ABB GPS2436 User Manual

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PRODUCT MANUAL

GPS2436 (H5692436) User's Guide

GPS2436 is available with Galaxy Millennium II or Galaxy Pulsar Plus controllers.

This manual is based on and includes information specific to the Galaxy

Millennium II controller.

Refer to these documents for information specific to the Galaxy Pulsar Plus

controller

Galaxy Pulsar Plus Product Manual CC848815341

•

GPS2436 Ordering Guide H5692436.

•

Notice:

The information, specifications, and procedures in this manual are subject to change without notice.

ABB Power assumes no responsibility for any errors that may appear in this document.

Product Manual

Ordering Code

850022020

Page 1

GPS2436_MAN

Rev. 1.3

Table of Contents

Troubleshooting

Summary of Contents for ABB GPS2436

Page 1 GPS2436 Ordering Guide H5692436. • Notice: The information, specifications, and procedures in this manual are subject to change without notice. ABB Power assumes no responsibility for any errors that may appear in this document. Product Manual Ordering Code 850022020 Page 1 ©...
Page 2: Table Of Contents
Front Panel Display ............................44 Controller Defaults ............................47 Controller Display Menu Maps ........................53 10 Acceptance Testing..........................63 Introduction ..............................63 Tools and Test Equipment ..........................63 Page 2 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 3 Rectifier Installation and Replacement Procedures .................. 79 15 Troubleshooting Procedure ....................... 81 Preliminary ................................ 81 Troubleshooting Procedure ........................... 82 16 Product Warranty ..........................83 17 Revision ............................... 85 Page 3 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 5: Introduction
Galaxy Power System. GPS2436 is available with Galaxy Millennium or Galaxy Pulsar Plus controllers. Both controllers provide many advanced functions and features, including;...
Page 6: Customer Service Contacts
On-Line Power Systems Product Manuals and Software Power Systems product manuals and software are available on-line. Software includes Easy View and SNMP MIB. Page 6 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 7: System Description
A basic block diagram of the Galaxy Power System 2436 is shown in Figure 2-1. It illustrates the arrangement and interconnection of the system components from the ac input to the dc output. Figure 2-1 Block Diagram of the GPS2436 System The power system accepts alternating current from the commercial utility or a standby ac power source and rectifies it to produce dc power for the using equipment.
Page 8: Architecture
Architecture Configurations The GPS2436 is a 7-foot cabinet that can provide up to 3600 amps of DC power in a single cabinet. Figures 2-1 and 2-2 show diagrams of single cabinets. Each cabinet contains ac distribution, dc distribution panels, a battery connection panel, rectifiers, termination points for load circuits, and a system controller.
Page 9 Figure 2-3 Schematic of two-cabinet system architecture Controller Rectifier Rectifier Battery Rectifier Battery Battery Distribution Distribution Distribution Cabinet Cabinet Cabinet Figure 2-4 Schematic of Three-cabinet System Architecture 1800A Maximum per system. Page 9 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 10 AC Panel Circuit Breakers or Terminal strip Miscellaneous DC Distribution Panels Rectifier Shelves 3,6 or 9 Figure 2-5 GPS2436 Six shelf cabinet with door removed Page 10 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 11: Galaxy Millennium Ii Controller
3 Galaxy Millennium II Controller Overview Introduction The GPS2436 comes equipped with the Galaxy Millennium II Controller. This section describes the controller operation and general information about the features of the front panel keys, LEDs, and display. The Galaxy Millennium II Controller provides advanced local and remote monitoring and data acquisition features.
Page 12 A rubber flap can be opened to access the local port connector. The DB-9 local port connector supports standard RS232 serial communication. Refer to the Galaxy Millennium II Controller product manual for additional details on port configuration and isolation. Page 12 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 13 RPM System Product Manual Refer to the Galaxy Remote Peripheral Monitoring System product manual (Ordering Code 107570517) for additional information regarding RPM module operation. Page 13 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 15: Rectifiers
When the output current tends to increase above the current limit set point, the current limit circuit overrides the voltage regulating signal and safely limits the output current of the rectifier, thus preventing damage to itself or the load. Page 15 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 16 “Forced” Load Sharing Internal rectifier circuitry will allow rectifiers to share load in the event communication to the controller is lost or the controller malfunctions. Page 16 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 17: Ac Input Panels
Overview AC Service The ac input panel provides the facility to terminate 3-phase ac service to the GPS2436 system or to distribute individual 1-phase ac supplies to each of the system rectifier positions. Depending upon the option ordered, the panel will connect 3-wire (three phases), 4-wire (three phases + neutral), or individual 2-wire (single phase, either 2 hot leads or 1 hot lead and neutral) input ac service.
Page 18 Figure 5-3: AC Input circuit Breaker Panel CB10 CB11 CB12 Figure 5-4: AC circuit breaker wiring and rectifier positions Page 18 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 19: Battery Connection Panels
Overview Function Batteries are connected to the GPS2436 cabinets on battery connection panels located in the cabinet directly below or behind the ac input panel. All panels include the battery shunt and an alarm card that communicates with the controller to provide battery current and status information. The panel includes a low voltage battery disconnect/reconnect (LVBD/R) contactor.
Page 21: Dc Distribution Panels
6 Positions for Terminal Card large U.S. Circuit Breakers with shunts Connects to Charge Return Bus 12” REF (305mm) Alarm Card Figure 7-2: H569-4827 G43 (ED83143-31 G1) DC Distribution Panel Page 21 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 22 Figure 7-4: H569-4827 G96 (ED83143-31 G15) DC Distribution Panel Alarm/Terminal Card 10 Medium U.S. Fuse Holders Connects to Charge Return Bus 6”REF (152mm) Figure 7-5: H569-4827 G52 (ED83143-31 G53) DC Distribution Panel Page 22 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 23 DIN Fuse Holders (14 x 51mm fuses, 1-50A) Alarm Cards Connects to Charge Return Bus 6” REF (152mm) Figure 7-7: H569-4827 G60/61/65/66 (ED83143-31 G71) DC Distribution Panel Page 23 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 24 Figure 7-9 H569-4827 G68 (ED83143-31 G21) DC Distribution Panel Alarm/Terminal Card Connects to Charge Return Bus G97: 6” REF (152mm) G98: 9” REF (229MM) Figure 7-10 H569-4827 G97, G98 (ED83143-31 G17) DC Distribution Panel Page 24 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 25 6’’REF (152mm) TPL-C Fuse Head Furnished With Block. Order 408472322 TPL-B Fuse Block Head for 70A - 250A Fuses. Figure 7-12 H569-4827 G59 (ED83143-31 G21) DC Distribution Panel Page 25 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 27: External Return Bars
8 External Return Bars Overview Modular external return bus bar kits are available for the GPS2436 system. These kits are alternatives to the standard internal return buses. These kits allow for modular growth of the bars from bay to bay and offer additional cable landings.
Page 28 CC109170197 Wide Bay CC109170511 Standard Bay Modular Distribution Bay Overhead Buses CC109170180 Modular Rectifier Bay Overhead Bus Figure 8-2 Horizontal Rectifier Standard and Wide Distribution Bay bus bar system Page 28 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 29 CC109170412 Modular Distribution Wide Bay Overhead Bus Field Option A Field Option B CC109170404 Rectifier Bay Overhead Bus Figure 8-3 Vertical rectifier standard and Wide distribution bay return bus bar systems Page 29 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 31: Millennium Ii Controller Operation
Use only insulated tools. Make sure the system is properly grounded per the National Electrical Code and local building codes. Remove all metal jewelry before beginning the installation. Page 31 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 32 Jewelers screwdriver (Flat and Phillips) Small needle nose pliers Digital meter, +/- 0.02% Screw Drivers (flat-blade and Phillips) ESD wrist strap Wire-wrap tool or Amp alarm punch-down tool Figure 9-1: Millennium II Page 32 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 33: Controller Connections
Terminal block interface for RS232/RS485 Auxiliary port and Remote Peripheral Module (RPM) connections Terminal block interface for three additional 10K thermistor probe or 210E connection options USB interface (reserved for future use) Table 9-A: Millennium II Interface Reference Page 33 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 34: Installing Circuit Packs
Secure the BSW board to the standoffs with two 900562208 screws. To install the Data Switch Extension board, please see the User’s Guide for Millennium II Controller Advanced NOTE: Features manual. Page 34 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 35 • Temperature monitor (7 Channels) • Control Relay module (3 sets of programmable form C relay outputs) The user may connect a maximum of 95 of any combination of these modules serially. Page 35 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 36 After approximately 1 minute, the green LED on the front of the module will blink once approximately every 5 seconds. Detailed troubleshooting information may be found in the User’s Guide for Millennium II Controller Advanced Features manual. Page 36 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 37: Thermal Probes
This interface is reserved for future use. Local Port Software EasyView software is a Windows-compatible communications package designed specifically for use with Galaxy controllers. Download EasyView software from abbpowerconversion.com Page 37 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 38: Wiring Alarm Outputs
USR3PRESETN/ BTPFLT now general I/O- 3 UR3R Now VLVR USR3DETECT/ BTMJ UR3C Now VLVC 0-5V in PMNER UR3O Now VLVO 0-5V Rtn PMNEC LVD2 PMNEO LVD2R MJFO MJFC Page 38 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 39 Power Minor-Audio PMNAR PMNVR PMNVC Power Minor –Visual PMNVO PMNER PMNEC Power Minor –External PMNEO MJFO MJFC Major Fuse MJFR MNFR MNFC Minor Fuse MNFO Battery On Discharge Page 39 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 40: Wiring Alarm And Control Inputs
Fuse Alarm Major Fuse Alarm Minor Auxiliary Alarm Major Auxiliary Alarm Minor Timer Float Control TFLT Timer Boost Control TBST Plant Battery Test Open String Detect Transfer Rectifier 1 Page 40 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 41 Low Voltage 3 Disconnect State Detect Also LVD3/ BTMJ Battery Thermal Protect Major General Purpose 0-5Vdc Measuring Circuit 0-5V General Purpose 0-5Vdc Measuring Circuit-RTN 0-5VR Table 9-C: Controller Alarm Controller Inputs Page 41 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 42 A battery potential input is required, which must use an external 1K ohm, 2W current limiting resistor at the source if not using standard ABB Power LVD circuit boards or controller. This circuit is used to inform Galaxy that the monitoring circuit of a Low Voltage Disconnect device has failed. In standard Galaxy Power Systems, the Bay Interface board monitors these alarms and informs the Controller through the serial interface connection.
Page 43 This is an alternate plant voltage source for user alarm systems. This power is fused with a 1-1/3 ampere ABS fuse. BSL-95,96 DG: Discharge Ground Plant ground/return source for user alarm systems. Page 43 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 44: Fuses
Millennium. It looks very similar to the L51 option. LCD assembly, but the L52 also provides a built-in audible alarm and digital contrast adjust that are only available when used with the Millennium II controller. Page 44 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 45 (Critical, Major, Minor, Nominal) of the various alarms. Operation of the status LEDs can be reconfigured via the local or remote controller interfaces. Page 45 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 46 A ground referenced RS-232 local port is provided at the front of the display to allow easy connection to a personal computer or terminal using ANSI T1.317 object oriented command language. ABB Power’s EasyView is also available to provide a user friendly system interface locally or remotely. See figure 4-6.
Page 47: Controller Defaults
DISABLED SW202-3 Boost Mode ENABLED DISABLED SW202-2 Reserved for Future Use ENABLED DISABLED SW202-1 Reserved for Future Use ENABLED DISABLED Table 9-G: Millennium II Controller Dip Switch Settings Page 47 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 48 Change Reserve Time Low Alarm Threshold and Severity Change Multiple Converter Fail Alarm Threshold and Severity Change Battery On Discharge Alarm Threshold and Severity Table 9-H: Enhanced Remote Security Features Page 48 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 49 Battery Test Failed Minor None Bay Interface ID Conflict Major CTLR CTLR Battery Test Active Battery Thermal Major Major None Table 9-J:Controller Alarm Severity, LED and Relay Default Values (Continued) Page 49 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 50 Minor None Major Communication Fail Minor CTLR None Module Failure Minor None Measurement Out Of Range Minor None Table 9-J:Controller Alarm Severity, LED and Relay Default Values (Continued) Page 50 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 51 MMAN Multiple MAN Alarm Major RECT None Phase Or Low Output Minor None Rectifier Incomplete Config Warning None None Rectifier Fail Minor RECT Table 9-K: Rectifier Alarm Defaults Page 51 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 52 • Configure • Control • View Status • View History • View Statistics • Perform Diagnostics These menu operations are accomplished by navigating through different screens. Page 52 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 57 12 or 24 hour. Use the <+> or <-> key to select the desired format and press <ENTER> to save the change. Time Allows you to change/set the time. Enables or Disables Daylight Savings. Daylight Page 57 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 58 Move the cursor to the SHUNT I field by using the <UP>/ <DOWN>/<LEFT>/<RIGHT> ARROW keys. Use the <+> or <-> key to step through the available values (0-99999). Select the desired value; press <ENTER> to save the change. Page 58 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 59 Very Low Voltage generated. Move the cursor to the field and use the <+> or <-> key to adjust the threshold value. Press <ENTER> to save the change. Page 59 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 60 Cells/String battery test features. Move the cursor to the field and use the <+> or <-> key to adjust the threshold value. Press <ENTER> to save the change. Page 60 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 61 This enables or disables the low temperature compensation feature. This sets the minimum temperature for which thermal compensation is Low Comp Limit active. Increase This sets the slope (mV/degC) for low temperature compensation. Page 61 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 62 Reconnect voltage is recommended. Use the <+> or <-> key to adjust the voltage to the desired level. Press <ENTER> to save the change. Page 62 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 63: Acceptance Testing
Press Enter again to start the test, or Escape to return to the menus. Observations: • LCD Refreshes • Front Panel LEDs ALL turn on momentarily and return to normal • NO alarms are generated from this test Page 63 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 64 DVM. The DVM reading will be the one to change since Rectifier Manager will adjust rectifier outputs as NOTE: necessary per the calibration performed. Page 64 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 65 Press ENTER to save. Observe: • The plant voltage decreases to the original set voltage • Power Minor alarm (PMN) retires • RECT and MIN LEDs are extinguished Page 65 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 66 RFA (HO) alarm is received. After the second RFA (HO) is received, the controller waits 5 minutes before sending one additional restart signal. Verify the Auto Restart is enabled from the front panel menus: Page 66 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 67 • Prior to this occurring, change the value of the system voltage to its original value. Press ENTER to save the change. • Restart the rectifier from the front panel by using the menus: Page 67 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 68 BD and MAJ LEDs are illuminated Turn on all rectifiers Controller Observations: • PMJ Alarm retires • BD and MAJ LEDs are extinguished • System Voltage is normal Page 68 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 69 Using the Up/Down Arrows, Scroll to Control/Operations and press Enter. Select Clear History, and press Enter. Press Enter again to clear the History Log, or Escape to return to the menus. Page 69 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 71: 11Circuit Boards
Every cabinet in a Galaxy Power System has a Bay Interface Card (BIC). The BIC provides controller access to alarm monitoring, battery voltages, battery currents, and temperature probes in the cabinet through the serial rectifier bus Page 71 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 73: Specifications
Maximum discharge is 1600 amps per cabinet. No distribution panels can be installed in a DC Distribution rectifier only cabinet, as many distribution panels as will fit can be installed in other cabinets. 1. With Galaxy Millennium Controller Page 73 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 74 Earthquake Rating Zone 4, upper floors Standards Compliance CE Marked, UL Agency Approvals Underwriters Laboratories (UL) Listed per Subject Letter 1801, DC Power Distribution Centers for Telecommunications Equipment Page 74 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 75: Rectifier
Rectifier Rectifier Specifications850022020 GPS2436 Prod Man r01.docx Electrical Input Voltage Range 175-275Vac, 2-wire, single phase (150 Vac - 300 Vac with reduced performance) Frequency Range 45 - 66 Hz Power Factor > 0.98 at > 50% rated output AC Surge Protection: It is important that ac surges reaching rectifiers do not exceed the capacity of the rectifier internal surge protection.
Page 76 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. Page 76 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 77: Safety
• This product operates equally well if installed as part of the Isolated Ground Plane (Isolated Bonding Network) or the Integrated Ground Plane (Mesh- Bonding Network, aka, Common Bonding Network). ABB recognizes there are different grounding techniques that are equally successful. Adhere to a commonly accepted and consistent grounding approach to ensure personnel safety, network protection, and proper equipment operation.
Page 79: Maintenance And Replacement
Slide the rectifier into the slot until it engages with the rear of the shelf. Swing the faceplate closed to seat the rectifier. Verify the faceplate is latched. Page 79 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 81: Troubleshooting Procedure
Coordinate all troubleshooting activities with other personnel that may be working on the system. Table 1: Warnings Tools The following tools are necessary in order to troubleshoot the GPS2436: • Calibrated digital voltmeter (DVM) (0.05 accuracy on dc scale) • ESD wrist strap...
Page 82: Troubleshooting Procedure
3. To view the Alarms Menu: If the default screen appears normal, press the MENU button. The main menu appears with “Alarms” blinking. Press ENTER to obtain the Alarms menu. Additional data appears that will help to identify the problem. Page 82 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 83: Product Warranty
F. If Seller determines that a Product for which warranty service is claimed is not defective or nonconforming, Customer shall pay Seller all costs of handling, inspecting, testing, and transportation and, if applicable, traveling and related expenses. Page 83 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 84 WARRANTIES, INCLUDING BUT NOT LIMITED TO WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. CUSTOMER’S SOLE AND EXCLUSIVE REMEDY SHALL BE SELLER’S OBLIGATION TO REPAIR, REPLACE, CREDIT, OR REFUND AS SET FORTH ABOVE IN THIS WARRANTY. Page 84 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 85: Revision
17 Revision Rev. Description Date Dept./Init. Updated as per template 11/12/2021 Updated page footer 3/30/2023 Page 85 © Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3...
Page 86 – in whole or in parts – is regard to purchase orders, the agreed particulars shall forbidden without prior written consent of ABB. prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this Copyright© 2021 ABB document.

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