Professional Documents
Culture Documents
Note: Instructions in this manual reference installation and setup of the Galaxy
Millennium Controller. For Galaxy Millennium II installation and setup,
refer to the Millennium II Product Manual 167-792-181.
Installation Guide
Select Code 167-792-157
Comcode 108327362
Issue 10
February 2008
Installation Guide
Select Code 167-792-157
Comcode 108327362
Issue 10
February 2008
Installation Guide
for Galaxy Power Systems
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.
Table of Contents
1
Introduction
Product Documentation
This Installation Guide
Revisions
Related Documentation
Customer Service Contacts
Customer Service, Technical Support, Product
Repair and Return, and Warranty Service
Customer Training
Downloads and Software
1-1
1-1
1-1
1-1
1-3
1-3
1-3
1-3
Safety
Safety Statements
Warning and Safety Symbols
Precautions
Special Installation Notes
German
Spanish
2-1
2-3
2-4
2-9
2-9
2-11
Getting Started
Tools and Hardware
Torque Settings for Hardware
Unpacking
Location
3-1
3-3
3-4
3-4
4-1
4-2
4-3
4-6
5-2
5-12
5-13
5-14
5-16
5-16
5-16
5-19
Table of Contents - 1
6-1
6-1
6-2
6-2
6-4
6-7
6-9
6-9
6-11
6-11
6-13
2 - Table of Contents
8-1
8-2
8-3
8-3
8-3
8-4
8-4
8-5
8-20
8-20
Converters
Introduction
Installing the Converter Carrier
Setting the CIC ID
Converter Wiring
10
9-1
9-2
9-4
9-5
11
10-1
10-1
10-2
10-2
10-3
12
11-1
11-2
11-3
11-4
11-7
11-7
11-7
11-8
11-9
11-9
11-10
11-11
12-1
12-2
12-3
12-3
12-4
12-5
12-5
12-6
12-6
12-7
12-8
12-11
12-12
12-13
Table of Contents - 3
13
14
13-1
13-2
15
14-1
14-1
16
4 - Table of Contents
15-1
15-1
15-2
15-3
15-4
15-4
15-5
15-6
15-6
15-7
15-9
15-11
15-12
15-13
15-14
15-15
15-17
15-19
15-21
15-22
15-23
15-24
15-25
15-25
16-1
16-2
16-5
16-6
16-7
List of Figures
2-5
4-2
4-4
4-5
4-6
5-2
5-2
5-3
5-4
5-5
5-6
5-7
5-8
5-9
5-10
5-11
5-15
5-17
5-18
List of Figures - 1
2 - List of Figures
5-19
6-3
6-6
6-8
6-10
6-11
6-12
6-14
6-16
7-5
7-6
7-7
7-10
7-11
7-12
7-13
7-14
7-15
7-16
7-17
7-18
7-19
7-20
7-21
7-22
7-23
7-24
7-25
7-26
7-27
7-28
List of Figures - 3
8-3
8-5
8-6
8-7
8-8
8-9
8-10
8-11
8-12
8-13
8-14
8-15
8-16
8-17
8-18
8-19
8-20
9-3
9-3
9-4
9-6
9-7
9-8
10-2
Issue 10 February 2008
10-5
10-6
10-7
10-8
10-9
11-3
11-4
11-5
11-6
11-9
11-10
12-3
12-4
12-5
12-5
12-6
12-7
12-9
12-10
12-11
12-12
12-13
List of Figures - 5
6 - List of Figures
13-2
14-2
14-3
14-4
15-2
15-2
15-3
15-3
15-9
15-10
15-20
16-3
16-5
16-7
16-8
List of Tables
2-6
2-7
3-3
5-12
5-13
7-2
7-8
7-9
8-2
10-1
11-2
12-2
List of Tables - 1
Introduction
Product Documentation
This Installation
Guide
Revisions
Related
Documentation
GPS2424/30
Ordering Guide
Manufacturing Drawings
H569-437
ED83142-30 (AC)
ED83143-31 (DC)
J85582E-1 (System)
T83314-30
167-792-159
Wiring Diagram
Users Guide
GPS4812/24
Ordering Guide
Manufacturing Drawings
H569-436
ED83142-30 (AC)
ED83143-31 (DC)
J85582E-1 (System)
T83314-30
167-792-161
Wiring Diagram
Users Guide
GPS4848/100
Ordering Guide
Manufacturing Drawings
Wiring Diagram
Users Guide
H569-434
ED83142-30 (AC)
ED83143-31 (DC)
J85582C-1 (System)
T83314-30
167-792-155
Introduction 1 - 1
J85501K-1
T83413-30
167-792-180
T83314-30
167-792-112
167-792-115
J85501G-1
T83275-30
SD-83275-01
167-790-063
EasyView Software
Product Manual
193-104-105
1 - 2 Introduction
193-104-106
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
Downloads and
Software
Introduction 1 - 3
Safety
Safety Statements
Please read and follow all safety instructions and warnings before
installing, maintaining, or repairing a Galaxy Power System. Reference
the individual module product manuals for additional safety statements
specific to the modules.
Safety 2 - 1
2 - 2 Safety
DANGER
Indicates the presence of a hazard that will cause death or severe personal injury if the
hazard is not avoided.
WARNING
Indicates the presence of a hazard that can cause death or severe personal injury if the hazard
is not avoided.
CAUTION
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.
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.
Safety 2 - 3
Precautions
When working on or using this type of equipment, the following
precautions should be noted:
The Galaxy Power System 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 Galaxy Power System may be powered by multiple ac inputs.
Make sure that the appropriate circuit protection device for each ac
input being serviced is disconnected before servicing the equipment.
If batteries are connected to the Galaxy Power System, disconnecting
the ac alone will not necessarily remove power to the equipment.
Make sure the equipment is not also powered by the batteries or the
batteries are not connected to the output of the equipment.
High leakage currents may be possible on this type of equipment.
Make sure the equipment is properly safety earth grounded before
connecting power.
Hazardous energy and voltages are present in the Galaxy Power
System and on the interface cables that can shock or cause serious
injury. Exercise care and follow all safety warnings and practices
when servicing this equipment.
Load cables must be sized in accordance with the cable lengths
shown in Table 2-A and Figure 2-1 to keep short circuit currents less
than the interrupt ratings of dc protectors in each panel (as shown in
Table 2-B).
2 - 4 Safety
Precautions, continued
Safety 2 - 5
Precautions, continued
Note: Provide cable run lengths as least as long as the minimum length
indicated in Table 2-A to assure that the short circuit currents are less
than the interrupt current rating of the fuse or circuit breaker chosen.
1. Find the interrupt current rating of the chosen fuse or circuit
breaker from Table 2-B.
2. See Table 2-A for the minimum length (L) for the engineered cable
size to be run at the interrupt rating found in Step 1.
A minimum cable length for a given cable size and protector type must
be used to ensure proper short circuit protection in the case of a bolted
fault.
Table 2-A: Cable Run Lengths
Cable Size
10 GA
(6mm2)
8 GA
(10 mm2)
6 GA
(16 mm2)
4 GA
(25 mm2)
2 GA
(35 mm2)
1/0 GA
(50 mm2)
2/0 GA
(70 mm2)
4/0 GA
(120 mm2)
(2) 4/0 GA
((2) 120 mm2)
(3) 4/0 GA
((3) 120 mm2)
350 MCM
(2) 350 MCM
(3) 350 MCM
2 - 6 Safety
--
5 feet
--
--
8 feet
--
5 feet
12 feet
--
8 feet
19 feet
3 feet
12 feet
30 feet
5 feet
19 feet
--
6 feet
24 feet
--
10 feet
38 feet
--
19 feet
76 feet
--
29 feet
113 feet
--
17 feet
32 feet
47 feet
63 feet
125 feet
188 feet
----
Precautions, continued
Table 2-B: Interrupt Current Ratings for Fuses
and Circuit Breakers
Description
Large bolt-in circuit breakers
Small plug-in circuit breakers
Small bullet-style circuit breakers
Large fuse (TPL)
Medium fuse (TPS)
Small plug-in fuse (TPA)
DIN-style fuses
DIN-style circuit breakers
Interrupt
ED83143-31
Current
Rating
Groups
(amps)
1, 2, 5
25,000
11, 12
10,000
15 - 17
10,000
54 - 55
100,000
53
100,000
11, 12
100,000
Not available from Lineage Power.
Contact fuse or circuit breaker manufacturer.
Not available from Lineage Power.
Contact fuse or circuit breaker manufacturer.
Safety 2 - 7
Precautions, continued
Electricity produces magnetic fields that can affect implanted
medical electronic devices, such as pacemakers. The strength of the
magnetic field depends on the amount of current in the circuit, as
well as other conditions (such as number of conductors, placement,
and distance from the conductor). DC power and distribution
systems, including the batteries, that are typically used in
telecommunications utility rooms can operate at high current levels.
Personnel with electronic medical devices need to be aware of their
restrictions when working around electricity.
In addition to proper job training and safety procedures, the
following are some basic precautions that should always be used:
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.
Use only properly insulated tools.
Remove all metallic objects (key chains, glasses, rings, watches,
or any other jewelry).
Wear safety glasses.
Test circuits before touching.
Lock out and tag any 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 any
wiring).
Use care when removing or replacing any covers; avoid
contacting any circuits.
Note: Refer to Section 15, Power Up and Installation Completion, for
precautions and proper methods for handling rectifiers and converters.
2 - 8 Safety
Safety 2 - 9
H569-434
H569-436
H569-437
Ausgangsspannungen
-48
-48
+24
und -stme
14,080
2400
3000
2 - 10 Safety
50/60Hz
Las dimensiones son nicamente para referencia:
(Dimensions are for Reference only)
600mm x 500mm (H569-436, H569-437)
600mm x 600mm (H569-434)
Temperatura mxima de operacin:
(Max. operation temperature)
40C (104F) for H569-434
45C (113F) for H569-436 and H569-437
Advertencia: Para una proteccin continua contra incendios,
reemplace por el mismo tipo y clasificacin de fusible.
(Warning: For continued protection against fire replace with same
type and rating of fuse.)
La fuente de alimentacin es un equipo clase I
(Power Supply is a Class I Equipment)
Voltaje y corriente de salida
(Output Voltage and Current)
(Acceso restringido) (Restricted access)
Adecuado para sistemas de 4 conductores o de 5 conductores.
(Suitable for 4 conductor or 5 conductor systems)
Se requiere un interruptor de desconexin de la lnea principal
en la instalacin (Mains disconnect switch required in the
installation.)
Sin cabina contra incendios, suelo no combustible (No fire
enclosure, non-combustible floor)
Debe estar anclado al piso (Must be bolted to the floor)
Nmero de modelo H569-436, H569-437: Evaluado en
EN60950 (Evaluated to EN60950)
Safety 2 - 11
Getting Started
Tools and
Hardware
You will need the following tools and hardware to install the Galaxy
Power System:
Material-handling equipment to unload the cabinet at the installation
site, remove from shipping container, and set in final position
[minimum lifting capacity: 900 lbs. (410Kg)] Note: Use the
equipment weights and dimensions as a guideline for choosing
material-handling equipment.
Drill and drill bits to install floor anchors
3/16-inch (5mm) Allen-head wrench (provided)
Insulated hand tools
Screw drivers (flat-blade and Phillips)
Wire cutters and stripper
Torque wrenches (see Table 3-A)
35-513 inlbs (4-58 Nm)
Sockets:
Metric
8mm
10mm
13mm
17mm
19mm
---
English Equivalent
5/16"
-1/2"
11/16"
3/4"
3/8"
9/16"
Hardware
M5
M6
M8
M10
M12
1/4"
3/8"
Getting Started 3 - 1
22-16 gauge
10-500 MCM (5-120mm2)
Jewelers screwdriver
Digital multimeter (DMM) with 0.05% accuracy on dc scale
Load box (100 amperes @ 24V)
Load box (200 amperes @ 48V)
Laptop or personal computer (PC) loaded with Windows 3.1 or later
(optional)
ESD wrist strap*
*Equipment is ESD sensitive. It is required that an ESD wrist strap
be worn during installation and repair. An ESD wrist strap
(408157105) is provided with each controller.
3 - 2 Getting Started
Torque (Nm)
Torque (inlbs)
M2
0.24
M2.5
0.48
M3
0.9
M3.5
1.4
12
M4
18
M5
35
M6
62
M8
18
145
M10
34
300
M12
58
513
English
Screw Size
Torque (Nm)
Torque (inlbs)
6-32
1.1
10
8-32
2.3
20
10-32
2.8
25
12-24
35
1/4-20
65
5/16-18
15
135
3/8-16
27
240
Getting Started 3 - 3
Unpacking
Location
3 - 4 Getting Started
Introduction
Battery
String
AC
AC
Cabinet
Ground
AC
Ground
Battery
Shunt
Cabinet
Ground
AC
Ground
System (CO)
Ground
System (CO)
Ground
To Loads
Battery
Shunt
To Loads
Control
and
Monitor
Control
and
Monitor
Battery String(s)
Mounted Below
Half Height Cabinet
Half Height Cabinet
Distributed Architecture
A distributed architecture is best thought of as small systems combined
together to form a much larger system. Each small system (cabinet)
contains an entire dc power system that includes ac input, rectifiers,
battery connection modules (with external batteries), and dc distribution
modules.
The dc power generated by the rectifiers and supported by the batteries
in a given cabinet will approximately equal the dc power distributed to
the loads from that cabinet. The dc power of each cabinet is electrically
interconnected so that power may be shared (up to 1200A) between the
cabinets. This sharing allows the system of cabinets to handle
imbalances in cabinet loads (due to improper sizing or to rectifier or
battery module failure).
Distributed architecture is summarized as follows: Each cabinet
(system) generates and distributes all the dc power it needs but is able to
borrow, or give up, power (up to 1200A) from other cabinets in the
system. Growth of the system is accomplished by adding another
cabinet (system) and interconnecting it to the original cabinets (system).
Multiple-cabinet configurations are shown in Figure 4-2 (two-cabinet
configuration) and Figure 4-3 (three-cabinet (or more) configuration).
Battery
String
AC
Battery
String
AC
Shared DC Power
Cabinet
Ground
AC
Ground
Battery
Shunt
Cabinet
Ground
AC
Ground
System (CO)
Ground
To Loads
Battery
Shunt
To Loads
Control
and
Monitor
Initial Cabinet
Supplemental Cabinet
AC
Battery
String
AC
Ground
Shared DC Power
Cabinet
Ground
AC
Battery
String
AC
Ground
AC
Shared DC Power
Cabinet
Ground
Battery
String
AC
Ground
Cabinet
Ground
System (CO)
Ground
To Loads
To Loads
To Loads
Control
and
Monitor
Controller
Rectifier
Battery
Distribution
Cabinet
Rectifier
Battery
Distribution
Cabinet
Rectifier
Battery
Distribution
Cabinet
Centralized Architecture
The centralized architecture is best thought of as all the rectifiers and all
the batteries in the system connected together at a central point and then
taken from that central point to the distribution modules and then in turn
to the system loads. Since all the system power is brought together at a
central point, the central point must be sized for the ultimate capacity of
the system. Growth of the system is accomplished by adding rectifiers
(either to an existing cabinet or in a new cabinet), adding distribution
panels (either to an existing cabinet or in a new cabinet), and adding
batteries.
Figure 4-4 illustrates the centralized architecture.
System (CO)
Ground
Charge Bus
Battery Strings
AC
To Loads
AC
Cabinet
Ground
AC
Cabinet
Ground
Cabinet
Ground
Cabinet
Ground
Control
and
Monitor
Controller
Rectifier
Cabinet
Rectifier
Only
Cabinet
Rectifier
Only
Cabinet
Distribution
Only
Cabinet
Illustrates
5-1
5-2
5-3
5-4
5-5
5-6
5-7
5-8
5-9
5-10
5-11
5-12
5-13
5-14
5-15
Cabinet Installation
12V, 310Ah
6V, 630Ah
6V, 700Ah
848275509
6A-75-11
3A-75-21
3A-75-23
12V, 390Ah
6V, 785Ah
6V, 865Ah
848275517
6A-75-13
3A-75-25
3A-75-27
12V, 470Ah
6V, 945Ah
6V, 1025Ah
848275533
6A-75-15
3A-75-29
6A-75-31
12V, 550Ah
6V, 1100Ah
6V, 1175Ah
848275558
3A-85-33
6V, 1400Ah
848299673
Step
1
For:
GPS4812/24, GPS2424/30, or GPS4848/100
2VR375 Battery Stand
2VR250 Battery Stand
12IR125LP Battery Stand
Step
Central Office
Ground Procedure
Cabinet Ground
Action
Centralized or Distributed
Architecture Connections
Multiple-Cabinet Installations
Special
Requirements
Centralized Architecture
Introduction
DC Power
Connections to
Central Bus Bar
Step
Run and connect new wires from positive and negative bus
bars in each cabinet to charge and charge return centralized
bus bars located outside the equipment.
Note: In centralized architectures all return wires from the
load must be terminated to the external discharge return bus.
These return wires may not be terminated in the cabinet.
To Centralized
Charge Battery Bus Bar
To Centralized Charge
Ground Bus Bar
Rectifier Output
Negative for 48V systems
Positive for 24V systems
Return
Positive for 48V systems
Negative for 24V systems
Type
405348228
405348236
406021725
405348251
405347923
407890763
407890748
407850833
407890755
406335141
407890730
Bat/Rtn
Bat/Rtn
Bat/Rtn
Bat/Rtn
Bat/Rtn
Bat/Rtn
Bat/Rtn
Bat/Rtn
Bat/Rtn
Bat/Rtn
Bat/Rtn
Metric
Std Wire Ga Flex Wire Ga
Wire Size
(Class I)
(Class B)
(mm2)
1/0
-50
2/0
1/0
70
-2/0
-4/0
---4/0
120
350
---350
-500
---500
-750
---750
--
Hardware Kit
(Grade 2)
847867132
(One or two
required per
connection.)
(Note)
Action
Cut the regulation wires that run from the controller to the rear bus
bars in the cabinet (RB and RG, Slate and Black wires, respectively).
Remove and discard the ends of the wires that run to the cabinet bus
bars.
Run new wires from the central bus bars; butt splice to the cut wires
that remain connected to the controller.
Note: If central bus bars have LVBD, sense leads must be on the
rectifier side of the contactor.
System Shunt for Galaxy Millennium Controller
Step
Action
To System Shunt
To System Bus Bars
Butt Splice
Action
Remove the regulation wires that run from the BLJ terminals on the
controller (V1+ and V1-, Black and Slate wires) to the cabinet bus
bars.
Step
Action
BLJ Board
Distributed Architecture
Intercabinet DC
Power Bus
Connections
Step
Step
1
BLJ2/3
1st Cabinet
J5
J5
J6
J6
BLJ2/3
2nd Cabinet
J7
Millennium
Controller
To Rectifiers
in This Cabinet
Factory Installed
J7
Leave Resistor In
Place If Last Cabinet
or
Remove Resistor and
Connect to J6 of Next
Cabinet
To Rectifiers
in This Cabinet
Set the DIP switch on the BLJ2/3 board for the bay ID number.
(Factory default is Bay 1.)
Bay ID S1.1 S1.2 S1.3 S1.7 S1.8
1
0
0
0
0
0
2 (shown) 0
0
1
0
0
3
0
0
0
1
0
4
0
1
0
1
0
5
0
0
0
0
1
6
0
1
0
0
1
7
0
0
0
1
1
8
0
1
0
1
1
9
1
0
0
0
0
10
1
1
0
0
0
11
1
0
0
1
0
12
1
1
0
1
0
13
1
0
0
0
1
14
1
1
0
0
1
15
1
0
0
1
1
16
1
1
0
1
1
17
0
0
1
0
0
18
0
1
1
0
0
19
0
0
1
1
0
20
0
1
1
1
0
21
0
0
1
0
1
22
0
1
1
0
1
23
0
0
1
1
1
24
0
1
1
1
1
25
1
0
1
0
0
26
1
1
1
0
0
27
1
0
1
1
0
28
1
1
1
1
0
29
1
0
1
0
1
30
1
1
1
0
1
31
1
0
1
1
1
32
1
1
1
1
1
1
0
S1.5
0
1
0
1
0
1
0
1
S1.6
0
0
0
0
1
1
1
1
Step
To Battery Shunt
in 1st Cabinet
+ SH1
+ SH2
+ SH3
+ SH4
+ SH1
+ SH2
+ SH3
+ SH4
To Battery Shunt
in 2nd Cabinet
see above
To Next Cabinet
As Required
J5
J5
J6
BLJ3 With
Vector Controller
J7
1st Cabinet
J6
BLJ3
2nd Cabinet
To Rectifiers
in This Cabinet
Factory Installed
J7
Leave Resistor In
Place If Last Cabinet
or
Remove Resistor and
Connect to J6 of Next
Cabinet
To Rectifiers
in This Cabinet
Step
Set the DIP switch on the BLJ3 board. (Factory default for DIP switches is 0.)
Contactors
Alarm Outputs
Unused
Alarm Inputs
Fuses
Unused
Power In/Out
Vector Controller
Vector
Controller
Board
Board
Not Shown
(GCM2, GCM3)
To Rectifiers
Unused
Shunts 1 and 2
System Configuration
DIP Switches
To Modem/
Gateway/
Local Terminal
Unused
Thermal Inputs
Unused
Plant Voltage
Bay
Regulation Input Alarm Out
26 Conductor
Ribbon Cable
S1
Front Panel
Control/Display
1
0
1
3 4 5 6 7 8
S1.6: - Set to 0
1. Setting both SW1.2 and SW1.5 to "1" will result in activating the HV alarm cont act.
2. SW1.2 setting will only be read by the software when the GCM is powered up.
Safety
Reference
Information
Attaching AC Conduit
Figure 7-2
Figure 7-3
Figure 7-4
Figure 7-5
Figure 7-6
Figure 7-7
Figure 7-8
Figure 7-9
Figure 7-10
Figure 7-11
Figure 7-12
Figure 7-13
Figure 7-14
Figure 7-15
Figure 7-16
Figure 7-17
Figure 7-18
Figure 7-19
Figure 7-20
Figure 7-21
Figure 7-22
Metric (mm2)
10
10
50
16
65
25
85
35
115
1/0
50
150
2/0
70
175
4/0
120
230
Note: For NEC code compliance, all wire sizing calculations are made assuming
75C rated wire. Lineage Power recommends the use of 90C rated wire, which
has a higher current carrying capacity, for all ac connections.
AC Input Schemes
595 Rectifiers (48V,
200A) and 595LT
Rectifiers (48V,
220A)
595 and 595LT series rectifier input and output voltages are as shown
below.
Input
Rectifier
Output
48Vdc
596 series rectifier input and output voltages are as shown below.
Input
176-264Vac, 1-phase, 50/60 Hz
Rectifier
Output
48Vdc
596B series
24Vdc
Note: All wire sizes are based on the US National Electric Code.
AC Cable Routing
Caution: Follow all local codes and practices when performing the steps
to connect ac to the power system.
Step
AC Cable Routing
Action
Connecting AC Conduit
Rectifier Positions
AC
Feeds
Rectifiers
ED83142-30
H569-434
GPS4848/100
4
6
4
6
4
6
3
4
2
4
10
11
20, 220
21
22
23
70, 270
71
4
6
8
4
6
8
5
5
18
5
5
18
24, 224
25
129, 131
26, 226
27
128, 130
3
4
25
2
4
24
10
11
320
321, 421
335
322
323
334
370
371, 471
5
5
18
26
26
5
5
18
26
26
324
325, 425
331
329
333
326
327, 429
330
328
332
None
None
28
29
H569-436
GPS4812/24
H569-437
GPS2424/30
6
7
6
6M
6M
71H
72F
73F
74H
74F
71H
72F
73F
74H
74F
8
9
9
8
76H
77F
78F
79F
76H
77F
78F*
-
21
19
23
171H
172F
173F
22
22
20
20
22
175H
176H
177F
178F
179F
Rectifiers
4
8
12
16
8
AC Input Panels
Figure 7-6: ED83142-30 Group 4 (H569-434 G21, G23, G321, G323, G421)
AC Input Panel for 595A, B, LTA, LTB, or C (DA) Series Rectifiers
Figure 7-12: Wire Termination for ED83142-30 G-8, G9, G20, G22
(H569-436 G76H, G77F, G78F, G79F, G175H, G176H, G177F, G178F, G179F;
H569-437 G76H, G77F, G78F)
Figure 7-15: ED83142-30 Group 18 (H569-434 G128, G129, G130, G131, G224, G226, G330, G331)
AC Input Panel for 595A or 595B Series Rectifiers
Figure 7-18: ED83142-30 Group 20, 22 (H569-436 G175H, G176H, G177F, G178F, G179F)
AC Input Panel for 596D Series Rectifiers
7 - 24 AC Connection and Wiring
Figure 7-21: Neutral AC Input for ED83142-30 G6, G7, G19, G21 or G23 H569-436 G71H,
G72F, G73F, G171H, G172F, G173F; H569-437 G71H, 72F, or G73F
Standard cabinets are designed to that ac, battery, and dc load cables are
run through the top of the cabinet. Any of the battery panels and dc load
panels may also be used in cabinets arranged for feeding ac or dc cables
from the floor. However, only G22 and G26 ac panels are available for
these cabinets (see Figure 7-22). For ac input from the bottom of the
cabinet, these panels have a 2 inch diameter hole in the back to accept a
90 conduit fitting. Suffixes of these ac panels indicate the cabling
arrangements listed below:
AC
Panel
Suffix
Cabling Arrangement
AC
Step
Overview
Height
(in.)
14
14
22
22
3
6
6
9
9
6
CB Large
CB Large
3
5
6
9
2
5
CB Large
CB Large
5
6
9
12
5
1
CB Large
CB Bullet
CB Bullet
CB Bullet
CB Bullet
CB Bullet
CB Bullet
Fuse Medium
Fuse Medium
Fuse Large
Fuse Large
Fuse Large
Fuse Large
Fuse Large
CB DIN Small
CB DIN Small
CB DIN Large
CB DIN Large
Fuse DIN 10 x 38mm
Fuse DIN 10 x 38mm
Fuse DIN 14 x 51mm
Fuse DIN 14 x 51mm
Fuse DIN NH00
Fuse DIN NH00
Fuse DIN NH2
Fuse DIN NH2
Small Fuse, 6-GMT
Blank Panel
Blank Panel
Blank Panel
Blank Panel
6
10
10
14
14
22
22
10
10
2
2
2
5
5
14
14
10
10
14
14
10
10
8
8
2
2
6
-
12
6
6
6
6
9
9
6
6
6
9
9
9
9
6
6
6
6
6
6
6
6
6
6
6
6
0
3
6
9
12
1
15
15
16
16
17
17
53
53
56, 56A
55
55
54
54
71/171
71/171
71/171
71/171
71/171
71/171
71/171
71/171
22
22
21
21
58
JD
JA
JB
JC
Fuse or CB
LVLD
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
ED83143-31
11
11
12
12
2
H569-434 GPS4848/
H569-436 GPS4812/24 H569-437 GPS2424/30
100
40, 50, 40A, 50A
45, 45A, 55, 55A
41, 51, 41A, 51A
46, 46A, 56, 56A
42, 42A, 106, 106A,
107, 107A, 108, 108A,
109, 109A
47, 47A
48, 48A, 110, 110A,
111, 111A, 112, 112A,
113, 113A
48B, 48C
43, 43A, 101, 101A,
102, 102A, 103, 103A,
104, 104A
43B, 43C
96, 96A
96B, 96C
97, 97A
97B, 97C
98, 98A
98B, 98C
52, 52A
52B, 52C
59, 59A
53, 53A
57, 57A
54, 54A
54B, 54C
60, 60A
60B, 60C
61, 61A
61B, 61C
65, 65A
65B, 65C
66, 66A
66B, 66C
67, 67A
67B, 67C
68, 68A
68B, 68C
58
93
90
91
92
42C, 42D
44A, 44B
42C, 42D
44A, 44B
44C, 44D
43A, 43B
44C, 44D
43A, 43B
43C, 43D
46A, 46B
46C, 46D
47A, 47B
47C, 47D
48A, 48B
48C, 48D
52A, 52B
52C, 52D
43C, 43D
46A, 46B
46C, 46D
47A, 47B
47C, 47D
48A, 48B
48C, 48D
52A, 52B
52C, 52D
53A, 53B
53C, 53D
54A, 54B
54C, 54D
60A, 60B
60C, 60D
61A, 61B
61C, 61D
65A, 65B
65C, 65D
66A, 66B
66C, 66D
67A, 67B
67C, 67D
68A, 68B
68C, 68D
58
93
90
91
92
53A, 53B
53C, 53D
54A, 54B
54C, 54D
60A, 60B
60C, 60D
61A, 61B
61C, 61D
65A, 65B
65C, 65D
66A, 66B
66C, 66D
67A, 67B
67C, 67D
68A, 68B
68C, 68D
58
93
90
91
92
Connecting Loads
Cable Routing
Strategy
Capacitor Charge
Unit
Step
Mounting Small
Plug-in Circuit
Breakers and
Fuses
Secure the breaker to the input bus bar with the 3/8"
hardware provided.
Secure the output bus bar to the plastic standoffs with the
M6 screws provided.
Secure the breaker to the output bus bar with the 3/8"
hardware provided.
Place the ring terminal provided between the bus bar and the
securing hardware.
Disrtibution Panels
Converters
Introduction
In This Section
This section covers the installation of the optional converter carrier and
the connection of the converter ground reference to the system ground
for the GPS2424/30 only.
Converters 9 - 1
Step
1
9 - 2 Converters
Converters 9 - 3
Step
Remove the CIC card from the carrier. On the front side of
the CIC (component side), the cover is scored so that the
CIC ID switch may be exposed.
9 - 4 Converters
Converter Wiring
Refer to Figures 9-4, 9-5, and 9-6 for the following procedure.
Step
Converter Wiring
Action
Connect the 48V load and return wires from the converter
carrier to the using equipment. (See Figure 9-4 for converter
carrier connection.)
Converters 9 - 5
9 - 6 Converters
Converters 9 - 7
9 - 8 Converters
10
Overview
RPM Modules
Overview, continued
Current Limiting
Resistors
Mounting
Locations
Panel
848535332
10-32x7/16" Screw
901252726
10-32x7/16" Screw
901252726
Panel
848412367
(Provided with H569-434 G28 and G29
1200A and 4800A Distribution Only Cabinets)
RPM Installation
Step
RPM Installation
Action
Step
5
TB101
X1
+
CH1
-
TB102
+
CH3
-
IN
IN
SHIELD
Mounting Holes
+
CH2
-
SHIELD
OUT
OUT
+
CH4
+
CH5
+
CH6
-
EXT TEMP
X2
100K Thermistor
(407209808) or any of the
100K Ring Type Probes
and Connecting Cable
Shown in Figure 10-3.
Cable Tie
100K
100K
CLR Assembly
(847540424)
Source
TB101
X1
NC
Relay 1 COM
NO
TB102
Two Wire and
Shield Input
NC
IN
Relay 2 COM
IN
NO
SHIELD
Mounting Holes
SHIELD
OUT
NC
COM
OUT
NO
Relay 3
X2
X1
X1
TB102
Inductor Bead
(406712968)
TB101
TB102
IN
IN
SHIELD
SHIELD
OUT
OUT
IN
IN
SHIELD
SHIELD
OUT
OUT
X2
X2
To Galaxy
Controller
RPM Bus
Input
Inductor
Bead
11
Overview
LVBD
Shunt
H569-434
ED83143-31 GPS4848/100
H569-436
GPS4812/24
H569-437
GPS2424/30
No Battery Panel
None
33
33F
33F
38/138
30
40
137
135
134
35
37
34
36/136
31/131
139
32/132
133
39
33
32
39
31
30
-
89F
88F
85F
85H
84H
39
31
30
32H
36H
89F
85H
85F
84H
39
31
32H
30
36H
-
34
35
80
34
35
80
34
35
80
81
81
81
82
82
82
86
87
86
87
86
87
3 x 1,000A
60
37
37F
3 x 1,000A
61
38
38F
1. ED83143-31 group numbers less than 100 are -48Vdc and greater than 100 are +24V2.
2. HH indicates panels for Half Height Cabinets.
Additional Battery
Leads
Figure 11-1 shows options for connecting more than eight battery leads
(16 maximum).
Battery (+) conductors are connected to the bus bar ends of the battery
fuse holders, contactors, or shunts. Battery (-) conductors are connected
to the battery return bus. See Figure 11-4 to locate the battery connection
panels and battery return bus. Also see Figures 4 and H3 in the
T83314-30 drawing for additional information.
-48-volt Systems
Battery (-) conductors are connected to the exposed bus bar ends of the
battery fuse holders, contactors, or shunt. Battery (+) conductors are
connected to the battery return bus. See Figures 11-2 and 11-3 to locate
the battery connection panels and battery return bus. Also see Figures 4
and H3 in the T83314-30 drawing for additional information.
For all battery connection panels, connect the first wire lead
toward the back of the cabinet.
On the panel with two bus bars, use the back four mounting
locations on the top bus. On the lower bus bar, use the front four
locations.
Step
1
12
Introduction
or
D
1. Connect to a fused ABS source. Can be spliced to extend if necessary.
2. Part of the J85501X1 L-K30 or 108298514 210E kit.
Cable Routing
Action
Connect the 210E Power Cable Assembly (847925435 or 848341632) to the ABS and
DG terminals of the BLJ Terminal Board. See Figure 12-7 (BLJ) or 12-8 (Millennium).
Connect the Alarm and Signal Cable Assembly to the BLJ board using cable assembly
848302048 (see Figure 12-7) or 848153003 to the BSH board on the Millennium (see
Figure 12-8).
Note: The length of the 848302048 cable assembly is 8 feet (2.4 meters). The cable
assembly can be cut to a shorter length if mounting the 210E module on the bay door.
Step
Step
1
Figure 12-11: Monitoring a 210E Alarm off the BLJ-BIC7/8 in a Millennium System
13
Introduction
This section provides the installation procedure for the fascia covers.
The covers are optional on centralized architecture.
Step
1
14
Introduction
15
Prior to installing converters (if equipped) and rectifiers, verify that the
correct ac voltage is present at the ac connectors in the rectifier shelves.
Note: Disregard if this was done as part of the AC Connection and
Wiring procedure.
Safety Reminder
Alarms
Menu
Enter
Help
Escape
Adjust
BD
RM CTRL
Status
Menu
Enter
Help
Escape
Adjust
CRIT MAJ
MIN NORM
Alarms
BD
RM CTRL
Status
CRIT MAJ
MIN NORM
COM
Lamp
Test
COM
Lamp
Test
Plant
Voltage
Plant
Voltage
Figure 15-1a: Galaxy Millennium Controller Front Panel , Square Keys (DA)
Equipment Status
Critical
AC System
Major
Battery
Minor
Controller
Normal
Distribution
Rectifier
Battery on
Discharge
Escape
Help
Menu
Enter
Remote
Modules
VOLTS
VIEW ACTIVE
ALARMS
ACO
FLOAT
AMPS
ALARMS
BD
BATT
DIST
RECT
CONFIGURE
CTRL
AC
ENTER
THERMAL
COMPENSATION
BATTERY
TEST
STATUS
MAJ
MIN
NORM
LAMP
TEST
DEFAULT
ESCAPE
PLANT
VOLTAGE
Figure 15-2a: Galaxy Vector Controller Front Panel, Square Keys (DA)
Step
1
To turn up the system while using the factory default firmware and
software loaded in the controller, proceed as follows:
Warning
Before proceeding with the initial power up of the system,
verify:
Rectifier
Installation
Notes
Air Dam
(848754358)
Step
Install First
Rectifier
Step
Install Converter
Cards
Install converter cards. The cards click into place inside the
carrier. See Figure 15-3.
Note: Converters are optional equipment.
Verify Controller
10
12
Set Rectifier ID
13
15
Verify that the system voltage again reads 26.04 volts (or 52.08
volts).
Figure 15-3: Installing 595A/B Rectifiers, 596 Rectifiers, and 597A Converter Carriers
Lamp Test
Step
Lamp Test
Action
Voltage Calibration
Note: Do NOT attempt to set the system voltage in this with this
procedure. It is only to calibrate the display to the test jacks. Refer to
"Setting the System Voltage" (next procedure) for setting the system
voltage level.
Voltage Calibration
Action
Step
1
Step
1
Verify that the HFV, HVSD, and SHVSD alarm thresholds are
set above the float voltage to be specified in Step 3.
Step
1
Step
Step
2
Step
Step
2
Connecting Batteries
Caution: Review and observe precautions outlined in Section 2,
Safety, before proceeding.
Step
Connecting Batteries
Action
Step
Step
1
Allow the thermal probe to cool and verify that the system
voltage returns to the nominal value.
Step
Once the Alarm Test feature has been enabled, use the front
panel key sequence Menu Maint Oper Alarm Test
Enter to start the Alarm Test.
Connecting to Load
The system is ready to connect to equipment loads. Install or turn on
load protectors when needed.
16
Addition or Modification to a
Galaxy Power System
Upgrading a
GPS4848 System to
a GPS4848/100
System
Adding an
ED83143-31
Distribution Panel
to a GPS
Qty
Comcode
1 ED83143-31
901248815
7 901263327
3 901249839
7 901249813
7 901249821
1 848407888
1 848407938
1 848583720
1 848403481
1 Varies
1 Varies
Description
Distribution Panel
Screw, HH Tap M5 x 12mm
Screw, HH M8 x 25mm
Nut, Hex, M8
Flat Washer, M8
Lock Washer, M8
Bus Bar
Bus Bar
Linking Bracket
Instruction Sheet
Fuse/Breaker ID Label
Extension Bracket (not with H569-434)
3
4
5
7
1
If a Load Return Bus is ordered, the following items are also included:
Qty
4
3
3
3
3
1
1
2
2
Comcode
901248815
901263327
901249839
901249813
901249821
848122586 or 848122594
848418331
996523080
901349274
Description
Screw, HH Tap M5 x 12mm
Screw, HH M8 x 25mm
Nut, Hex, M8
Flat Washer, M8
Lock Washer, M8
Bus Bar
Bracket
Standoffs
Screw HWH 1/4-20 x 5/8
6
6
Installation Procedure
1
2
6
5
4
Cabinet (REF)
2
3
Cabinet (REF)
Adding a Cabinet
to an Existing GPS
System with
Distributed
Architecture.
Contactors
Alarm Outputs
Alarm Inputs
System
Shunt
Fuses
Power In/Out
Vector Controller
BICShown
Board Not
To Rectifiers
System Configuration
DIP Switches
Battery Shunts
Battery Temperatures
Battery
Voltage
Bay
Alarm
Out
26 Conductor
Ribbon Cable
Front Panel
Control/Display
BLJ3 Board
BIC
If the BLJ3 terminal board also needs to be replaced, use the following
procedure and Figure 16-3.
1. Remove power from the BLJ3 terminal board by disconnecting the
BAT (black) lead and DG (red) lead twisted pair. Make sure the
BAT lead is insulated with tape so as not to short against the door.
Please note that any equipment powered from the ABS leads will
lose power.
2. Remove and tag all leads to alarm outputs, ABS powered
equipment, contactors, alarm inputs, system shunt, rectifiers, bay
alarm light, battery voltage, battery shunts, battery temperature
probes and controller display.
3. Remove the five screws and or standoffs holding the BLJ3 terminal
board and replace with the new BLJ3.
4. Reattach all leads to the BLJ3, attaching BAT and DG power leads
last.
5. Restore LVLD contactors to controller control by placing switch
SW300 (EBV Board) in the down position as shown in Figure 8-16.
6. Restore LVBD contactors to controller control.
Full-Height Cabinets: Place switches SW100, SW200 and SW300
(BJN Board) in the up position as shown in Figure 11-5.
Half-Height Cabinets: Place switches SW100, SW200 and SW300
(BJN Board) in the down position as shown in Figure 11-6.