED on the rectifier is not lit.

• Upon the fourth shutdown, the rectifiers ALM LED lights and the rectifier’s display indicates “HO”.

• Any external RFA office alarm has occurred.

• The controller will wait 5-6 minutes and issue one final

restart signal initiating the final sequence of shutdown and restart events before the rectifier locks out, requiring personnel intervention.

o Prior to this occurring, change the value of the

system voltage to its original value. Press ENTER to save the change.

o Restart the rectifier from the front panel by using

the menus:

8. Using the Float Settings Menu Screens, select Set Point.

9. Use the Arrows, and UP/DOWN keys to change the system float voltage setpoint to it’s original value This value must be at least 0.5V below the HV alarm threshold setting. Press ENTER to save.

10. Controller Observations:

Issue 3 January 2008

• The plant voltage returns to it’s original value

• Power Major alarm (PMJ) retires

Basic Installation and User’s Guide for the Millennium II Controller

• RECT and MAJ LEDs are extinguished

Rectifier Observations:

• Rectifier is operating normally

Battery on Discharge Alarm

STEP Action for Testing the Battery on Discharge Alarm

NOTE:

If the BD alarm was observed during the High Voltage Shutdown test this test can be disregarded.

1. From the front panel follow the path(Voltage Alarms):

2. Note the setting of the Battery on Discharge Threshold. ________

3. With a dummy load added to the plant, operate all rectifiers to STBY until the plant voltage drops below the BD (FLOAT) threshold.

4. Controller Observations:

• PMJ Alarm is active

• BD and MAJ LEDs are illuminated

5. Turn on all rectifiers

6. Controller Observations:

• PMJ Alarm retires

• BD and MAJ LEDs are extinguished

• System Voltage is normal

Rectifier Fail Alarm

The RFA alarm was observed during the High Voltage Shutdown Test so no separate test is required.

Major Fuse Alarm

Major Fuse Alarm may be tested by placing a blown fuse in the alarm fuse position of any distribution fuse position in the plant or by inserting a paper clip into the alarm indicating hole of its fuse holder. For distribution circuit breakers, temporarily connect the pins 8 and 9 of any KS22010 or KS22012 style circuit breakers together. This is accomplished on the ED83143-30 circuit breaker panels by shorting the (-) panel bus to pin 1 on the P4 connector of its BNL1 alarm board. Observation:

• The DIST and MAJ LEDs and Power Major and MJF alarm relays will be active.

• Remove alarm condition and verify that DIST,MAJ LEDs and MJF relay retire.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Alarms should be tested in each distribution bay of the plant to verify the integrity of the alarm bus throughout the plant. If the distribution bays are equipped with “Bay Fuse Alarm” indicating LEDs, also verify that this LED activates during these tests for the bay in which the alarm originates (and not in any other).

Clear History

This feature is useful when there is a need to remove unnecessary historical data from the controller. An example might be after installation and testing and the controller is ready for operation. There may be history that is of no use to the customer. Also, since the history log has a finite number of entries, user can save the history using a PC, and then clear the logs.

Step Action

1. From the Default Screen, press the Menu button for the Main Menu.

2. Using the Up/Down Arrows, Scroll to Control/Operations and press Enter.

3. Select Clear History, and press Enter.

4. Press Enter again to clear the History Log, or Escape to return to the menus.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

6 Controller Retrofits

Millennium Basic Controller Retrofit

This section provides a method for changing the standard J85501K-1 Millennium Basic controller with the J85501-P1, Millennium II controller.

NOTE:

Safety

Always consider personal safety before beginning any procedure. Review the Safety section. Observe antistatic precautions during the procedure. Mark and tag all cables associated with the change before starting work. Use only insulated tools. Make sure the system is properly grounded per the National Electrical Code and local building codes. Remove all metal jewelry.

This procedure will cause the office alarms to operate. Inform the operating company before starting this procedure.

Action Verified

Retrofit Materials

Material Verified

Wire cutters and strippers 18 to 22 AWG wire Jewelers screwdriver (Flat and Phillips) Small needle nose pliers Pen for Marking/Tagging connections Digital meter, +/- 0.02% Screw Drivers (flat-blade and Phillips) ESD wrist strap Wire-wrap tool or Amp alarm punch-down tool (Alarm terminations) 6-32 Nut Driver

Preparing the Controller

Preparation of the controller consists of:

• Placing the system in Float Mode

• Turn all available rectifiers on

• Noting the Dip Switch Positions that enable/disable features in hardware

• Noting the Alarm Threshold Settings and Rectifier Setpoints

• Placing any battery/load contactors in an independent, safe state

• Power Down

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Step Action

NOTE:

Verify that the Alarm center has been notified of potential alarms being generated.

Place System in Float Mode

From the Default Display of the controller, note the system mode of operation:

IF the mode is FLOAT, go to Step 2. If the mode is NOT Float (ex. – BOOST), place the system in FLOAT mode before going to Step 2.

Turn all Available Rectifiers On

If rectifiers have been manually turned off, turn them back on. Verify that all rectifiers are on and sharing load.

Noting the Dip Switch Settings

Dip Switch settings determine if some controller features are enabled or disabled. If the Millennium II controller is to have the same configurations, the old settings on SW202 must be noted:

Record the Switch Positions for future reference –

Switch

Position

SW202-8 Front Panel Configuration SW202-7 Auto Rectifier Restarts SW202-6 Critical = Major Relays SW202-5 Alarm Test SW202-4 HVSD during Alarm Test SW202-3 Boost Mode SW202-2 External Timed Boost SW202-1 Password Reset for Indep Modem

Issue 3 January 2008

Figure 6-1:

Millennium Controller Dip Switch Positions

Basic Controller (BSH) Dip Switch Settings

Description Switch Setting

(1 or 0)

Basic Installation and User’s Guide for the Millennium II Controller

Alarm Threshold Settings

Alarm thresholds are designed to generate low/high voltage alarms.

Record the Float Alarm Thresholds by selecting the following menus from the front panel display: MENU ÆCONFIGÆ ALARM THRESHOLDS

Alarm Float Boost

(optional)

High Voltage High Float Voltage Battery on Discharge Rectifier On Very Low Voltage

Plant Shunt

Shunt information should be recorded, so that it can be programmed when the new controller has been installed.

Record this information by selecting the following menus from the front panel display: MENUÆ CONFIGÆ PLANT

Shunt I Shunt mV Shunt Type

Low Voltage Disconnects

Low voltage disconnect information, if installed in the system, should be recorded, so that it can be programmed when the new controller has been installed.

Record this information by selecting the following menus from the front panel display: MENUÆ CONFIGÆ LOW VOLTAGE DISCONNECT Note: Contactor State cannot be changed by the user.

Contactor 1 Type Disconnect Reconnect

Contactor 2 Type Disconnect Reconnect

Contactor 3 Type

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Disconnect

Reconnect

Slope Thermal Compensation

Slope thermal compensation information, if implemented in the system, should be recorded, so that it can be programmed when the new controller has been installed.

Record this information by selecting the following menus from the front panel display: MENUÆ CONFIGÆ STC

STC Enabled/Disabled Nominal Temperature Step Temperature Disconnect Temperature Low Temperature Upper Temperature Raise Voltage Enable

Temperature Units

Rectifier Float Setpoints

Rectifier float setpoint determines the system voltage.

Record the float setpoint by selecting the following menus from the front panel display: MENU ÆCONFIGÆ RECT MANAGER

Plant V I limit

SHVSD

Securing Contactors

If Battery and Load contactors are in the system, contactor control boards should be configured so that they do not OPEN during the controller replacement. To ensure that these contactors do not open, force all LVLD and LVBD contactors closed. NOTE: These contactors may have already been forced closed per customer requirements. If so, then proceed to the next step.

To force LVLD contactors closed, place SW300 in the up position as shown in figure 6-2 and 6-3.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Figure 6-2: LVLD Contactor Board SW300

Figure 6-3: LVBD Contactor Control Board SW300 Full Height Cabinets

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Contactor Type Control Board and

Switch

To Force Closed,

Change to

Load EBV – SW300 UP

Battery BJN – SW300 UP for ½ height

cabinets

Down for full height

cabinets

Figure 6-4: Millennium Controller Fuse Positions

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Figure 6-5: Millennium Controller Connections

10.

Controller Power Down

Step Action

NOTE: STOP!

Before proceeding with this step, veirify that ABS supply (pins 93/94) and DG(pins 95/96) on the BSL board are not connected to anything. IF they are, perform proper transitioning procedures and move these connections to another source.

a. Using a fuse puller, remove all 5 controller fuses,

BEGINNING with F1. (see Figure 6-4)

b. Next, locate P6 and the Input Power, Shunt and

Regulation cable at the upper left hand corner of the

basic (BSH) controller. (see Figure 6-5) c. Mark, Tag and Insulate this cable as Input Power. d. Remove this connector and reposition the cable so

that it is to the right of the controller housing. The

Millennium II P6 connector is on the right side.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Removing the Old Controller

Step Action

1..

Disconnect Rectifiers from Old Controller

The RJ45 connector is located at top of the BSH board. Remove the cable connected to J8.

Step Action

a. On the Basic controller (BSH), locate J8.

(see Figure 6-5) b. Mark, Tag and Insulate the cable terminating at J8.

This is the Rectifier Control Cable. c. Remove this cable from J8 and take it out of the

Millennium housing.

Remove Alarm Wiring

Step Action

a. On the Basic controller (BSH), locate the BSL alarm

block. It is located in the upper right hand corner of

the BSH board. (see Figure 6-5) b. c. Mark, Tag and Insulate all connections terminating

on this block. You may need to reference a

Millennium controller product manual for labeling

the connections. d. Remove the alarm wires from the alarm block and

take them out of the Millennium housing.

Remove Thermal Probe(s)

Step Action

a. On the Basic controller (BSH), locate P3. It is

located at the upper left hand corner of the BSH

board, and is white connector. (see Figure 6-5) b.

If NO cable terminates on P3, then proceed to the next item for removal. If a cable terminates on P3, Mark, Tag and Remove this cable.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Remove Modem Connections

Step Action

a. On the Basic controller (BSH), locate P201. It is

located on the lower left hand side of the BSH board.

(see Figure 6-5) b.

If NO cable terminates on P201, then proceed to the next item for removal. If a cable terminates on P201, Mark, Tag and Remove this cable.

Remove Controller Display Cable

Step Action

a. On the Intelligent controller (BSJ), locate P1. It is

located at the lower right hand corner of the BSJ

board.

b. Mark, Tag and remove this cable.

Remove Millennium Controller from the Cabinet Door

With all connectors and wires removed from the Millennium circuit packs:

• Make sure that they have been removed from the Millennium housing.

• If other wires or cables are connected to the Millennium, then Mark, Tag, Insulate and remove them.

With two people, one supporting the controller, remove all 6 nuts (3 on left side and 3 on right side), using a 6-32 hex nut driver. Slowly remove the controller unit from the cabinet door.

THIS COMPLETES THE CONTROLLER REMOVAL SECTION

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Installing the Millennium II Controller

Figure 6-6: Millennium II Connections

Step Action

Mount the Millennium II Controller

With two people, one supporting the controller, position the Millennium II controller housing over the six standoffs (3 on left side and 3 on right side) on the inside of the cabinet door. Using a 6-32 nut driver, secure the controller housing to the cabinet door.

Connect the Controller Display Cable

Step Action

a. On the controller locate P1. It is located at the

lower right hand corner of the board. (see Figure 6-6)

b. Using the existing display cable, pass it through the

slot at the bottom of the controller housing and

connect it to P1.

Install Modem Connections

Step Action

a. Inside of the controller housing, determine if a

Modem card is installed. It will be located to the left of the MCR1 board. (see Figure 6-6)

If a Modem is installed:

Connect the existing telephone cable to the RJ11 connector at the top of the board

Connect Tip/Ring conductors to TB1 at the top of the board. NOTE: Tip is TB1 pin 1 (Pin closest to the RJ11 connector) and Ring is Pin 3. Pin 2 is not used.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

If a Modem is to be installed:

Please see the Modem installation section, in this manual.

Connect Alarm Wiring

Step Action

a. On the controller, locate the BSL alarm block. It is

located in the upper right hand corner of the MCR1 board. (see Figure 6-6)

NOTE:

It is very important, in the next step, to follow the

Alarm Input/Output table in this manual when connecting the alarms. Some Pins may have changed their function.

b. Route the alarm wires through the open holes above

the alarm block and terminate them accordingly. You may need to reference the Millennium II Alarm Input/Output section for proper connections.

Step Action

Controller Power Up

Step Action

NOTE:

F1 is the bottom of the two fuses.

a. Using a fuse puller, remove F1 on the MCR1 board.

This is the controller power fuse. (see Figure 6-6)

b. Next, locate P6 at the right hand corner of the

MCR1 board. (see Figure 6-6)

c. Route the J6 power connector through the top right

opening of the controller housing. Secure this to P6. d. Using a fuse puller, Install F1 on the MCR1 board. e. Observe the controller power up sequence.

Hardware/Software Dip Switch Settings

Some features which originally required enabling/disabling through a dip switch, now require software enabling.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Figure 6-7: Millennium Controller Switch Locations

Refer to the Switch Settings section in the Removal section.

Millennium Controller – Millennium II Dip Switch Settings Mapping

Millennium

Description Millennium II Setting

Switch

Position

NOTE:

Position 8 is the leftmost dip switch

SW202-8 Front Panel

Configuration

SW202-7 Auto Rectifier

0 if Millennium was 0 1 if Millennium was 1

Using the front panel, go to:

Restarts

Enabled if Millennium was 1 Disabled if Millennium was 0

SW202-6 Critical = Major

Relays

Using the front panel, go to:

MenuÆConfigÆSystem Settings

Enabled if Millennium was 1 Disabled if Millennium was 0

SW202-5 Alarm Test Using the front panel, go to:

MenuÆConfigÆAlarm Test

Enabled if Millennium was 1 Disabled if Millennium was 0

SW202-4 HVSD during Alarm

Test

Using the front panel, go to:

MenuÆConfigÆAlarm Test

Enabled if Millennium was 1 Disabled if Millennium was 0

SW202-3 Boost Mode Using the front panel, go to:

Set SW202-8 to:

MenuÆConfigÆPlant

Config Auto Restart to:

Config Crit=Major to:

Config Test to:

Config HV Shutdown to:

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

MenuÆConfigÆRect Boost

Config Enable to:

Enabled if Millennium was 1

SW202-2 External Timed

Boost

Disabled if Millennium was 0

Using the front panel, go to:

MenuÆConfigÆRect Boost

Config Timed to:

Enabled if Millennium was 1

SW202-1 Password Reset for

Disabled if Millennium was 0

Not Applicable for Millennium II

Indep Modem

Configuring the Millennium II Controller

Step Action

Setting the Date/Time

Set the Time and Date to the present.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Plant Shunt

Enter this information, recorded earlier, by selecting the following menus from the front panel display:

Shunt I Shunt mV Shunt Type

Low Voltage Disconnects

Enter the Low Voltage Disconnect information recorded earlier, by selecting the following menus from the front panel display:

Contactor 1 Type Disconnect Reconnect

Contactor 2 Type Disconnect Reconnect

Contactor 3 Type Disconnect Reconnect

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Slope Thermal Compensation

Enter the STC information recorded earlier, by selecting the following menus from the front panel display:

Millennium

Controller

Millennium II

Configuration Item

Description

STC

Enabled Enabled/Disabled Nominal

Nominal (Under High Temp Comp) Temperature Step

Volt Step Down (Under High Temp Comp) Temperature Disconnect

Value Recorded from Old

Controller

Low Temperature Upper Temperautre Raise Voltage Low T Comp (Under Low Temp Comp)

Issue 3 January 2008

Low Comp Limit (Under Low Temp Comp)

High Comp Limit (Under High Temp Comp)

Basic Installation and User’s Guide for the Millennium II Controller

Temperature Units

N/A Decrease (Under High Temp Comp) Consult

N/A Increase (Under Low Temp Comp) Consult

Alarm Threshold Settings

Enter the Float Alarm Thresholds recorded earlier, by selecting the following menus from the front panel display:

customer

for this

value in

mV/deg C

customer

for this

value in

mV/deg C

High Voltage High Float Voltage Battery on Discharge Very Low Voltage

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Rectifier Float Setpoints

Enter the float setpoint by selecting the following menus from the front panel display:

Plant V I limit SHVSD

Connect Serial Rectifier Cable

The RJ45 connector is located at top of the MCR1 board and is labeled P9. (see Figure 6-6)

Step Action

a. Locate P9 (Not to be confused with P7-Aux) b. Using the existing serial cable, connect to P9.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Removing the Forced Contactor Conditions

If Battery and Load contactors are in the system, contactor control boards should have be configured so that they did not OPEN during the controller replacement. NOTE: Contactors may have always been in the FORCED state per customer requirements. If no changes were made to the Contactor States in the “Securing Contactors” section, then DO NOT change the switch positions. To return contactors to their normal state, place SW300 in the position as shown In figure 6-2 and 6-3.

Contactor Type Control Board and

Switch

Under Millennium II

Control

Load EBV – SW300 DOWN

Battery BJN – SW300 DOWN for ½ height

cabinets

UP for full height

cabinets

9. If a Gateway or Data Switch option will be used, see the New Installation section for instructions.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Millennium Intelligent Controller Retrofit

This section provides a method for changing the standard J85501K-1 Millennium Intelligent controller with the J85501-P1, Millennium II controller.

NOTE:

Safety

• This procedure will cause the office alarms to operate. Inform the operating company before starting this procedure.

• Inform all personnel responsible for the power system that History and Statistics will be lost, unless written to file before power down.

Action Verified

Retrofit Materials

Material Verified

Preparing the Controller

Preparation of the controller consists of:

• Placing the system in Float Mode

• Turn all available rectifiers on

• Backing up the existing configuration so that it may be loaded onto the new

controller

• Writing history and statistics files (If required)

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

• Noting the Dip Switch Positions that enable/disable features in hardware

• Placing any battery/load contactors in an independent, safe state

• Power Down

Figure 6-8: Millennium Controller Dip Switch Locations

Figure 6-9: Millennium Controller Fuses

Step Action

Note:

Verify that the Alarm center has been notified of potential alarms being generated.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Place System in Float Mode

From the Default Display of the controller, note the system mode of operation:

If the mode is FLOAT, go to Step 2. If the mode is something other than Float (ex. – BOOST), place the system in FLOAT mode before going to Step 2.

Turn all Available Rectifiers On

If rectifiers have been manually turned off, turn them back on. If they have been placed in standby because of the Energy Management feature of the controller, then disable this by changing Dip Switch 204-1 on the intelligent controller board to DISABLED. (see Figure 6-8) Verify that all rectifiers are on and sharing load.

Backup Configuration –A Computer is Required

A system backup is required if the present configuration is to be used in the Millennium II. Configuration items include but are not limited to the following:

• Remote Peripheral Monitors

• User Defined Alarms

• Changes to Standard/Threshold Alarm Default Values

• Battery Management Features

Using a computer, connect to the Millennium either locally or remotely and perform a backup, saving the file so that it may be loaded into the Millennium II.

NOTE: If the backup is performed using Easy View:

Once connected to the controller, select the FILE Æ BACKUP menu and proceed with the backup.

Write History to File

If controller history logs are to be saved, then they must be written to a file. NOTE: History logs CANNOT be loaded into the Millennium II. They can only be printed, viewed and exported to other programs.

Using a computer, connect to the Millennium either locally or remotely and write the History log(s) to a file.

NOTE: If using Easy View:

Once connected to the controller, select the REPORTS Æ HISTORY menu and proceed with saving this information.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Write Statistics to File

If controller statistics are to be saved, then they must be written to a file. NOTE: Millennium Controller Statistics CANNOT be loaded into the Millennium II. They can only be printed, viewed and exported to other programs.

Using a computer, connect to the Millennium either locally or remotely and write the Statistics to a file.

NOTE: If using Easy View:

Once connected to the controller, select the REPORTS Æ STATISTICS menu and proceed with saving this information.

Noting the Dip Switch Settings

Dip Switch settings determine if some controller features are enabled or disabled. If the Millennium II controller is to have the same configurations, the old settings must be noted: (see Figure 6-8)

Record the Switch Positions for future reference –

Basic Controller (BSH) Dip Switch Settings

Switch

Position

IntelligentController (BSJ) Dip Switch Settings

Switch

Position

SW203-8 Remote Rectifier in Standby SW203-7 Remote Rectifier Turn On SW203-6 Full Access through Local Port SW203-5 Full Access through Aux Port SW203-4 Full Access through Modem Port SW203-3 Modem/Local/Aux Setting Config SW203-2 Local Port(Event Log or Terminal) SW203-1 Aux Port(RS232 or RS485) SW204(4-8) NOT USED SW204-3 Enhanced Remote Security SW204-2 Remote Alarm Test SW204-1 Rectifier Energy Management

Description Switch Setting

(1 or 0)

Description Switch Setting

(1 or 0)

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Securing Contactors

To force LVLD contactors closed, place SW300 in the up position as shown in figure 6-2 and 6-3.

Contactor Type Control Board and

Switch

To Force Closed,

Change to

Load EBV – SW300 UP

Battery BJN – SW300 UP for ½ height

cabinets

DOWN for full

height cabinets

Disconnect Rectifiers from Old Controller

The RJ45 connector is located at top of the BSH board. Remove the cable connected to J8. (see Figure 6-10)

Step Action

a. On the Basic controller (BSH), locate J8. b. Mark, Tag and Insulate the cable terminating at J8.

This is the Rectifier Control Cable.

c. Remove this cable from J8 and take it out of the

Millennium housing.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Figure 6-10: Millennium Controller Connections

Controller Power Down

Step Action

NOTE: STOP!

a. Next, locate P6 and the Input Power, Shunt and

Regulation cable at the upper left hand corner of the

basic (BSH) controller. (see Figure 6-10) b. Mark, Tag and Insulate this cable as Input Power. c. Remove this connector and reposition the cable so

that it is to the right of the controller housing. The

Millennium II P6 connector is on the right side.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Removing the Old Controller

Step Action

Remove Alarm Wiring

Step Action

a. On the Basic controller (BSH), locate the BSL alarm

block. It is located in the upper right hand corner of

the BSH board. (see Figure 6-10) b. c. Mark, Tag and Insulate all connections terminating

at on this block. You may need to reference a

Millennium controller product manual for labeling

the connections. d. Remove the alarm wires from the alarm block and

take them out of the Millennium housing.

Step Action

Remove RPM Wiring (Bus)

a. On the Intelligent controller (BSJ), locate TB200. It

is located at the top of the BSJ board. (see Figure 6-

10)

If NO cable terminates on TB200, then proceed to the next item for removal. If a cable terminates on TB200, Mark, Tag and Remove this cable.

Remove Thermal Probe(s)

Step Action

a. On the Basic controller (BSH), locate P3. It is

located at the upper left hand corner of the BSH

board, and is white connector. (see Figure 6-10) b.

If NO cable terminates on P3, then proceed to the next item for removal. If a cable terminates on P3, Mark, Tag and Remove this cable.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Remove Modem Connections

Step Action

a. On the Intelligent controller (BSJ), locate P201. It

is located on the left hand side of the BSJ board. (see

Figure 6-10) b.

If NO cable terminates on P201, then proceed to the next item for removal. If a cable terminates on P201, Mark, Tag and Remove this cable.

Remove Data Switch Cables

Step Action

a. On the Intelligent controller (BSJ), locate P205. It

is located on the left hand side of the BSJ board. b.

If NO circuit board is connected to P205, then proceed to the next item for removal.

If a circuit board is connected to P205, with DB9 connectors, Mark, Tag and Remove these

cables, making note the Port numbers they are connected to.

Remove PC Serial Port

Step Action

a. On the Intelligent controller (BSJ), locate P202. It

is located at the bottom of the BSJ board. (see Figure

6-10) b.

If NO cable is connected to P202, then proceed to the next item for removal. If a cable is connected to P202, Mark, Tag and Remove this cable.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Remove Aux Port

Step Action

a. On the Intelligent controller (BSJ), locate P203. It

is located at the top of the BSJ board. (see Figure 6-

10)

If NO cable terminates on P203, then proceed to the next item for removal. If a cable terminates on P203, Mark, Tag and Remove this cable.

c. On the Intelligent controller (BSJ), locate TB201. It

is located at the top of the BSJ board. (see Figure 6-

10)

If NO wires terminate on TB201, then proceed to the next item for removal. If wires terminate on TB201, Mark, Tag and Insulate these wires and remove them. Make sure to mark:

TB-201

Name

Terminal

1 TX+ 2 TX3 RX+ 4 RX-

Remove Controller Display Cable

Step Action

a. On the Intelligent controller (BSJ), locate P1. It is

located at the lower right hand corner of the BSJ

board. b. Mark, Tag and remove this cable.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Remove Millennium Controller from the Cabinet Door

With all connectors and wires removed from the Millennium circuit packs:

• Make sure that they have been removed from the Millennium housing.

• If other wires or cables are connected to the Millennium, then Mark, Tag, Insulate and remove them.

With two people, one supporting the controller, remove all 6,6-32 nuts (3 on left side and 3 on right side). Slowly remove the controller unit from the cabinet door.

THIS COMPLETES THE CONTROLLER REMOVAL SECTION

Installing the Millennium II Controller

Figure 6-11: Millennium II Controller Connections

Step Action

Mount the Millennium II Controller

With two people, one supporting the controller, position the Millennium II controller housing over the six standoffs (3 on left side and 3 on right side). Using 6, 6-32 nuts, secure the controller housing to the cabinet door. (Torque to 10 in-lbs, or 1.1 N-m)

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Connect the Controller Display Cable

Step Action

a. On the controller locate P1. It is located at the

lower right hand corner of the board.

b. Using the existing display cable, route it through the

bottom of the controller housing and connect it to P1

Connect PC Serial Port

Step Action

If NO cable was connected to P202 on the Millennium, then proceed to the next item for

connection.

If a cable was connected to P202, AND The Front panel display is a L51 display:

Verify that J1 on the display is connected to P202 on the MCR1 board. IF NOT, Using the cable assy (comcode – 848570115),connect J1 on the display to P202 on the MCR1 board. Connect the serial port cable to the front of the Display by pulling up on the tab covering the local port.

If a cable was connected to P202, AND The Front panel display is a L50 display:

Route the serial cable through the rectangular opening at the top of the controller housing and connect it to P202 on the MCR1 board. NOTE: Use a DB9-DB9 Ribbon Cable connector so that the controller cover can be installed while using the port.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Install Data Switch Cables

Step Action

a. b.

If NO circuit board was connected to P205, on the old Millennium, then proceed to the next item for connection. If a circuit board was connected to P205, with DB9 connectors AND the Data Switch option is installed (circuit

pack connected to P205), connect them to Data Switch Ports 1-3.

IF the Data Switch card has not yet been installed, please see Data Switch installation section in this manual.

Install Gateway (LAN) Cable

Step Action

a. On the controller (MCR1), locate P2 (Gateway

LAN). It is located at the bottom of the controller. (see Figure 6-11)

If NO Gateway card was installed in the Millennium, then proceed to the next item for

connection.

If Gateway card was installed in the Millennium:

1. Take the existing LAN cable and route it through the top of the controller housing

2. Down the right side

3. Through the bottom of the housing

4. Under the display cable

5. Connect it P2 on the MCR1.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Install Modem Connections

Step Action

a. Inside of the controller housing, determine if a

Modem card is installed. It will be located to the left of the MCR1 board. (see Figure 6-11)

IF a Modem is installed:

Connect the existing telephone cable to the RJ11 connector at the top of the board OR Connect Tip/Ring conductors to TB1 at the top of the board. NOTE: Tip is TB1 pin 1 (Pin closest to the RJ11 connector) and Ring is Pin 3. Pin 2 is not used.

If a Modem is to be installed:

Please see the Modem installation section, in this manual.

Install Thermal Probe

Step Action

If NO cable terminated on P3 on the Millennium, then proceed to the next item for

connection. If a cable terminated on P3 on the Millennium, connect the old cable to P3 on the Millennium II. P3 is a white connector located at the top of the MCR1 board. (see Figure 6-11)

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Connect Alarm Wiring

Step Action

a. On the controller, locate the BSL alarm block. It is

located in the upper right hand corner of the MCR1 board. (see Figure 6-11)

NOTE:

It is very important, in the next step, to follow the

Alarm Input/Output table in this manual when connecting the alarms. Some Pins may have changed their function.

b. Route the alarm wires through the open holes above

the alarm block and terminate them accordingly. You may need to reference the Millennium II Alarm Input/Output section for proper connections.

Connect RPM Bus Wire

Action

If NO cable terminated on TB200 on the Millennium, then proceed to the next item for

connection.

If a cable terminated on TB200 on the Millennium, connect the old bus cable to TB1 on

the Millennium II. (see Figure 6-11)

NOTE:

Wrap the cable through the EMI inductor bead twice. Place the bead approximately 3 inches from the end of the cable, closest to the controller.

TB- 1 Pin

Assignments

TB-1 Pin

Descriptions

RPM

Conductor

RPM Conductor

Description

Color

6 *6 Blue or

Power/Communications

White

8 *8 Blue or

Power/Communications

White

9 or 10 FGND Bare wire Shield

*connections of the bus wire are NOT polarity sensitive.

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

10.

11.

Aux Port Connections

Step Action

a. On the controller, locate TB1. It is located at the top

of the board. (see Figure 6-11)

If NO wires terminated on P203 with the old Millennium, then proceed to the next item for

installation.

If a cable terminated on P203, with the old Millennium, install the wires according to the

table below:

TB1 on

Millennium

Wires from

Millennium

1 TX+ 2 TX3 RX+ 4 RX-

c. If a cable terminated on P203 with the old

Millennium, it was most likely a Gateway interface cable. With the Millennium II, since the Gateway is integrated, there is no need to connect a cable to the Aux port, which is a new RJ45 connector anyway.

Hardware/Software Dip Switch Settings

Whereas the Millennium controller had 3 sets of dip switches, the Millennium II only has one set. Some features which originally required enabling/disabling through a dip switch, now require software enabling.

Refer to the Switch Settings section in the Removal section.

Millennium Controller – Millennium II Dip Switch Settings Mapping

Millennium

Description Millennium II Setting

Switch

Position

SW202-8 Front Panel

Configuration

SW202-7 Auto Rectifier

Restarts

0 if Millennium was 0 1 if Millennium was 1

Set SW202-8 to:

Using the front panel, go to:

MenuÆConfigÆPlant

Issue 3 January 2008

Basic Installation and User’s Guide for the Millennium II Controller

Enabled if Millennium was 1 Disabled if Millennium was 0

SW202-6 Critical = Major

Relays

MenuÆConfigÆSystem Settings

Enabled if Millennium was 1 Disabled if Millennium was 0

SW202-5 Alarm Test Using the front panel, go to:

Enabled if Millennium was 1 Disabled if Millennium was 0

SW202-4 HVSD during Alarm

Test

Enabled if Millennium was 1 Disabled if Millennium was 0

SW202-3 Boost Mode Using the front panel, go to:

Enabled if Millennium was 1 Disabled if Millennium was 0

SW202-2 External Timed

Boost

Enabled if Millennium was 1 Disabled if Millennium was 0

SW202-1 Password Reset for

Not Applicable for Millennium II

Indep Modem

IntelligentController (BSJ) Dip Switch Settings

Millennium

Description Millennium II Setting

Switch

Position

SW203-8 Remote Rectifier in

Standby

0 if Millennium was 0 1 if Millennium was 1

SW203-7 Remote Rectifier

Turn On

Enabled if Millennium was 1 Disabled if Millennium was 0

SW203-6 Full Access through

Local Port

Using the front panel, go to: MenuÆConfigÆComm PortsÆLocal Port

Config Auto Restart to:

Using the front panel, go to:

Config Crit=Major to:

MenuÆConfigÆAlarm Test

Config Test to:

Using the front panel, go to:

MenuÆConfigÆAlarm Test

Config HV Shutdown to:

MenuÆConfigÆRect Boost

Config Enable to:

Using the front panel, go to:

MenuÆConfigÆRect Boost

Config Timed to:

Set SW202-4 to:

Using the front panel, go to:

MenuÆConfigÆPlant

Config Remote On to:

Config Write to:

Issue 3 January 2008

100

GE Industrial Solutions J85501P-1 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

1 Introduction

Millennium II

Customer Service Contacts

2 Product Description

Overview

Feature Summary

General Specifications

Hardware

3 Safety

Safety Statements

Warning Statements and Safety Symbols

Precautions

Special Installation Notes

4 New Installations

Controller Connections

Installing Circuit Packs

Thermal Probes

USB Interface

Wiring Alarm Outputs

Wiring Alarm and Control Inputs

Fuses

Front Panel Display

Controller Defaults

Controller Display Menu Maps

5 Acceptance Testing

Introduction

Tools and Test Equipment

Test Precautions

Test Sequences

6 Controller Retrofits

Millennium Basic Controller Retrofit

Millennium Intelligent Controller Retrofit