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Lucent Technologies Galaxy Power System 4804AP H569-450

Issue 1 June 2000

Troubleshooting Millennium Systems 14 - 1

Troubleshooting Millennium
Systems

Introduction

In This Section

This section provides information for locating and interpreting visual
indicators to help identify problems in Galaxy Power Systems equipped
with the Millennium controller.

Preparation

Read Section 13, Troubleshooting Preparations, thoroughly before pro-
ceeding.

Technical
Assistance

When visual indicators do not identify a defective part, notify the local
Regional Technical Assistance Center (RTAC) or LFS Team at
65-240-8680

Summary of Contents for Galaxy 4804AP

Page 1: ...Galaxy Power System 4804AP GPS 4804AP H569 450 Product Manual Select Code 167 792 162 Comcode 108780917 Issue 1 June 2000 2000 Lucent Technologies ...

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Page 3: ...hnologies Galaxy Power System 4804AP GPS 4804AP H569 450 Notice Every effort was made to ensure that the information in this document was complete and accurate at the time of printing However information is subject to change 2000 Lucent Technologies All Rights Reserved Printed in U S A ...

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Page 5: ...s 1 4 2 System Description Overview 2 1 Block Diagram 2 1 System Components 2 2 Architecture 2 3 Configuration 2 3 Illustrations 2 3 3 Galaxy Controllers Introduction 3 1 Galaxy Millennium Controller 3 2 Design 3 2 User Interface and Display 3 2 Default Display 3 2 LEDs 3 3 Test Jacks 3 3 Pushbutton Keys 3 4 Galaxy Vector Controller 3 5 Design 3 5 User Interface and Display 3 5 Default Display 3 5...

Page 6: ...start 4 4 Fan Alarm and Control 4 4 Thermal Alarm 4 4 Autonomous Operation 4 4 Controller Communications Alarm 4 4 Connectorized 4 5 Forced Load Sharing 4 5 5 AC Input Panels Overview 5 1 AC Service 5 1 Cross Reference of Cabinets and AC Panels 5 1 Illustrations 5 1 6 Battery Connection Panels Overview 6 1 Function 6 1 Cross Reference of Cabinets and Battery Connection Panels 6 1 Illustrations 6 1...

Page 7: ...3 AC Input Panels 9 5 Battery Connection Panels 9 5 DC Distribution Panel 9 5 10 Safety Safety Statements 10 1 Warning Statements and Safety Symbols 10 3 Precautions 10 5 11 Installation Introduction 11 1 Relevant Product Documentation 11 1 Installation Preparations 11 2 Tools and Hardware 11 2 Torque Settings for Metric Hardware 11 3 Unpacking 11 3 Location 11 3 Cabinet Installation 11 4 Illustra...

Page 8: ...g Locations 11 27 Battery Connection Panels 11 28 Overview 11 28 Options 11 28 Connecting and Conductors 11 32 Installing Battery Connection Panels 11 32 Thermal Probe Connections 11 34 Safety 11 34 Making Connections 11 34 Connecting Thermal Probe Cable Assembly to a BLJ Board 11 35 Connecting a 210E Module to a BLJ Board 11 36 Connecting Thermal Probe Cable Assembly to Ring Type or Paddle Type P...

Page 9: ...Assembly 12 5 Replacement Parts 12 6 System 12 6 Millennium Controller Circuit Boards 12 7 Vector Controller Circuit Boards 12 7 Documentation 12 8 Software 12 8 13 Troubleshooting Preparations Preliminary 13 1 Introduction 13 1 Safety 13 1 Tools 13 1 Troubleshooting Procedure 13 2 Purpose 13 2 Cabinet Alarm 13 2 System Status 13 3 Alarms Menu 13 3 Troubleshooting Tables 13 4 Identifying Problems ...

Page 10: ...isplay Reference 14 2 AC Alarm LED 14 3 BATT Alarm LED 14 4 CTRL Alarm LED 14 6 DIST Alarm LED 14 12 RECT Alarm LED 14 13 BD and RM Alarm LEDs or No LED 14 19 15 Troubleshooting Vector Systems Introduction 15 1 In This Section 15 1 Preparation 15 1 Technical Assistance 15 1 Troubleshooting Tables 15 2 Table Reference 15 2 Vector Display Reference 15 2 AC Alarm LED 15 3 BATT Alarm LED 15 4 CTRL Ala...

Page 11: ...569 450 G20 AC Panel Three Phase for GPS 4804AP Power System 5 2 Figure 5 2 H569 450 G21 AC Panel Single Phase for GPS 4804AP Power System 5 3 Figure 6 1 H 569 450 G30 Battery Connection Panel with 2 x 400A Battery Contactors LVBD R 6 2 Figure 6 2 H 569 450 G31 Battery Connection Panel with 2 x 400A Battery Contactors LVBD R 1 x 400A Contactor for DC Distribution LVLD R 6 3 Figure 6 3 H 569 450 G ...

Page 12: ...nd Numbering Scheme 11 14 Figure 11 8 24 Position DC Distribution Circuit Breaker Panel for GPS 4804AP 11 16 Figure 11 9 Inserting a Circuit Breaker in the DC Panel 11 18 Figure 11 10 Switch Positions for Controlling Low Voltage Load Disconnection 11 19 Figure 11 11 Connection Unit 847635851 for all Modules Except Control Relay 11 23 Figure 11 12 Connection Unit 847629342 for Control Relay Module ...

Page 13: ...inal Alarm Board 11 41 Figure 11 27 Galaxy Millennium Controller with Wire Wrap Alarm Board 11 42 Figure 11 28 Galaxy Vector Controller with Barrel Terminal Alarm Board 11 43 Figure 11 29 Galaxy Vector Controller Front Panel 11 45 Figure 11 30 Galaxy Millennium Controller Front Panel 11 45 Figure 11 31 Installing Rectifiers 11 48 Figure 12 1 Detail of Rectifier Position 12 3 Figure 13 1 Location o...

Page 14: ...Technologies Galaxy Power System 4804AP H569 450 4 List of Figures Issue 1 June 2000 Figure 13 9 Detail of DC Distribution Panel 13 11 Figure 13 10 Low Voltage Load Disconnect Contactor Control Switches 13 12 ...

Page 15: ...ic Hardware 11 3 Table 11 B GPS Mounting Specifications 11 6 Table 11 C Mounting Plates for Unigy Batteries 11 6 Table 11 D Cable Size and Termination Lug Requirements 11 11 Table 11 E Connection Units 11 20 Table 12 A GPS 4804AP System Replacement Parts 12 6 Table 12 B Galaxy Millennium Controller Circuit Boards 12 7 Table 12 C Galaxy Vector Controller Circuit Boards and Temperature Module 12 7 T...

Page 16: ...H569 450 2 List of Tables Issue 1 June 2000 Table 15 A AC Alarms 15 3 Table 15 B Battery Alarms 15 4 Table 15 C Controller Alarms 15 5 Table 15 D Distribution Alarms 15 7 Table 15 E Rectifier Related Alarms 15 8 Table 15 F Miscellaneous Alarms 15 15 ...

Page 17: ...es easy access simplified installation and maintenance and allows the system to expand in capacity and features as power needs grow With 400 ampere maximum capacity distribution flexibility and universal ac input capability the GPS 4804AP supports switching transmission and wireless applications in central office locations and environmentally controlled remote sites huts or vaults The main emphasi...

Page 18: ...Lucent Technologies Galaxy Power System 4804AP H569 450 1 2 Introduction Issue 1 June 2000 Figure 1 1 GPS 4804AP Cabinet with Galaxy Millennium Controller with Battery Stand ...

Page 19: ...Lucent Technologies Galaxy Power System 4804AP H569 450 Issue 1 June 2000 Introduction 1 3 Figure 1 2 GPS 4804AP Cabinet with Galaxy Vector Controller without Battery Stand ...

Page 20: ...ic contractual agreements extend this service Customers can call 65 240 8680 to contact a product specialist to answer your technical questions and assist in troubleshooting problems Product Repair and Return Repair and return service is provided for Lucent Technologies customers around the region Customers can 65 240 8680 Alternatively contact your local sales representative Warranty Service For ...

Page 21: ...Figure 2 1 It illustrates the arrangement and interconnections of the system components from the ac input to the dc output Figure 2 1 Block Diagram of the GPS 4804AP Rectifiers LVLD 48V Returns Loads Battery Distribution DISCHG RTN To 48 Volt DC Distribution CARD ALARM AC Input power AC Input Bus Bus Return Chg Connections Sense Control Controller Battery Battery CHG RTN LVBD Shunt Battery BAT BUS...

Page 22: ...is sized to provide 3 to 8 hours of reserve time AC Input connects the commercial and or standby ac power sources to the rectifiers within the system and provides over current protection Rectifiers convert an ac source voltage into the dc voltage level required to charge and float the batteries and to power the using equipment Controller provides the local and remote control monitoring and diagnos...

Page 23: ...istribution panels a battery connection panel rectifiers termination points for load circuits and a system controller Illustrations Figure 2 1shows the block diagram of the GPS 4804AP Figures 2 2 and 2 3 show the schematic and open door view of the GPS 4804AP cabinet Figure 2 2 Schematic of GPS 4804AP Cabinet Control and Monitor Battery Shunt AC Cabinet Ground System co Ground To Loads AC Ground B...

Page 24: ...Lucent Technologies Galaxy Power System 4804AP H569 450 2 4 System Description Issue 1 June 2000 Architecture continued Figure 2 3 GPS 4804AP Cabinet with Door Open ...

Page 25: ...rs 3 1 3 Galaxy Controllers Introduction The GPS 4804AP is available with the Galaxy Millennium Controller and Galaxy Vector Controller This section describes the operation of each controller It also provides detailed information about the features of their front panel keys LEDs and displays ...

Page 26: ...lay that can be viewed in English or Spanish two rows of LEDs an array of pushbutton keys and a pair of test jacks Figure 3 1 illustrates the Millennium s front panel Default Display The default display shows basic system status The controller returns to this display approximately three minutes after the last time a key is pressed The information on the screen is updated automatically approximatel...

Page 27: ...t severe active alarm The first row of seven LEDs labeled ALARMS indicates the source of the alarm BD battery on discharge BATT battery DIST distribution RECT rectifier AC ac power supply RM remote monitoring CTRL controller The second row includes four LEDs labeled STATUS They indicate the severity of the reported alarm CRIT critical MAJ major MIN minor NORM normal The COM LED illuminates when th...

Page 28: ...s The following is a general description of the pushbutton keys MENU View the MAIN menu ENTER Select a menu item HELP Displays limited on line help information ESCAPE Return to the immediate higher level menu Up arrow Moves the cursor up one line Down arrow Moves the cursor down one line Left arrow Moves the cursor left one field Right arrow Moves the cursor right one field ADJUST and Increase or ...

Page 29: ...f LEDs an array of pushbutton keys and a pair of test jacks Figure 3 2 illustrates the Vector s front panel Default Display The default display shows the system voltage Toggle the VOLTS AMPS switch to view system voltage or current Press the VIEW ACTIVE ALARMS button to view the code for any active alarm The controller returns to the default display approximately 30 seconds after the last time a k...

Page 30: ...he most severe active alarm The ALARMS row of six LEDs indicates the source of the alarm BD battery on discharge BATT battery DIST distribution RECT rectifier CTRL controller AC ac input power The STATUS row of three LEDs indicates the severity of the reported alarm MAJ major MIN minor NORM normal THERMAL COMPENSATION Lights when the system voltage has been adjusted by the Thermal Compensation fea...

Page 31: ... ACTIVE ALARMS Display active alarms Use the arrow keys to page through multiple alarms The LED lights when this option is selected Note View Active Alarms and Configure cannot be active simultaneously CONFIGURE Enter Configuration Mode The LED lights when this option is selected Note Configure and View Active Alarms cannot be active simultaneously ENTER Select a menu item DEFAULT In Configure mod...

Page 32: ...uct manual Select Code 167 792 180 or Galaxy Vector Controller product manual Select Code 167 792 112 is furnished with every GPS 4804AP Refer to this manual for information regarding configuration and operation RPM System Product Manual Refer to the Galaxy Remote Peripheral Monitoring System product manual Select Code 167 790 063 for additional information regarding module operation ...

Page 33: ...nstallation into rectifier shelves at the site Interconnections to ac input dc output and control signals occur automatically during insertion The rectifier is keyed to prevent installation of the wrong rectifier No settings or adjustments to potentiometers are necessary The installer must set the rectifier s ID using the ON STBY switch to allow the controller to learn the rectifier s physical loc...

Page 34: ...e rectifier s condition The ALM LED is red and lights whenever the rectifier fails The LIM LED is yellow and lights when the unit is in current limit The FAN ALM LED is red and lights when the fan inside the rectifier is not functioning properly The BST LED is yellow and lights when the rectifier is in boost mode Current Display This display indicates the current of the rectifier Upon specific no ...

Page 35: ... Galaxy Power System 4804AP H569 450 Issue 1 June 2000 Rectifiers 4 3 Front Panel Display continued Illustration Figure 4 1 shows the rectifier s front panel Figure 4 1 Rectifier Front Panel ID ALM ON STBY LIM FAN ALM BST ...

Page 36: ... itself or the load Restart Upon shutdown the rectifier will attempt to restart The rectifier will also accept a restart command from the controller for a remote restart The rectifier will attempt to restart three times before issuing a rectifier fail alarm to the controller Fan Alarm and Control The rectifier contains a cooling fan The fan s speed which is based on ambient temperature and output ...

Page 37: ... The rectifier status and alarm signals ac input and dc output are all connectorized for easy installation and maintenance System connections are made when the rectifier is plugged into the shelf No additional connections are required Forced Load Sharing Internal rectifier circuitry will allow multiple rectifiers to share load in the event communication to the controller is lost or the controller ...

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Page 39: ...positions The panel will connect 2 wire one phase neutral input ac services In the systems Miniature Circuit Breakers MCB are provided to protect the conductor providing ac service to the individual rectifiers Cross Reference of Cabinets and AC Panels Table 5 A identifies which cabinet uses each of the AC panels Illustrations AC Input Panels are shown in Figures 5 1 and 5 2 Table 5 A AC Input Pane...

Page 40: ...Lucent Technologies Galaxy Power System 4804AP H569 450 5 2 AC Input Panels Issue 1 June 2000 Figure 5 1 H569 450 G20 AC Panel Three Phase for GPS 4804AP Power System ...

Page 41: ...Lucent Technologies Galaxy Power System 4804AP H569 450 Issue 1 June 2000 AC Input Panels 5 3 Figure 5 2 H569 450 G21 AC Panel Single Phase for GPS 4804AP Power System ...

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Page 43: ...anels and the DC Distribution Panels 2 When LVLD R Contactor is selected six positions in the DC Distribution will be assigned as critical loads Cross Reference of Cabinets and Battery Connection Panels Table 6 A identifies which cabinet uses each of the battery connection panels Illustrations The battery connection panels are shown in Figures 6 1 through 6 4 Table 6 A Battery Connection Panels Pa...

Page 44: ...Lucent Technologies Galaxy Power System 4804AP H569 450 6 2 Battery Connection Panels Issue 1 June 2000 Figure 6 1 H 569 450 G30 Battery Connection Panel with 2 x 400A Battery Contactors LVBD R ...

Page 45: ... Galaxy Power System 4804AP H569 450 Issue 1 June 2000 Battery Connection Panels 6 3 Figure 6 2 H 569 450 G31 Battery Connection Panel with 2 x 400A Battery Contactors LVBD R 1 x 400A Contactor for DC Distribution LVLD R ...

Page 46: ...Lucent Technologies Galaxy Power System 4804AP H569 450 6 4 Battery Connection Panels Issue 1 June 2000 Figure 6 3 H 569 450 G 32 Battery Connection Panel with 1 x 600A Battery Contactor LVBD R ...

Page 47: ...s Galaxy Power System 4804AP H569 450 Issue 1 June 2000 Battery Connection Panels 6 5 Figure 6 4 H 569 450 G33 Battery Connection Panel with 1 x 600A Battery Contactor LVBD R 1 x 400A Contactor for DC Distribution LVLD R ...

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Page 49: ...the Battery Connection Panels and the DC Distribution Panels 2 When LVLD R Contactor is selected six positions in the DC Distribution will be assigned as critical loads 3 When output current is greater than 63A multiple pole MCB will be used with the output terminals shorted When multiple pole MCB are used in DC Distribution number of output position will be reduced from 24 positions suitably Cros...

Page 50: ...Lucent Technologies Galaxy Power System 4804AP H569 450 7 2 DC Distribution Panel Issue 1 June 2000 Figure 7 1 H 569 450 G40 24 Position DC Distribution Miniature Circuit Breaker Panel for GPS 4804AP ...

Page 51: ...n the cabinet Alarm Board The circuit board performs the following functions Monitors battery connection and dc distribution panel functions and activate local indicators when faults occur on the panel Provides alarm data to the controller Provides local control for the LVBD R and LVLD R Contactors Provides capacitor charge Interfaces between Galaxy Controller and other plant components ...

Page 52: ...r Vector Systems The Vector controller which is installed in the cabinet contains a BLJ terminal connection board Bay Interface Card Millennium Systems Each cabinet in a Millennium system has a Bay Interface Card BIC that attaches to the cabinet s terminal board BLJ The BIC provides controller access to alarm monitoring battery voltages battery currents and temperature probes in the cabinet throug...

Page 53: ...old voltages the respective contactors will open generating alarm L2 LVD OPEN will glow on the alarm card and the alarm will be transmitted to the Galaxy Controller BATT MAJ or DIST MAJ LED on the Galaxy Controller will glow depending on the type of the contactor opening Load contactor will generate DIST and Battery contactor will generate BATT alarm Respective contactors will close automatically ...

Page 54: ...ribution When the fuse fails or trips L1 FUSE CB OPEN LED will glow in the alarm card and the alarm will be transmitted to the Galaxy Controller DIST MAJ alarm will be issued in the controller Capacitor Charge SW The switch S5 in the circuitry is the capacitor charge switch This switch has been provided for charging the Capacitors in the GPDF panel of the 5ESS switch or when the load is connected ...

Page 55: ...e BLJ Terminal Board and the Bay Interface Card BIC BIC Board Figure 8 2 shows the straps required prior to replacing a Bay Interface Card BIC See BIC Failure in Table 13 C Figure 8 1 Location of BLJ Terminal Board and Bay Interface Card BLJ BIC Figure 8 2 Required Straps Prior to Replacing a Bay Interface Card BIC BLJ2 3 Straps For Replacing BIC Board ...

Page 56: ...Galaxy Power System 4804AP H569 450 8 6 Circuit Boards Issue 1 June 2000 Illustrations continued Battery DC Distribution Alarm Circuit Pack Figure 8 3 Battery DC Distribution Alarm Circuit Pack for GPS 4804AP Power System ...

Page 57: ... for single phase maximum 8 rectifiers 2 shelf system 75A circuit breaker for three phase maximum 8 rectifiers 2 shelf system Wire Size 70 mm2 cable for single phase 25 mm2 cable for three phase System Output System Voltage 48 Output Current 50 400 amperes Physical Cabinet Nominal Cabinet Dimensions H x W x D 1066 H x 600 W x 600 D mm Units Per Cabinet Rectifiers 1 8 Controller 1 Battery Disconnec...

Page 58: ...ted Emission EN 55022 CISPR 22 Radiated Conducted Emission Class A Electromagnetic Immunity IEC EN 61000 4 2 ESD level 4 IEC EN 61000 4 3 Radiated Immunity 10V m Level 3 IEC EN 61000 4 4 Electrical Fast Transients Burst Level 4 Damage Free IEC EN 61000 4 5 Lightning Surge Level 4 IEC EN 61000 4 6 Conducted Immunity Level 3 Safety Applicable sections of IEC 60950 Standards Compliance Agency Approva...

Page 59: ...ac RMS 0A 940Vpeak 1mA 1600Vpeak 100A Output Output Current 50 amperes Float Boost Voltage 44 58Vdc Regulation 0 5 Ripple 100 mVrms Noise 2mV Psophometric Permanent Overload 55A Current Limit Set Point 15A 55A Note When using the maximum 16 rectifiers in a cabinet do not exceed 50 amperes current limit per rectifier at 65 C Physical Width 133 mm 5 2 in Height 203 mm 8 in Depth 502 mm 19 8 in Weigh...

Page 60: ...ance Safety Standard EN 60950 IEC950 Certification Marks UL VDE CE Rectifiers are individually UL Recognized and or CSA Certified to UL1950 and CSA C22 2 No 234 950 Rectifiers are also approved to IEC 950 EN60950 by an EC Notified Body and have outputs classified as SELV Table 9 B 596A Rectifier Specifications ...

Page 61: ...mum of 8 single pole circuit breakers that are connected to single phase 1Φ 2 wire G21 Table 9 D Battery Connection Panels Description H 569 450 Group Number Battery Connection Panel with 2 x 400A Battery Contactors LVBD R G30 Battery Connection Panel with 2 x 400A Battery Contactors LVBD R 1 x 400A contactor for DC Distribution LVLD R G31 Battery Connection Panel 1 x 600A battery Contactor LVBD R...

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Page 63: ...idity 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 Do not install this equipment over combustible surfaces This equipment has been evaluated for use in a continuous ambient temperature of up to 50 C Torque electrical connections to the values specified on labels or...

Page 64: ...efer to the equipment ratings to assure rating of equipment will not exceed 80 of the value of the breaker chosen The short circuit current capacity of the battery input to the dc distribution panel is 10 000 amperes Caution The equipment is to be used in the building installation with 4 pole 125A Circuit Breaker or 2 pole 175A Circuit Breaker and Earth leakage current detector on all conductors ...

Page 65: ...mportant 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 som...

Page 66: ...t is or could be at hazardous voltage levels This symbol may also be used to identify the presence of a hot surface The marked item should not be touched without taking care 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...

Page 67: ...pment 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 unit and on the interface cables that can shock or cause serious injury Follow all safety warnin...

Page 68: ...l 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...

Page 69: ... Ordering Guide H 569 450 Manufacturing Drawings YYH4804XX Wiring Table WD YYH4804XX Product Manual 167 792 162 Galaxy Millennium Controller Manufacturing Drawings J85501K 1 Wiring Diagram T83413 30 Product Manual 167 792 180 Galaxy Vector Controller Wiring Diagram T83314 30 Product manual 167 792 112 Remote Peripheral Monitoring System Ordering Guide J85501G 1 Wiring Diagram T83275 30 Schematic D...

Page 70: ...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 11 A 35 513in lbs 4 58Nm Sockets Metric English Equivalent Hardware 8mm 5 16 M5 10mm M6 13mm 1 2 M8 17mm 11 16 M10 19mm 3 4 M12 Crimp t...

Page 71: ...ned it should be repacked in the original shipping crate Location Before continuing verify that the following conditions exist at the installation site Floor is conditioned1 and clean Batteries and associated stands are in place Cable rack not supported by cabinets is in place Job Site Documentation is available that details cabinet locations dc distribution assignments and Remote Peripheral Monit...

Page 72: ...Refer to the following figures for the cabinet installation procedure Figure Number Illustrates 11 1 Footprint for a Galaxy Power System GPS 4804AP without a battery stands 11 2 Footprint for a standard IR battery stands 11 3 Details of the cabinet installation procedure 11 4 Details of cabinet and System Central Office Ground ...

Page 73: ... Technologies Galaxy Power System 4804AP H569 450 Issue 1 June 2000 Installation 11 5 Cabinet Installation continued Figure 11 1 Footprint No Battery Stand Figure 11 2 Footprint for Standard IR Battery Stand ...

Page 74: ... Table 11 B GPS Mounting Specifications Comcode Anchor Type HILTI Hole Size Wrench Torque 847135720 4 3 8 drop in 1 2 bit 1 9 16 deep 85 in lbs 847135712 4 3 8 self drill 85 in lbs Table 11 C Mounting Plates for Unigy Batteries Module Type Capacity 8 hour Rate Comcode 6A 75 9 3A 75 17 3A 75 19 12V 310Ah 6V 630Ah 6V 700Ah 848275509 6A 75 11 3A 75 21 3A 75 23 12V 390Ah 6V 785Ah 6V 865Ah 848275517 6A...

Page 75: ...o Figure 11 3 for this procedure Locating and Anchoring Cabinet Step Action 1 Using a drill bit drill anchor holes to the depths specified in Table 11 B 2 Locate the cabinet in position using two or four anchor bolts and hold down washers 3 Shim under cabinet corners to level 4 Torque anchors as specified in Table 11 B Figure 11 3 Locating and Anchoring Cabinet ...

Page 76: ...rocedure The system ground should be connected to the building s principal ground point Central Office Ground The conductor size must conform to local standards Connection to the power system is through the M10 studs located on the distribution return bus See Figure 11 4 to locate the studs Cabinet Ground Step Action 1 Run and connect the framework ground lead as shown in Figure 11 4 2 Torque conn...

Page 77: ...Lucent Technologies Galaxy Power System 4804AP H569 450 Issue 1 June 2000 Installation 11 9 Cabinet Installation continued Figure 11 4 Cabinet and Central Office Ground ...

Page 78: ...located in the cabinet The panel is factory equipped to have a phase to neutral or phase to phase distribution to each rectifier through a single pole ac circuit breaker Illustrations Figure 11 5 illustrates a three phase neutral AC panel Figure 11 6 illustrates a single phase neutral AC panel Figure 11 7 shows the rectifier positions and numbering scheme Table 11 D shows the lug requirement for t...

Page 79: ...per phase to phase or phase to neutral ac voltage is present at the input to the ac panel 5 Replace the ac panel front cover If the ac panel is equipped with rectifier circuit breakers mark the ac panel front cover label with rectifier position numbers they may already be factory marked See Figure 11 7 6 Do not turn the rectifier circuit breakers ON 7 Turn OFF the main ac circuit breaker Table 11 ...

Page 80: ...xy Power System 4804AP H569 450 11 12 Installation Issue 1 June 2000 AC Connection and Wiring continued Figure 11 5 AC Panel Three Phase for GPS 4804AP Power System Figure 11 6 AC Panel Single Phase for GPS 4804AP Power System ...

Page 81: ...17 4 Assemble bus bar links BBPTHDRXX and BBPTHDLXX bus bars connecting rectifier shelf the cabinet bus bars to the rectifier shelf using fasteners SCM08H25X M8 x 25 Bolt 5 Place the rectifier shelf in the cabinet aligning with the help of Keying bracket and the two supports at the back of the cabinet Once the shelf is aligned secure the shelf to the cabinet using fasteners 901078717 Note Ensure t...

Page 82: ...lack Cables Neutral Bus Bar Red Cable Breaker 5 output Yellow Cable No ferrule Breaker 6 output Blue Cable Breaker 7 output Yellow Cable Ferrule Number 4 Breaker 8 output 10 Connect the controller interface cable to the in line connector JK 555052 2 407671163 on the bottom rectifier shelf 11 Ensure that all the cable terminations are secure and properly terminated 12 Stick the rectifier number lab...

Page 83: ...on Quantity YDRS4812X YHACCAHH2 Rectifier shelf with AC Cable assembly 1 set 407671163 Inline Connector JK555052 2 1 901078717 Self taping Screw 12 SCM06H142 6mm Captive screw 6 SCM08H25X M8X25 Bolt 4 WAM08PXXX M8 plain washer 4 WAM08SXXX M8 Spring Washer 4 MSPCT150N Cable Tie 150mm 8 BBPTHDRXX Bus bar link Rect Shelf 1 BBPTHDLXX Bus bar link Rect Shelf 1 Rectifier Position Label 1 ...

Page 84: ...protectors from 1 225 amperes to satisfy a wide range of distribution needs Panels are available with a low voltage load disconnect LVLD contactor for load shedding applications DC distribution panel is equipped with an alarm card that monitors and communicates to the controller any operated circuit breaker and provides a visual LED that indicates an operated protector Figure 11 8 24 Position DC D...

Page 85: ...ble rack above the back of the cabinet Large Circuit Breakers The circuit breakers of higher capacity using three poles in parallel need a shorting link which is used to short the three poles of the circuit breaker The output dc cable is connected to the shorting link Caution Turn OFF breaker before beginning procedure Connecting Load Termination Cables Connecting Load Termination Cables Step Acti...

Page 86: ...r is to be mounted 3 Connect this tooth to the output of the circuit breaker required to be added to the system and tighten with the in built fasteners in the circuit breaker 4 Now place the circuit breaker in the dc distribution panel as shown in Figure 11 9 and tighten the circuit breaker using the circuit breaker fasteners in built 5 Connect the output tooth connected as per 1 to the dc distrib...

Page 87: ...distribution panel is equipped with a low voltage load disconnect LVLD feature the alarm card provided in the system is used to operate the load contactor The voltage levels will be set during the controller setup Refer to Chapter 8 Circuit Boards for operation details Figure 11 10 Switch Positions for Controlling Low Voltage Load Disconnection ...

Page 88: ...s Table 11 E shows the module types and the corresponding connection units Current Limiting Resistors Current limiting resistors 100K ohm are required for the measurement inputs of the voltage current and binary modules Comcode 847540424 current limiting resistor assemblies are available for connections that do not already have them All shunts load and battery and some voltage points that are prov...

Page 89: ...nd the connected wires for strain relief See Figures 11 11 and 11 12 3 In the connection units TB102 is used for communications input output Use shielded twisted pair cable comcode 407377704 to wire the communications bus as shown in Figure 11 13 Polarity is not essential for the input output communications bus wiring except for shield 4 To verify that no shorts exist between any of the three cabl...

Page 90: ...alid except 00 No two modules should have the same address The unique address is set via two switches SW1 Hi and SW2 Low located on the Peripheral Monitoring module The switch display numbers letters are in hexadecimal For example SW1 Hi D SW2 Low 8 The HEX address is D8 6 Connect from the first module back to the controller interface circuit pack as shown in Figure 11 13 Wrap each bus wire twice ...

Page 91: ...CLR Assembly Locate as close as possible to source Thermistor optional Two Wire and Shield Output If Not the Last Module Two Wire and Shield Input X2 OUT OUT Place Bus Terminating Resistor on Last Module in the Chain for Each Bus X1 TB102 IN SHIELD SHIELD IN Mounting Holes CH6 EXT TEMP CH5 CH4 CH3 CH2 TB101 CH1 Note These are not required for most voltage and load points in the GPS system The 100k...

Page 92: ...Lucent Technologies Galaxy Power System 4804AP H569 450 11 24 Installation Issue 1 June 2000 Remote Peripheral Monitoring continued Figure 11 12 Connection Unit 847629342 for Control Relay Module Only ...

Page 93: ...ction loop the RPM cable assembly through the inductor bead twice before connecting to the controller RPM Cable Assembly 2 wire shielded RPM Cable Assembly 2 wire shielded RPM Cable Assembly Inductor Bead 560 Ohm Resistor 405298308 Should be installed When using a single RPM module or When daisy chaining RPM modules as shown the resistor should only be installed in the last module in the chain Up ...

Page 94: ...Lucent Technologies Galaxy Power System 4804AP H569 450 11 26 Installation Issue 1 June 2000 Remote Peripheral Monitoring continued Figure 11 14 Remote Peripheral Monitoring Module Assembly ...

Page 95: ...ations for the RPMs Figure 11 15 Possible RPM Mounting Locations Part of kit 847910213 Voltage Module or 847910221 Shunt Module RPM Kits 847910213 ACU221C Kit 0 60Vdc Voltage Peripheral Monitoring Module 847910221 ACU221F Kit Shunt Peripheral Monitoring Module Kits consist of One 847635851 RPM Base Two 900633504 Hex Nuts One 847910239 Communication Cable 20 ft One ACU221C or ACU221F Module ...

Page 96: ... to obtain a system load reading The contactors are equipped with alarm cards that report back to the controller if the battery section is taken off the system bus Charge and discharge current can be read from the front panel of the Galaxy controller when battery section shunts are properly wired and programmed Disconnect voltage levels on contactor panels are controlled by the Galaxy controller O...

Page 97: ...s Galaxy Power System 4804AP H569 450 Issue 1 June 2000 Installation 11 29 Battery Connection Panels continued Options continued Figure 11 17 LVD Battery Panel with 2 x 400A Battery Contactors and 1 x 400A Load Contactor ...

Page 98: ...nt Technologies Galaxy Power System 4804AP H569 450 11 30 Installation Issue 1 June 2000 Battery Connection Panels continued Options continued Figure 11 18 LVD Battery Panel with 1 x 600A Battery Contactor ...

Page 99: ...s Galaxy Power System 4804AP H569 450 Issue 1 June 2000 Installation 11 31 Battery Connection Panels continued Options continued Figure 11 19 LVD Battery Panel with 1 x 600A Battery Contactor and 1 x 400A Load Contactor ...

Page 100: ... board in the forced OPEN position See Figure 11 20 2 Verify that all ac and dc protectors are OFF 3 Terminate the appropriate conductors with terminal lugs as required Use heat shrink insulating sleeves over any exposed lug shanks as necessary 4 Connect the cabinet end of the battery cables to the contactors and return bus Next connect the battery end of the cables Tape the terminal lugs as requi...

Page 101: ...ent Technologies Galaxy Power System 4804AP H569 450 Issue 1 June 2000 Installation 11 33 Battery Connection Panels continued Figure 11 20 Switch Positions for Controlling Low Voltage Battery Disconnection ...

Page 102: ...xperience with electrical equipment and who understand the hazards that can arise when working on this type of equipment Refer to the controller manuals for additional connections Making Connections Thermal monitoring connections to the controller are made through the BLJ board located on the cabinet door Cables are then routed to the lower cable guide as shown in Figure 11 21 then to thermal prob...

Page 103: ...ge to make the enable strap connection 2 Proceed to Connecting Thermal Probe Cable Assembly to Ring Type or Paddle Type Probes Figure 11 22 Thermal Probe Cable Assembly Connection to BLJ Board ALARM OUTPUTS ALARM INPUTS 91 85 87 93 89 95 86 88 90 92 94 ABS DG 96 79 81 83 80 82 84 73 75 77 74 76 78 67 69 71 68 70 72 61 63 65 62 64 66 55 57 59 56 58 60 49 51 53 50 52 54 43 45 47 44 46 48 37 39 41 38...

Page 104: ...S and DG terminals of the BLJ board Multiple ABS and DG terminals are available as required The Alarm and Signal Cable Assembly connects to the BLJ board using cable assembly 848302048 8 feet 2 4 meters Note The order of connections is not important but it should be noted that alarms will be generated if a 210E module is connected to the controller and powered up with no thermal probes connected C...

Page 105: ...55 57 59 56 58 60 49 51 53 50 52 54 43 45 47 44 46 48 37 39 41 38 40 42 31 33 35 32 34 36 25 27 29 26 28 30 19 21 23 20 22 24 13 15 17 14 16 18 7 9 11 8 10 12 1 3 5 C O R C ALARM OUTPUTS ALARM OUTPUTS ALARM INPUTS R O 2 4 6 BLJ Board Required for each 210E Module ABS DG Black Red Power Cable Alarm and Signal Cable Connection to BLJ Board 210E Power Cable Assembly 847900180 ABS DG ABS DG ABS ABS To...

Page 106: ...Lucent Technologies Galaxy Power System 4804AP H569 450 11 38 Installation Issue 1 June 2000 Thermal Probe Connections continued Figure 11 24 Cable Connections to 210E Module ...

Page 107: ...of thermal probes are currently available see Figure 11 25 Ring type which connects directly to a battery terminal Paddle type which is inserted between adjacent batteries Connecting Thermal Probe Cable Assembly to Ring Type or Paddle Type Probes Step Action 1 Connect cable to ring type or paddle type probes See Figure 11 25 Figure 11 25 Thermal Probe Connection Ring Type Paddle Type 0 25 6 4mm 0 ...

Page 108: ...oose the appropriate illustration from the following list Figure 11 26 Galaxy Millennium Controller with Barrel Terminal Alarm Board Figure 11 27 Galaxy Millennium Controller with Wire Wrap Alarm Board Figure 11 28 Galaxy Vector Controller with Barrel Terminal Alarm Board 2 Route wires installer provided 22 gauge maximum from the office alarm block back to the controller by following the numbered ...

Page 109: ...cent Technologies Galaxy Power System 4804AP H569 450 Issue 1 June 2000 Installation 11 41 Connection of Office Alarms continued Figure 11 26 Galaxy Millennium Controller with Barrel Terminal Alarm Board ...

Page 110: ...Lucent Technologies Galaxy Power System 4804AP H569 450 11 42 Installation Issue 1 June 2000 Connection of Office Alarms continued Figure 11 27 Galaxy Millennium Controller with Wire Wrap Alarm Board ...

Page 111: ...Lucent Technologies Galaxy Power System 4804AP H569 450 Issue 1 June 2000 Installation 11 43 Connection of Office Alarms continued Figure 11 28 Galaxy Vector Controller with Barrel Terminal Alarm Board ...

Page 112: ... 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 Some of the following procedures are performed while ac voltage is present at the cabinet exercise extreme caution and observe all precautions described in the safety section of this product manual Refer to the following figures for illustrations of th...

Page 113: ...alaxy Power System 4804AP H569 450 Issue 1 June 2000 Installation 11 45 Power Up and Installation Completion continued Figure 11 29 Galaxy Vector Controller Front Panel Figure 11 30 Galaxy Millennium Controller Front Panel ...

Page 114: ...he appropriate shelf assembly Note Install rectifiers vertically starting at the bottom left side of the shelf assembly and working up and left to right if applicable Carefully slide the rectifier toward the rear of the shelf assembly Push until the unit is seated Gently pushing against the right side of the rectifier use a 5mm 3 1 inch Allen head wrench T handle to turn the recessed locking screw...

Page 115: ...This alarm will retire on its own after the rectifier ID is set in Step 10 10 To set the rectifier slot ID number follow these steps a Depress and hold the rectifier s power switch in the UP position for approximately five seconds The number displayed will begin to blink indicating that a new ID can be set b To set the ID depress and release the switch until the desired ID number is reached c Once...

Page 116: ...Lamp Test Step Action 1 Depress LAMP TEST on the controller display 2 Verify that the LEDs on the rectifiers and controller illuminate Note The green NORMAL LEDs will remain illuminated on the rectifiers controller and the remote peripheral monitoring modules optional The other controller LEDs will extinguish after several seconds and the remaining system LEDs will extinguish within approximately ...

Page 117: ...roller display To move to the correct screen to make the adjustment follow the appropriate procedure below Galaxy Millennium controllers press the following key sequence Main Config Plant Enter Move to ADJ PLV on the menu Galaxy Vector controllers use the following key sequence Config Up arrow key until FPC is on the display Enter 3 Use the ADJUST keys to calibrate the system voltage to match the ...

Page 118: ...controllers Config Up arrow key until FSP is on the display Enter 2 Verify that the HFV and HVSD alarm thresholds are set above the float voltage to be specified in Step 3 3 Use the adjust keys to set the system float voltage Setting the System Shunt Step Action 1 Enter the appropriate key sequence Galaxy Millennium controllers Main Config Shunt Type Enter Galaxy Vector controllers Config Up arrow...

Page 119: ...rrow key until C2tY is on the display 2 battery Enter Note The LVBD configuration must be set No alarm lights will show if this is not set Connecting Batteries Step Action 1 Turn the system OFF Turn the rectifiers to STBY Open the rectifier circuit breakers and system load circuit breakers if equipped 2 Connect the batteries to the system Set the battery contactor board switches from forced open t...

Page 120: ...Reduce the system load Verify that the rectifiers continue to share the load 7 Remove system load Testing Temperature Compensation Optional Feature Step Action 1 Enter the appropriate key sequence Galaxy Millennium controllers Main Config Bat Mngr STC Enter Galaxy Vector controllers Config Up arrow key until btAt is on the display Enter 2 Enable the slope thermal compensation feature if installed ...

Page 121: ... Simulate a load circuit breaker alarm by shorting the alarm contacts on the circuit breakers or inserting an operated alarm fuse Verify that the DIST and MAJ alarm LEDs illuminate and the controller alarms screen indicates EXTERNAL FUSE MAJOR Millennium controllers or FAJ Vector controllers Testing the BD Alarm and High Voltage Shutdown Step Action 1 Set the system load to 25 amperes 2 Turn all r...

Page 122: ...ady to connect to using equipment Install or turn on load protectors when needed Galaxy Millennium Controller System Alarm Test Step Action 1 Connect all office alarm wiring from the controller s office alarm terminal block to the office alarm monitoring system 2 Enable the alarm test feature Note Both the Galaxy Millennium controllers have factory hardware and software switches to enable the alar...

Page 123: ...e building must be maintained with in specified limits The temperature and humidity within the power room must be maintained within the limits specified in Section 9 of this product manual Refer to Table 12 A for system replacement parts Batteries The batteries must be maintained as directed by the battery manufacturer s requirements Rectifiers With the exception of a fan failure rectifiers are re...

Page 124: ...n the field under normal operating conditions This approach is appropriate when there are no remote alarm facilities at the site The second approach assuming one has remote alarm capability is to wait until the fan fails The rectifier will safely shut down and issue both a fail alarm and a thermal alarm The fan can then be replaced Since it is likely that all the rectifiers in that installation ar...

Page 125: ...tifier that is in operation is HOT to the touch Use appropriate precautions 3 Steps 3 and 4 for replacement only For a new installation proceed to Step 5 Locate the Allen head bolt in the center of the rectifier front panel Using the Allen wrench provided rotate the bolt counterclockwise to release the rectifier for removal 4 Caution Handle the rectifier with two hands one hand supporting the rear...

Page 126: ...n head bolt clockwise to pull the rectifier into the shelf 7 Once the rectifier has been installed set the rectifier ID Follow the directions for the ID Not Configured alarm in Table 14 E Millennium or rid in Table 15 E Vector Note The red LED on the rectifier will blink until the rectifier establishes communication with the controller After communication is established the controller will issue a...

Page 127: ...or capacitors to discharge 3 Loosen the white front cover by removing 14 screws 5 top 5 bottom 2 on each side Before fully removing the cover disconnect the ribbon cable from the display circuit pack 4 Remove the screws attaching the old fans to the chassis and carefully unplug the fan connector The fan connector is keyed and can be loosened by inserting a screwdriver into the slotted side of the ...

Page 128: ...ere alarm fuse 405673161 0 5 ampere alarm fuse 406530725 1 1 3 ampere alarm fuse 406421032 2 ampere alarm fuse 848262622 BLJ3 terminal board MSPMLNK2X Wire insertion tool 108409343 BIC7 bay interface card Millennium only PWCALCPXX Alarm Card MSLRD4818 Cabinet alarm lamp holder MSBD4802X Cabinet alarm lamp 48V Rectifier 107598120 596A 50A rectifier 407840792 Fan assembly MSDTA3E16 Allen head wrench...

Page 129: ... 12 B Galaxy Millennium Controller Circuit Boards Ordering Code Description 108029679 Display board BSK1 108029687 Alarm wire wrap board BSL1 848194551 Alarm barrel terminal BSL2 108029653 Basic control board BSH1 847950912 LCD module assembly display board 108029661 Intelligent control board BSJ1 108029695 Modem board BSM1 108163601 Data switch board BSW1 Table 12 C Galaxy Vector Controller Circu...

Page 130: ...Documentation GPS 4804AP Document Number Description GPS 4804AP H569 450 GPS 4804AP Ordering Guide YYH4804XX Manufacturing Drawings WD YYH4804XX Wiring Table Galaxy Millennium Controller J85501K 1 Manufacturing Drawings T83413 30 Wiring Drawing 167 792 180 Product Manual Galaxy Vector Controller T83314 30 Wiring Drawing 167 792 112 Product Manual Remote Peripheral Monitoring J85501G 1 Manufacturin...

Page 131: ...echnical Assistance Center RTAC at 65 240 8680 Safety Review all safety instructions and warnings in Section 10 before troubleshooting the GPS 4804AP Tools The following tools are necessary in order to troubleshoot the GPS 4804AP 3 16 inch 5mm Allen head wrench Insulated hand tools Calibrated digital voltmeter DVM with 0 05 accuracy on dc scale ESD wrist strap Warnings Hazardous ac and dc voltages...

Page 132: ...a technician has been dispatched to the system location as a first and fundamental step in diagnosing and correcting the problem For all trouble conditions proceed as follows Cabinet Alarm 1 Locate the plant Galaxy controller The controller is typically located in the cabinet identified as BAY ONE Because a trouble condition exists the red alarm on the top of the cabinet will be illuminated See Fi...

Page 133: ...uminated call your RTAC representative If the entire panel is blank check the controller fuse F3 basic power for the Millennium F1 on the BLJ board for the Vector See Figures 13 3 and 13 5 Verify that the controller is getting power If not replace fuse If the display is still blank call your RTAC representative Alarms Menu 3 To view the Alarms Menu Millennium controller If the default screen appea...

Page 134: ... Troubleshooting Millennium Systems Alarm LED Table AC 14 A AC Alarms BATT 14 B Battery Alarms BD 14 F Miscellaneous Alarms CTRL 14 C Controller Alarms DIST 14 D Distribution Alarms RECT 14 E Rectifier Related Alarms No LED 14 F Miscellaneous Alarms If an alarm condition exists but no alarm LED is lit refer to Table 14 F Section 15 Troubleshooting Vector Systems Alarm LED Table AC 15 A AC Alarms B...

Page 135: ...er a reset the green and yellow LEDs will both be lit while self diagnostics are in progress which will take about 30 seconds If all diagnostics pass the yellow LED will extinguish and the green LED will remain lit If a failure is detected during diagnostics the green LED will extinguish and the yellow LED will remain lit If a terminal is attached to the local port during diagnostics the diagnosti...

Page 136: ...CRIT BATT MAJ DIST MIN RECT NORM AC RM COM CTRL Lamp Test Plant Voltage V Help Escape Menu Enter Adjust BD CRIT BATT MAJ DIST MIN RECT NORM AC RM COM CTRL Lamp Test Plant Voltage V Help Escape Alarms Status Alarms Status BSM Modem Board BSH Basic Controller Board BSJ Intelligent Controller Board BSL Alarm Termination Board BSW Data Switch Board mounting location Controller Fuses F1 Option Power F2...

Page 137: ... display along with associated alarm LEDs These mnemonics and related alarms are described in the Galaxy Vector Controller product manual Figure 13 4 Vector Controller Display Figure 13 5 Location of Vector Controller Fuses and Boards PLANT VOLTAGE BATTERY TEST THERMAL COMPENSATION FLOAT BOOST VOLTS AMPS ESCAPE ENTER CONFIGURE DEFAULT BD MAJ BATT MIN DIST NORM RECT ALARMS STATUS CTRL VIEW ACTIVE A...

Page 138: ...ubleshooting Preparations Issue 1 June 2000 Reference Figures continued Rectifiers During normal operation the rectifier s green ON LED will be lit and the display will show the rectifier s output current Figure 13 6 Rectifier Display ID ALM ON STBY LIM FAN ALM BST ...

Page 139: ...age battery disconnect LVBD feature consists of a contactor circuitry on the Alarm Card board and associated wiring Control of the contactor is dictated by the Alarm Card contactor control board and the controller Figure 13 7 shows the location of the contactor control board in the GPS cabinet Figure 13 7 Low Voltage Battery Disconnect Contactor Control Switches ...

Page 140: ...tions Issue 1 June 2000 Reference Figures continued Miscellaneous Alarms Miscellaneous alarms include those related to AC input see Figure 13 8 DC distribution see Figure 13 9 Low voltage load disconnect see Figure 13 10 AC Input Figure 13 8 Detail of AC Input Panel and Rectifier Shelf ...

Page 141: ...Lucent Technologies Galaxy Power System 4804AP H569 450 Issue 1 June 2000 Troubleshooting Preparations 13 11 Reference Figures continued DC Distribution Figure 13 9 Detail of DC Distribution Panel ...

Page 142: ...nual The Alarm Card is mounted on the left side of the cabinet as shown in Figure 13 10 The manual contactor control switch S4 DIP Switch S7 Switch 1 is not meant to be used to permanently override the LVLD function It is only to be used temporarily while servicing or testing the equipment Switch S1 is used to disconnect the load It is to be used during servic ing or for emergency disconnection of...

Page 143: ...es information for locating and interpreting visual indicators to help identify problems in Galaxy Power Systems equipped with the Millennium controller Preparation Read Section 13 Troubleshooting Preparations thoroughly before pro ceeding Technical Assistance When visual indicators do not identify a defective part notify the local Regional Technical Assistance Center RTAC or LFS Team at 65 240 86...

Page 144: ...illennium Display Reference The Millennium display is illustrated below for quick reference while using the troubleshooting tables Alarm LED Table AC 14 A AC Alarms BATT 14 B Battery Alarms BD 14 F Miscellaneous Alarms CTRL 14 C Controller Alarms DIST 14 D Distribution Alarms RECT 14 E Rectifier Related Alarms RM 14 F Miscellaneous Alarms No LED 14 F Miscellaneous Alarms If an alarm condition exis...

Page 145: ...voltage is out of range Internal rectifier failure 1 Verify that ac circuit breaker is closed close circuit breaker if operated 2 If the problem is not corrected replace the rectifier AC MIN Engine Transfer Timeout Engine may have alarm Remote engine or connection to engine has failed Call your local RTAC representative AC MIN Phase Alarm PF on Rectifier Display Phase failure Rectifier high voltag...

Page 146: ...ent but the system voltage remains low call your local RTAC representative 2 Investigate other alarms that may be present rectifier related alarms and the AC Fail alarm may also occur during the fault condition BATT Alarm must be configured to turn on the BATT LED not a factory default MAJ Contactor 1 Open Red LED on contactor drive board is lit Contactor is open Open has been initiated by control...

Page 147: ... Millennium Controller Display Other Indication s Possible Problem s Possible Solution s BATT MIN Open String Alarm LED on battery fuse panel is lit Battery fuse has operated Replace the operated fuse BATT MIN Low Reserve Time Controller has calculated that batteries are low Call your local RTAC representative Table 14 B Battery Alarms See Figure 13 7 ...

Page 148: ... perform the following steps 1 Press the SW200 reset switch on the top of the BSH board If all diagnostics pass it is possible that some type of one time abnormality occurred to cause the failure 2 If the diagnostics did not pass or if the problem recurs unplug all the optional circuit board cables then press the reset switch on the top of the BSH board again If all the diagnostics pass install op...

Page 149: ...perform the following steps 1 Press the SW201 reset switch on the top of the BSJ board This circuit has an automatic restart which will try three times to restart the microprocessor 2 If the diagnostics did not pass or if the problem recurs remove all the optional circuit board cables then press the reset switch on the top of the BSJ board again If all the diagnostics pass install optional circuit...

Page 150: ...re BSJ failure Option board failure Display failure BIC failure Check the option boards modem and data switch to see if the green LED is extinguished and the yellow LED is lit If so perform the following steps 1 Press the SW201 reset switch on the top of the BSJ board This circuit has an automatic restart which will try three times to restart the microprocessor If the BSJ is not present press the ...

Page 151: ...otherwise mangled Replace the cable if damaged 2 Press SW200 to reset the BSH board 3 If the LCD module is still not operating replace the LCD module if the switches and LEDs are still not operating replace the BSH board CTRL MAJ Controller Fail BSH failure BSJ failure Option board failure Display failure BIC failure 1 Strap K1 K2 K3 on BLJ3 from C to R prior to replacing BIC See Figure 8 2 2 Repl...

Page 152: ...use has operated Replace the controller fuse labeled F4 voltage sense CTRL MAJ Bay Interface ID Conflict Two or more bay interface cards BICs have the same ID number Following instructions printed on the label over the BIC adjust the DIP switches to change the ID number CTRL MAJ Major Communication Fail Alarm Blinking ALM LED on rectifiers or red LED on BIC Loss of communication with controller De...

Page 153: ...ller Defective interface from rectifier to controller Internal controller or rectifier failure 1 Verify that the controller is powered and operating correctly 2 If there are no controller alarms replace the equipment that has lost communication 3 If the problem is not corrected call your local RTAC representative CTRL MIN Self Fail Test See Controller Fail Alarm See Controller Fail Alarm CTRL MIN ...

Page 154: ...ker has operated Replace fuse or reset circuit breaker DIST Alarm must be configured to turn on the DIST LED not a factory default MAJ Contactor 2 or 3 Open Red LED on contactor drive board is lit Contactor is open Open has been initiated by controller Open has been initiated manually 1 Follow instructions on the label adjacent to the contactor drive board see Figure 13 10 2 If the problem is not ...

Page 155: ... 1 Press ON STBY switch up and hold for five seconds until display starts blinking 0 2 Release switch display should continue to blink 3 Depress switch and release Display will increment up one number on each release of the switch but will remain flashing 4 Once the desired ID number appears depress and hold the switch for five seconds The display will cease to blink and then revert to the rectifi...

Page 156: ...ectifier failure 1 Toggle the ON STBY switch into the STBY position and then back into the ON position 2 If the problem is not corrected replace the rectifier RECT MIN Rectifier Fail ALM HO High output voltage Rectifier high voltage shutdown Internal rectifier failure 1 Verify the configurable HV thresholds in the controller 2 Toggle the ON STBY switch into the STBY position and then back into the...

Page 157: ...perature Internal rectifier failure 1 Verify that there is no obstruction of the fan inlet 2 Toggle the ON STBY switch into the STBY position and then back into the ON position 3 If the problem is not corrected replace the rectifier RECT MIN Rectifier Fail ALM CB Circuit breaker alarm DC output circuit breaker open Internal rectifier failure 1 Toggle the ON STBY switch into the STBY position toggl...

Page 158: ... Place the ac circuit breaker for the rectifier in the OFF position 2 Remover the rectifier from the shelf 3 Wait for 30 seconds or until all front panel display LEDs have extinguished 4 Replace the rectifier 5 Return the ac breaker to the ON position 6 Place the rectifier ON STBY switch into the ON position 7 If the problem is not corrected replace the rectifier RECT MIN Rectifier Fail ALM FSE Fu...

Page 159: ...the STBY position and then back into the ON position 2 If the problem is not corrected replace the rectifier RECT MIN Rectifier Fail ALM SEN Thermal sensor failure Internal rectifier failure 1 Place the ac circuit breaker for the rectifier in the OFF position 2 Remover the rectifier from the shelf 3 Wait for 30 seconds or until all front panel display LEDs have extinguished 4 Replace the rectifier...

Page 160: ...CT MIN External Transfer Shutdown STBY TR System is operating on external engine No action required RECT MIN High Float Voltage None None Configuration Problem Call your local RTAC representative RECT MIN Excess Rectifier Drain None None Internal rectifier fault Replace rectifier RECT MIN Excess System Drain None None System load exceeds shunt rating Call your local RTAC representative RECT MIN Li...

Page 161: ... not blink Remote Peripheral Module has failed Call your local RTAC representative RM MIN Measurement Out of Range Data being sensed exceeds remote peripheral module s capability Remote peripheral module has failed Call your local RTAC representative None MAJ Auxiliary Major Auxiliary equipment may have alarm Problem with operation of auxiliary equipment Call your local RTAC representative None MI...

Page 162: ...ontroller Display Other Indication s Possible Problem s Possible Solution s None None None Red LED is lit on some battery contactor drive boards while green LED is lit on others If a green LED is lit despite a contactor open command issued by the controller the drive card or the contactor has failed Call your local RTAC representative Table 14 F Miscellaneous Alarms ...

Page 163: ... information for locating and interpreting visual indicators to help identify problems in Galaxy Power Systems equipped with the Vector controller Preparation Read Section 13 Troubleshooting Preparations thoroughly before proceeding Technical Assistance When visual indicators do not identify a defective part notify the local Regional Technical Assistance Center RTAC or LFS Team at 65 240 8680 ...

Page 164: ...Vector front display is shown below for quick reference while using the troubleshooting tables Alarm LED Table AC 15 A AC Alarms BATT 15 B Battery Alarms BD 15 F Miscellaneous Alarms CTRL 15 C Controller Alarms DIST 15 D Distribution Alarms RECT 15 E Rectifier Related Alarms No LED 15 F Miscellaneous Alarms If an alarm condition exists but no alarm LED is lit refer to Table 15 F PLANT VOLTAGE BATT...

Page 165: ...is closed close circuit breaker if operated 2 If the problem is not corrected replace the rectifier s AC MIN ACF ACF on Rectifier Display Rectifier not receiving ac power AC input circuit breaker has operated AC input voltage is out of range Internal rectifier failure 1 Verify that ac circuit breaker is closed close circuit breaker if operated 2 If the problem is not corrected replace the rectifie...

Page 166: ...er is present but the system voltage remains low call your local RTAC representative 2 Investigate other alarms that may be present rectifier related alarms and the AC Fail alarm may also occur during the fault condition BATT MAJ C1O Red LED on contactor drive board is lit Contactor is open Open has been initiated by controller Open has been initiated manually 1 Follow instructions on the label ad...

Page 167: ...e Solution s CTRL MAJ None Controller failure Check controller to see if the green LED is extinguished and the red LED is lit If so perform the following steps 1 Remove and reset the controller circuit board If all diagnostics pass it is possible that some type of one time abnormality occurred to cause the failure 2 If the diagnostics did not pass Replace the controller circuit board and verify th...

Page 168: ...play failure If the front panel LED module LEDs or switches fail perform the following steps 1 Verify that the ribbon cable from the controller board to the BMW display is not cut abraded or otherwise mangled Replace the cable if damaged 2 Reset the controller board 3 If the display is still not operating replace the display module CTRL MIN tPA Battery thermal probe has failed Call your local RTAC...

Page 169: ...tactor is open Open has been initiated by controller Open has been initiated manually 1 Follow instructions on the label adjacent to the contactor drive board see Figure 13 10 2 If the problem is not corrected call your local RTAC representative DIST MAJ C2F Contactor or drive board has failed Call your local RTAC representative DIST MAJ FAJ Alarm LED on dc distribution panel will be lit DC load f...

Page 170: ...oblem s Possible Solution s RECT MAJ rid None None Rectifier ID number has not been set 1 Press ON STBY switch up and hold for five seconds until display starts blinking 0 2 Release switch display should continue to blink 3 Depress switch and release Display will increment up one number on each release of the switch but will remain flashing 4 Once the desired ID number appears depress and hold the...

Page 171: ...oss of communication with controller Defective interface from multiple rectifiers to controller Internal failure of controller or multiple rectifiers 1 Verify that the controller is powered and operating correctly 2 If there are no controller alarms replace rectifiers that have lost communication 3 If the problem is not solved call your local RTAC representative RECT MAJ HO ALM HO Lightning has st...

Page 172: ...l controller or rectifier failure 1 Verify that the controller is powered and operating correctly 2 If there are no controller alarms replace the rectifier 3 If the problem is not corrected call your local RTAC representative RECT MIN rFA ALM HO High output voltage Rectifier high voltage shutdown Internal rectifier failure 1 Verify the configurable HV thresholds in the controller 2 Toggle the ON S...

Page 173: ...into the STBY position and then back into the ON position 3 If the problem is not corrected replace the rectifier RECT MIN rFA ALM FSE Fuse alarm DC fuse open Internal rectifier failure 1 Toggle the ON STBY switch into the STBY position and then back into the ON position 2 If the problem is not corrected replace the rectifier RECT MIN rFA ALM LO Low output voltage Excessive output current Internal...

Page 174: ...S IP5 IP6 IP7 Internal rectifier failure 1 Place the ac circuit breaker for the rectifier in the OFF position 2 Remove the rectifier from the shelf 3 Wait for 30 seconds or until all front panel display LEDs have extinguished 4 Replace the rectifier 5 Return the ac breaker to the ON position 6 Place the rectifier ON STBY switch into the ON position 7 If the problem is not corrected replace the rec...

Page 175: ...or failure Internal rectifier failure 1 Place the ac circuit breaker for the rectifier in the OFF position 2 Remover the rectifier from the shelf 3 Wait for 30 seconds or until all front panel display LEDs have extinguished 4 Replace the rectifier 5 Return the ac breaker to the ON position 6 Place the rectifier ON STBY switch into the ON position 7 If the problem is not corrected replace the recti...

Page 176: ...splay Rectifier LED Rectifier Display Possible Problem s Possible Solution s RECT MIN rFA FAN ALM None Fan failure Replace the fan in the rectifier RECT MIN rOFF STBY Blank Rectifier has been manually turned off Turn rectifier on RECT MIN HFO None None Configuration problem Call your local RTAC representative Table 15 E Rectifier Related Alarms See Figures 13 6 and 13 8 ...

Page 177: ...t may be associated with other alarms Call your local RTAC representative None MAJ AUJ Auxiliary equipment may have alarm Problem with operation of auxiliary equipment Call your local RTAC representative None None None Red LED is lit on some battery contactor drive boards while green LED is lit on others If a green LED is lit despite a contactor open command issued by the controller the drive card...

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Page 179: ...nties given to Seller by its Vendor of such Vendor Items such assignment to be effective upon Customer s acceptance of such Vendor Items With respect to Vendor items recommended by Seller in its specifications for which the Vendor s warranty cannot be assigned to Customer or if assigned less than Sixty 60 days remain of the Vendor s warranty or warranty period when the Vendor s items are shipped t...

Page 180: ... 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 f...

Page 181: ...nt 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 yea...

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