Off Line Equalization (OLE)
Panel and Converter
for GPS4848 and GPS4812
ED83143-30 G60/G61 (Panel)
ES671 (Converter)
Product Manual
Select Code 167-792-200
Comcode 108626409
Issue 4
January 2008
Product Manual
Select Code 167-792-200
Comcode 108626409
Issue 4
January 2008
Off Line Equalization (OLE)
Panel and Converter
for GPS4848 and GPS4812
ED83143-30 G60/G61 (Panel)
ES671 (Converter)
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.
© 2008 Lineage Power
All International Rights Reserved
Printed in U.S.A.
Off Line Equalization Panel and Converter for GPS4848/GPS4812
Table of Contents
1 Introduction
Off Line Equalization Panel and Converter 1 - 1
Overview 1 - 1
OLE Panel 1 - 1
Converter 1 - 1
Documentation References 1 - 2
Product Manual 1 - 2
Drawings 1 - 2
Customer Service Contacts 1 - 2
Customer Service, Technical Support,
Product Repair and Return 1 - 2
Customer Training 1 - 2
Warranty Service 1 - 2
On-Line Power Systems Product Manuals 1 - 2
EasyView Software 1 - 2
2 Product Description
Overview 2 - 1
Introduction 2 - 1
Safety Certifications 2 - 1
EMI Performance 2 - 1
OLE Panel 2 - 2
Illustration 2 - 2
Features 2 - 2
ES671 Converter 2 - 3
Illustration 2 - 3
Features 2 - 3
3 Converter Status Indicators
Front Panel 3 - 1
Status Indicator LEDs 3 - 1
Illustration 3 - 1
LED Functions and Descriptions 3 - 2
Issue 4 January 2008 Table of Contents - 1
Off Line Equalization Panel and Converter for GPS4848/GPS4812
4 Converter Installation
Installation Guidelines and Procedures 4 - 1
Guidelines 4 - 1
Installation Sequence 4 - 2
5 Converter Installation Testing
Checking Converter Operation 5 - 1
Test Procedure 5 - 1
6 Off Line Equalization Operation
Preparation 6 - 1
Equalization 6 - 2
Output Voltage Adjustment 6 - 4
Partially Discharged Batteries 6 - 5
Equalization Completion 6 - 6
Introduction 6 - 6
Returning to Normal Operation 6 - 6
7 Product Warranty
2 - Table of Contents Issue 4 January 2008
Off Line Equalization Panel and Converter for GPS4848/GPS4812
List of Figures
Figure 2-1: ED83143-30 Off Line Equalization (OLE) Panel 2 - 2
Figure 2-2: ES671 Converter 2 - 3
Figure 3-1: Front Panel of ES671 Converter 3 - 1
Figure 4-1: Switch Positions on the ES671 Converter 4 - 2
Figure 4-2: Home Position on the OLE Panel 4 - 3
Figure 6-1: Voltage Measurement Points 6 - 3
Issue 4 January 2008 List of Figures - 1
Off Line Equalization Panel and Converter for GPS4848/GPS4812
List of Tables
Table 3-A: LED Functions and Descriptions 3 - 2
Issue 4 January 2008 List of Tables - 1
Off Line Equalization Panel and Converter for GPS4848/GPS4812
1 Introduction
Off Line Equalization Panel and Converter
Overview This product manual describes the Off Line Equalization Panel and
Converter designed for use in distributed architecture configurations of
Lineage Power -48V Galaxy Power Systems GPS4848 and GPS4812.
OLE Panel The Off Line Equalization (OLE) Panel is primarily a three-string
battery connection panel with a built-in capability to disconnect a
battery string and apply an equalization voltage to the off-line battery
string.
There are two available Off Line Equalization Panels:
• ED83143-30 G60, with a Low Voltage Battery Disconnect (LVBD)
contactor
• ED83143-30 G61, without a Low Voltage Battery Disconnect
(LVBD) contactor
Converter The ES671 is a removable, integrated DC/DC converter that generates
the equalization voltage that is applied to the off-line battery string.
Issue 4 January 2008 Introduction 1 - 1
Off Line Equalization Panel and Converter for GPS4848/GPS4812
Documentation References
Product Manual This product manual is part of a set of documentation developed to assist
engineering, installation, and maintenance personnel.
Drawings Additional product information is available on the following drawings:
ED83143-30 Off Line Equalization Panel
H569-436 GPS4812
H569-434 GPS4848
T83314-30 Wiring Diagram
Customer Service Contacts
Customer Service, Technical Support, Product Repair and Return, and Warranty Service
Customer Training Lineage Power offers customer training on many Power Systems
Downloads and Software
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.
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.
To download the latest product information, product software and
software upgrades, visit our web site at
http://www.lineagepower.com
1 - 2 Introduction Issue 4 January 2008
Off Line Equalization Panel and Converter for GPS4848/GPS4812
2 Product Description
Overview
Introduction The distributed architecture configurations of the -48V GPS4848 and
GPS4812 Galaxy Power Systems can be fitted with the Off Line
Equalization (OLE) Panel. The panel can be ordered with or without a
Low Voltage Battery Disconnect (LVBD) contactor.
One panel per bay can be used in multi-bay systems. Each panel
occupies 15 inches of vertical space in the bay.
The OLE panel will accept a custom designed DC/DC converter
(ES671) that provides power to a battery string section taken off line to
be equalized.
Figure 2-1 illustrates the OLE Panel, and Figure 2-2 illustrates the
ES671 DC/DC Converter.
Safety Certifications
EMI Performance EMI performance continues to meet CISPR 22 Class B for emissions
The safety certifications (UL, CE, and/or VDE) applicable to the
installation bay (GPS4848 or GPS4812) will still apply when the
optional OLE panel and converter are installed.
with the OLE panel installed. However, the system emissions only meet
Class A when the ES671 converter is operating and batteries are being
equalized.
Issue 4 January 2008 Product Description 2 - 1
OLE Panel
Illustration
Off Line Equalization Panel and Converter for GPS4848/GPS4812
Contactor Control Card
Converter Output Connector
In Home Position
Connects to
Charge Return Bus
Pilot Fuses
(3) 600A Fuses
(3) 1000A Shunts
Figure 2-1: ED83143-30 Off Line Equalization (OLE) Panel
Features • Low Voltage Battery Disconnect (LVBD) contactor (optional) with
the associated drive circuitry to disconnect all three battery string
sections
• Connection points for up to three separate battery string sections
• Battery shunt for each battery string section (1000A)
• Protection fuse for each battery string section (315-500A)
• Circuitry to provide controller interface for fuse alarms and shunt
monitoring
• Manual mechanism to disconnect the battery string sections
individually from the main charge bus and to connect them to the
OLE converter voltage for equalization
• Slot to accommodate a single OLE DC/DC Converter (ES671) that
is powered from the main charge bus
2 - 2 Product Description Issue 4 January 2008
Off Line Equalization Panel and Converter for GPS4848/GPS4812
ES671 Converter
Illustration
Features • Pluggable design
• Adjustable output voltage (56-67Vdc)
• Automatically timed shut-off (12 or 24 hours)
• Shutdown on plant alarm
• Internal current limit (66A or 100A nominal)
• DC input from the main charge bus of the system
• On/Standby switch on the front panel for local, manual control
• Alarm circuitry to indicate internal faults and OLE non-availability
• Capability to withstand connection to a partially or fully discharged
battery string without damage to the converter or delivering
excessive current to the battery
• Front panel indicators (see Table 3-A)
Figure 2-2: ES671 Converter
Issue 4 January 2008 Product Description 2 - 3
Off Line Equalization Panel and Converter for GPS4848/GPS4812
3 Converter Status Indicators
Front Panel
Status Indicator LEDs
Illustration
The front panel of the ES671 converter has three status indicator LEDs:
• On/Standby (LED #1)
• Alarm (LED #2)
• Equalize Current (LED #3)
Refer to Figure 3-1 for an illustration of the ES671 converter front panel,
and to Table 3-A for the function and description of the three status
indicator LEDs on the panel.
On –
Standby
Alarm
Equalize
Current
Output
Adjust
Figure 3-1: Front Panel of ES671 Converter
Issue 4 January 2008 Converter Status Indicators 3 - 1
Off Line Equalization Panel and Converter for GPS4848/GPS4812
Front Panel, continued
LED Functions and Descriptions
Table 3-A: LED Functions and Descriptions
LED Function Description
On/
Standby
(LED #1)
Alarm
(LED #2)
Power ON
(OLE on, with power
applied)
Standby (switch in
Standby position)
(OLE in charge mode
and providing current
>8A)
Battery voltage too
low (after trickle
charge interval)
Timer expiration Yellow, blinking
Plant alarm Red, flashing (resets when
Converter alarm
(output voltage <55V
or >67V)
(OLE fault)
Green, continuous
Yellow, continuous
Yellow/Green, alternating
plant alarm cleared)
Red, continuous
Equalize
Current
(LED #3)
Converter thermal
alarm
Converter delivering
power (>8A)
Completed timed
equalization interval
(12/24 hour)
Red, flashing (remains on
until converter is reset; this
distinguishes it from a plant
alarm)
Yellow, continuous
Yellow, blinking
3 - 2 Converter Status Indicators Issue 4 January 2008
Off Line Equalization Panel and Converter for GPS4848/GPS4812
4 Converter Installation
Installation Guidelines and Procedures
Guidelines • The ES671 DC/DC Converter is installed in the left-most slot of the
ED83143-30 panel.
• A single converter may be used in multiple panels in multiple
plants since the use of the OLE function is limited to a regular
maintenance schedule, and it is desirable that no more than one
battery string section per plant be taken off line at any given time.
Issue 4 January 2008 Converter Installation 4 - 1
Off Line Equalization Panel and Converter for GPS4848/GPS4812
Installation Guidelines and Procedures, continued
Installation Sequence
Installing the ES671 Converter
Step Action
1
Ensure that the front panel switch on the converter is in
the Standby position.
2
Set the time interval switch to the desired position
(12/24 hours). See Figure 4-1.
3
Set the current limit switch to the desired position. See
Figure 4-1.
66A
CURRENT
LIMIT
100A
12HR
EQUALIZE
TIME
24HR
Figure 4-1: Switch Positions on the ES671 Converter
Continued on next page.
4 - 2 Converter Installation Issue 4 January 2008
Off Line Equalization Panel and Converter for GPS4848/GPS4812
Installation Guidelines and Procedures, continued
Installing the ES671 Converter, continued
Step Action
4
Retaining
Screw
5
Ensure that the Converter output connector on the
ED83143-30 panel is in the Home Position. See Figure
4-2.
Converter Output Connector
In Home Position
Converter
Figure 4-2: Home Position on the OLE Panel
Push converter firmly into the slot, ensuring that the
bottom of the converter is aligned in the plastic rail in the
slot.
6
Screw in the retaining screw at the bottom of the
converter front panel.
7
Plug the interface connector
into the socket on the front
of the converter, ensuring
On –
Standby
full insertion and latching.
Alarm
Equalize
Current
Output
Adjust
Issue 4 January 2008 Converter Installation 4 - 3
Socket for
Interface
Connector
Off Line Equalization Panel and Converter for GPS4848/GPS4812
5 Converter Installation Testing
Checking Converter Operation
Test Procedure After completing the converter installation, use the following test
procedure to verify that the ES671 converter operates correctly.
Testing the Converter After Installation
Step Action
1
2
3
4
5
6
Verify that the converter output connector is in the Home
Position on the panel.
Switch on the converter. Verify that the On/Standby
LED remains in the Yellow condition.
Note: The output of the converter is interlocked with a
signal that is only received when the output is connected
to one of the battery string connectors.
Connect a resistive dc load box in place of one of the
battery strings.
Remove the pilot fuse associated with the battery string
connector selected for the load box.
Switch the converter to Standby. Remove the battery
fuse attached to the load box and replace with the
converter output connector.
Verify that the plant voltage is 52-56V. If not, adjust to
within this range.
Note: If a live load is already connected, verify that this is
acceptable before making any plant voltage changes.
Continued on next page.
Issue 4 January 2008 Converter Installation Testing 5 - 1
Off Line Equalization Panel and Converter for GPS4848/GPS4812
Checking Converter Operation, continued
Testing the Converter After Installation, continued
Step Action
7
8
9
10
11
12
13
Switch the load box to zero current, and switch on the
converter. Apply a load of 10-15A. Using a DVM
connected as shown in Figure 6-1, verify that an output
voltage is generated.
Note: The output voltage should be in the range of
56-67V and be adjustable using the front panel trim
potentiometer.
Adjust the output voltage to the desired value.
Switch the converter to Standby and return the plant to
normal operating voltage.
Remove the converter output connector and disconnect
the load box.
Reconnect the battery string, if applicable.
Replace the battery fuse, returning the batteries to float
condition.
Replace pilot fuse.
5 - 2 Converter Installation Testing Issue 4 January 2008
Off Line Equalization Panel and Converter for GPS4848/GPS4812
6 Off Line Equalization Operation
Preparation
Guidelines It is important that the battery string to be equalized be fully charged
prior to performing the equalization operation. To ensure full state of
charge, equalization should not be performed within 48 hours after a
significant discharge event.
Issue 4 January 2008 Off Line Equalization Operation 6 - 1
Off Line Equalization Panel and Converter for GPS4848/GPS4812
Equalization
Notes • During the equalization process the gassing rate of the batteries will
be dramatically increased. Ensure that adequate ventilation is
provided during this period.
• During the equalization process the converter status LEDs should
be as follows:
– On/Standby LED is Green, indicating On.
– Alarm LED is not lit.
– Equalize Current LED is Yellow, indicating current >10A.
• As the equalization process proceeds the battery current will
steadily decrease and the Equalize Current LED will go off; this is
normal operation.
• At the end of the 12/24-hour period the converter should switch to
standby mode, and LEDs should be as follows:
– On/Standby LED is Yellow, indicating Standby.
– Alarm LED is not lit.
– Equalize Current Yellow LED is flashing, indicating that the
equalization process is complete.
• The equalization process will terminate automatically after a period
of time set by the switch on the back of the converter (12/24 hours).
6 - 2 Off Line Equalization Operation Issue 4 January 2008
Off Line Equalization Panel and Converter for GPS4848/GPS4812
Equalization, continued
Procedure
Step Action
Equalization Procedure
1
2
3
Remove the battery string pilot fuse.
Remove the battery string power fuse.
Ensure converter is switched Off and set to desired time
interval (12/24 hours).
4
5
Install converter.
Insert the equalize cable into the battery string fuse block
that was vacated in Step 1.
6
Turn the converter On and adjust the output voltage.
DANGER
High voltage during equalize mode.
7
Verify that the voltage being applied to the battery string
reaches the desired value. When the voltage is first applied
to the battery the converter will usually go into current
limit, and the current limit setting will regulate the voltage.
Once the charge on the battery string has increased to where
the converter is no longer in current limit, the voltage can
be verified using a DVM at the points indicated in Figure
6-1.
Converter Output
Connector Home Position
Converter Output
Connector
DVM
Connects to
Charge Return Bus
Figure 6-1: Voltage Measurement Points
Issue 4 January 2008 Off Line Equalization Operation 6 - 3
Off Line Equalization Panel and Converter for GPS4848/GPS4812
Output Voltage Adjustment
Guidelines If the output voltage of the converter is not at the desired level, it can be
adjusted using the trim potentiometer on the converter front panel.
Voltage should be monitored using a portable DVM at the points shown
in Figure 6-1.
Note
It is important that adjustment of the output voltage be done slowly to
allow the voltage on the battery string to keep up with the converter
adjustment, since rapid changes can cause the converter to current
limit. When the converter is in current limit the output voltage does
not track the set point voltage.
Once the voltage has stabilized at the required level the DVM can be
removed and equalization can be completed.
6 - 4 Off Line Equalization Operation Issue 4 January 2008
Off Line Equalization Panel and Converter for GPS4848/GPS4812
Partially Discharged Batteries
Guidelines If the battery string voltage is less than the plant float voltage (Vf) the
equalization process will not start. In this situation, the converter will
attempt to raise the voltage to Vf using the built-in “trickle charge”
mode. In this mode the output current of the converter is limited to
approximately 3A for a period of about ten minutes. During trickle
charge mode it is normal for the Alarm LED (Red) to be lit, indicating
that the output voltage is outside the acceptable range.
If at the end of this 10-minute period the voltage is still lower than Vf,
the converter will shut down and the On/Standby LED will alternate
(Yellow/Green), indicating low battery voltage. Also, the Alarm LED
(Red) will be on, indicating that the output voltage is out of the
acceptable range. If during the 10-minute trickle charge period the
battery voltage rises to Vf, the converter will automatically switch to
normal Equalize mode and the Alarm LED will extinguish. (There may
be a delay of 20-30 seconds as the battery voltage rises above 56V
before the Alarm LED extinguishes.)
Issue 4 January 2008 Off Line Equalization Operation 6 - 5
Off Line Equalization Panel and Converter for GPS4848/GPS4812
Equalization Completion
Introduction As indicated previously, equalization can be terminated by the
automatic timer in the converter or by switching off the converter
manually. Use the following procedure to return the plant to normal
operation after termination of the equalization process.
Returning to Normal Operation
Returning to Normal Operation
Step Action
1
Switch the converter to the off (Standby) state and return
the battery string to the main charge bus by disconnecting
the converter output connector from the battery string
position and returning it to the home position.
2
Replace the battery fuse, noting the following warning.
Warning
The equalization process raises the battery string
voltage considerably above the plant bus voltage.
Before reconnecting the battery string to the charge
bus, allow the battery string to self-discharge back to
a voltage close to the plant float voltage (V
). This will
f
take 10-60 minutes, depending on the capacity of the
battery string and the equalization voltage used.
Failure to allow the battery string to self-discharge
may result in damage to the fuse connector contacts
and possible personal injury.
3
Once the battery has self-discharged and the battery fuse
has been replaced, replace the battery pilot fuse.
6 - 6 Off Line Equalization Operation Issue 4 January 2008
Off Line Equalization Panel and Converter for GPS4848/GPS4812
7 Product Warranty
A. Seller warrants to Customer only, that:
1. As of the date title to Products passes, Seller will have the right to sell,
transfer, and assign such Products and the title conveyed by Seller shall be
good;
2. During the warranty period stated in Sub-Article B below, Seller’s
Manufactured Products (products manufactured by Seller), which have been
paid for by Customer, will conform to industry standards and Seller’s
specifications and shall be free from material defects;
3. With respect to Vendor items (items not manufactured by Seller), Seller
warrants that such Vendor items, which have been paid for by Customer, will
be free from material defects for a period of sixty (60) days commencing
from the date of shipment from Seller’s facility.
B. The Warranty Period listed below is applicable to Seller’s Manufactured
Products furnished pursuant to this Agreement, commencing from date of
shipment from Seller’s facility, unless otherwise agreed to in writing:
Warranty Period
Product Type New Product Repaired Product*
Central Office
Power Equipment
*The Warranty Period for a repaired Product or part thereof is six (6) months
or, the remainder of the unexpired term of the new Product Warranty Period,
whichever is longer.
C. If, under normal and proper use during the applicable Warranty Period, a defect
or nonconformity is identified in a Product and Customer notifies Seller in
writing of such defect or nonconformity promptly after Customer discovers such
defect or nonconformity, and follows Seller's instructions regarding return of
defective or nonconforming Products, Seller shall, at its option attempt first to
repair or replace such Product without charge at its facility or, if not feasible,
provide a refund or credit based on the original purchase price and installation
charges if installed by Seller. Where Seller has elected to repair a Seller’s
Manufactured Product (other than Cable and Wire Products) which has been
installed by Seller and Seller ascertains that the Product is not readily returnable
for repair, Seller will repair the Product at Customer’s site.
24 Months 6 Months
Issue 4 January 2008 Product Warranty 7 - 1
Off Line Equalization Panel and Converter for GPS4848/GPS4812
With respect to Cable and Wire Products manufactured by Seller which Seller
elects to repair but which are not readily returnable for repair, whether or not
installed by Seller, Seller at its option, may repair the cable and Wire Products at
Customer’s site.
D. If Seller has elected to repair or replace a defective Product, Customer shall have
the option of removing and reinstalling or having Seller remove and reinstall the
defective or nonconforming Product. The cost of the removal and the
reinstallation shall be borne by Customer. With respect to Cable and Wire
Products, Customer has the further responsibility, at its expense, to make the
Cable and Wire Products accessible for repair or replacement and to restore the
site. Products returned for repair or replacement will be accepted by Seller only
in accordance with its instructions and procedures for such returns. The
transportation expense associated with returning such Product to Seller shall be
borne by Customer. Seller shall pay the cost of transportation of the repaired or
replacing Product to the destination designated by Customer.
E. Except for batteries, the defective or nonconforming Products or parts which are
replaced shall become Seller's property. Customer shall be solely responsible for
the disposition of any batteries.
F. If Seller determines that a Product for which warranty service is claimed is not
defective or nonconforming, Customer shall pay Seller all costs of handling,
inspecting, testing, and transportation and, if applicable, traveling and related
expenses.
G. Seller makes no warranty with respect to defective conditions or nonconformities
resulting from actions of anyone other than Seller or its subcontractors, caused by
any of the following: modifications, misuse, neglect, accident, or abuse;
improper wiring, repairing, splicing, alteration, installation, storage, or
maintenance; use in a manner not in accordance with Seller’s or Vendor’s
specifications or operating instructions, or failure of Customer to apply
previously applicable Seller modifications and corrections. In addition, Seller
makes no warranty with respect to Products which have had their serial numbers
or month and year of manufacture removed, altered, or experimental products or
prototypes or with respect to expendable items, including, without limitation,
fuses, light bulbs, motor brushes, and the like. Seller’s warranty does not extend
to any system into which the Product is incorporated. This warranty applies to
Customer only and may not be assigned or extended by Customer to any of its
customers or other users of the Product.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE IN LIEU OF
ALL OTHER EXPRESS AND IMPLIED WARRANTIES, INCLUDING BUT NOT
LIMITED TO WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. CUSTOMER’S SOLE AND EXCLUSIVE REMEDY
SHALL BE SELLER’S OBLIGATION TO REPAIR, REPLACE, CREDIT, OR
REFUND AS SET FORTH ABOVE IN THIS WARRANTY.
7 - 2 Product Warranty Issue 4 January 2008
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