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ABB Galaxy Power System Installation Manual

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INSTALLATION MANUAL
Installation Guide for Galaxy Power Systems
Note: Instructions in this manual reference installation and setup of GPS 4848/100, GPS 4827, and GPS
4830 power systems, using the Millennium II Controller. For installation and setup with other
controllers and rectifiers refer to their product manuals.
Page 1
© Copyright 2021 ABB. All rights reserved.

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Summary of Contents for ABB Galaxy Power System

  • Page 1 Note: Instructions in this manual reference installation and setup of GPS 4848/100, GPS 4827, and GPS 4830 power systems, using the Millennium II Controller. For installation and setup with other controllers and rectifiers refer to their product manuals. Page 1 © Copyright 2021 ABB. All rights reserved.

  • Page 2: Table Of Contents

    Cabinet Ground and Central Office Ground ..................32 Cabinet Ground Procedure ....................... 32 Central Office Ground Procedure ..................... 32 Centralized Architecture ........................32 Distributed Architecture ........................32 Recommended Cable Rack Layout ....................34 Page 2 © Copyright 2021 ABB. All rights reserved.
  • Page 3 Table 7-B2: AC Panels Cross Reference – GPS 4830 ............... 62 Table 7-B3: AC Panels Cross Reference – GPS 4827 ..............63 AC Input Panels ..........................64 Wiring Options for ED8314230 Group 2 ..................64 Page 3 © Copyright 2021 ABB. All rights reserved.
  • Page 4 9. Remote Peripheral Monitoring ......................112 Overview ............................112 RPM Modules ............................112 Table 9-A: RPM Modules and Connection Units ................112 Current Limiting Resistors ......................... 112 Mounting Locations..........................113 Page 4 © Copyright 2021 ABB. All rights reserved.
  • Page 5 Connecting Batteries ..........................141 Testing Rectifiers and Load Share ....................... 143 Testing Additional Alarms........................143 Testing the BD Alarm ..........................143 Millennium II Controller System Alarm Test ..................144 Connecting to Load ..........................144 Page 5 © Copyright 2021 ABB. All rights reserved.

  • Page 6: Introduction

    ED83143-31 (DC) J85582C-1 (System) Wiring Diagram T83314-30 Millennium II Controller Manufacturing Drawing J85501P-1 Product Manual 108994645 Remote Peripheral Monitoring System Manufacturing Drawing J85501G-1 Wiring Diagram T83275-30 Schematic Drawing SD-83275-01 Product Manual Select Code 167-790-063 Page 6 © Copyright 2021 ABB. All rights reserved.

  • Page 7: Customer Service Contacts

    For other customers worldwide contact your local field support center or your sales representative to discuss your specific needs. Customer Training ABB offers customer training on many Power Systems products. For information call 1-972-244-9288 (WATT). This number is answered from 8:00 a.m. until 4:30 p.m., Central Time Zone (Zone 6), Monday through Friday.

  • Page 8: Safety

    2. 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. · The Galaxy Power Systems, GPS 4848/100, GPS 4827, and GPS 4830, are Underwriters Laboratories...
  • Page 9 Grounding – Connect the equipment chassis directly to ground. In enclosed equipment cabinets connect to the cabinet AC service ground bus. In huts, vaults, and central offices connect to the system bonding network. Page 9 © Copyright 2021 ABB. All rights reserved.

  • Page 10: Warning And Safety Symbols

    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.” Page 10 © Copyright 2021 ABB. All rights reserved.

  • Page 11: Precautions

    DC protectors used in distribution panels, as shown in Table 2 - B. *This configuration is not recommended Figure 2 - 1: Short Circuit Current Calculations Page 11 © Copyright 2021 ABB. All rights reserved.
  • Page 12 11, 12 100,000 Small plug-in fuse (TPA) Not available from ABB DIN-style fuses Contact fuse or circuit breaker manufacturer. Not available from ABB DIN-style circuit breakers Contact fuse or circuit breaker manufacturer. Page 12 © Copyright 2021 ABB. All rights reserved.
  • Page 13 Identify exposed hazardous electrical potentials on connectors, wiring, etc. (note the condition of these circuits, especially any wiring). · Avoid contacting circuits when removing or replacing covers. · Use a personal ESD strap when accessing or removing electronic components. Page 13 © Copyright 2021 ABB. All rights reserved.

  • Page 14: Special Installation Notes

    (Warning: For continued protection against fire replace with same type and rating of fuse.) · Das Schaltnetzteil ist ein Gerät der Schutzklasse I (Power Supply is a Class I Equipment) Page 14 © Copyright 2021 ABB. All rights reserved.
  • Page 15 (Beton, Metall usw.) (No fire enclosure, must be mounted on non-combustible surface) · Das Gerät wird fest am Boden installiert (siehe weitere Anleitung) (Must be bolted to the floor) Page 15 © Copyright 2021 ABB. All rights reserved.

  • Page 16: Español - Spanish

    Advertencia: Para una protección continua contra incendios, reemplace por el mismo tipo y clasificación de fusible. · La fuente de alimentación es un equipo clase I (Power Supply is a Class I Equipment) Page 16 © Copyright 2021 ABB. All rights reserved.
  • Page 17 · Sin cabina contra incendios, suelo no combustible (No fire enclosure, must be mounted on non - combustible surface) · Debe estar anclado al piso (Must be bolted to the floor) Page 17 © Copyright 2021 ABB. All rights reserved.

  • Page 18: Français - French

    ATTENTION: Pour ne pas compromettre la protection contre les risques d’incendie, remplacer par un fusible de même type et de mêmes caractéristiques nominales. · Alimentation est un équipement de classe I (Power Supply is a Class I Equipment) Page 18 © Copyright 2021 ABB. All rights reserved.
  • Page 19 Aucune enceinte d'incendie, doit être monté sur une surface non combustible (No fire enclosure, must be mounted on non-combustible surface) · Doit être boulonné au sol (Must be bolted to the floor). Page 19 © Copyright 2021 ABB. All rights reserved.

  • Page 20: Getting Started

    3. 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.

  • Page 21: Torque Settings For Hardware

    Cable rack not supported by cabinets is in place. · Job Site Documentation is available that details cabinet locations, dc distribution assignments, and Remote Peripheral Monitoring System module location and assignment. Page 21 © Copyright 2021 ABB. All rights reserved.

  • Page 22: System Electrical Architecture Overview

    (+ polarity) currents. The shunt readings are summed with the rectifiers’ currents by the system controller to determine the plant’s total load current. Figure 4-1: Single-Cabinet Configuration, Distributed Architecture Page 22 © Copyright 2021 ABB. All rights reserved.

  • Page 23: Distributed Architecture

    ( - polarity) or discharge ( + polarity) current. The shunt readings are summed with rectifier loads to determine the plant’s total load current. Figure 4 - 2: Two-Cabinet Configuration, Distributed Architecture Page 23 © Copyright 2021 ABB. All rights reserved.
  • Page 24 Distributed Architecture (continued) Figure 4 - 3: Three-Cabinet (or more) Configuration, Distributed Architecture Page 24 © Copyright 2021 ABB. All rights reserved.

  • Page 25: Centralized Architecture

    (to an existing cabinet or adding a new cabinet), or by adding more batteries. Figure 4 - 4 illustrates the centralized architecture. Figure 4 - 4: Centralized Architecture Page 25 © Copyright 2021 ABB. All rights reserved.
  • Page 26 Busway applications) shunt channels. Shunts monitored directly by the M2 controller use no CLRs (Current Limiting Resistors), while shunts monitored by BIC or PIC shunt channels must include CLRs in the monitoring path. Refer to Section 6 for details. Page 26 © Copyright 2021 ABB. All rights reserved.

  • Page 27: Cabinet Floor Mounting And Grounding

    Mounting dimension of 24” Wide GPS 4830, 434, 4827 Bottom View Top View Figure 5 - 1: Footprint for Galaxy Power System Cabinets of 4830, 434, 4827 Note: Remove panels located on the back of the cabinet to access mounting hardware. Page 27...

  • Page 28: Mounting Dimension Of 4830, 434

    Mounting dimension of 36” wide GPS 4830, 434 Bottom View Top View Figure 5 - 2: Footprint for Galaxy Power System Cabinets of 4830, 434 Note: Remove panels located on the back of the cabinet to access mounting hardware. Page 28...

  • Page 29: Mounting Dimension Of 4827

    Mounting dimension of 30” Wide GPS 4827 Bottom View Top View Figure 5 - 3: Footprint for Galaxy Power System Cabinets of 4827 Note: Remove panels located on the back of the cabinet to access mounting hardware. Page 29 © Copyright 2021 ABB. All rights reserved.

  • Page 30: Procedure

    Locate the cabinet in position using two or four anchor bolts and hold - down washers. Shim under cabinet corners to level. Torque anchors as specified in Table 5 - A. Secure cabinets together using the hardware provided. Note: See H569 - 407 for more details. Page 30 © Copyright 2021 ABB. All rights reserved.
  • Page 31 Shown here is multi-cabinet installation. Shims provided For single cabinet installation, ignore the 842439861 (0.063”) side by side illustration. 842439879 (0.125”) 842439887 (0.25”) Figure 5 - 5: Air inlet cover installation Page 31 © Copyright 2021 ABB. All rights reserved.

  • Page 32: Cabinet Ground And Central Office Ground

    Run and connect the system ground lead to the initial cabinet return bus. This connection will connect the re- turn side of the dc system to earth ground. Torque connections as specified in Figure 5 - 6. Page 32 © Copyright 2021 ABB. All rights reserved.
  • Page 33 Cabinet Ground and Central Office Ground (Continued) Figure 5 - 6: Full-Height Cabinet and System Central Office Ground Page 33 © Copyright 2021 ABB. All rights reserved.

  • Page 34: Recommended Cable Rack Layout

    Recommended Cable Rack Layout Figure 5 - 7: Various Cable Rack Arrangements Page 34 © Copyright 2021 ABB. All rights reserved.

  • Page 35: Notes

    Notes Page 35 © Copyright 2021 ABB. All rights reserved.

  • Page 36: Centralized Or Distributed Architecture Connections

    This section covers the special requirements for multiple-cabinet installations. These are: · Centralized Architecture DC power connections to central bus bar Remote voltage sense (regulation) and system shunt for the Galaxy Power System controller · Distributed Architecture Inter cabinet dc power bus connections ·...
  • Page 37 Centralized Architecture (continued) To Centralized Charge Ground Bus Bar Figure 6-1: DC Power Connections to Centralized Bus Bars Page 37 © Copyright 2021 ABB. All rights reserved.

  • Page 38: Remote Voltage Sense And System Shunt For Millennium Ii Controller When In A Cabinet With Blj/Bic9 Bay Board

    Original Path of Slate and Butt Splice Black Voltage Sense Wires (dashed line) Figure 6 - 2: System Shunt and Remote Voltage Sense for Millennium II Controller in Cabinet with BLJ/BIC9 Bay Board Page 38 © Copyright 2021 ABB. All rights reserved.

  • Page 39: Remote Voltage Sense And System Shunt For Millennium Ii Controller When In A Cabinet With Bic10 Bay Board

    NOT use any CLRs (Current Limiting Resistors) in this circuit. Note: For -48V systems, the SH- connection is to the load side of the shunt (if it is in the return path), and the SH+ Page 39 © Copyright 2021 ABB. All rights reserved.
  • Page 40 Centralized Architecture (Continued) Figure 6-3: System Shunt and Remote Voltage Sense for Millennium II Controller in Cabinet with BIC10 Bay Board Page 40 © Copyright 2021 ABB. All rights reserved.

  • Page 41: Remote Voltage Sense And System Shunt For Millennium Ii Controller When In A Cabinet With Bic11 Bay Board

    CLRs (Current Limiting Resistors) in this circuit. Note: For -48V systems, the SH- connection is to the load side of the shunt (if it is in the return path), and the SH+ Page 41 © Copyright 2021 ABB. All rights reserved.
  • Page 42 Centralized Architecture (Continued) Table 6: BIC 11 - Terminal block positions Figure 6-4: System Shunt and Remote Voltage Sense for Millennium II Controller in Cabinet with BIC11 Bay Board Page 42 © Copyright 2021 ABB. All rights reserved.

  • Page 43: Ground Terminal Strip In 4800A Gps Distribution-Only Cabinets

    In order for the BIC or M2 to be powered in these cabinets, a 12 ga return lead must be extended from the external plant return bus to this ground terminal strip. Page 43 © Copyright 2021 ABB. All rights reserved.
  • Page 44 Refer to Figures 6 - 9 or 6 - 10 and the configuration section that follows them for information on the wiring and configuration of the distribution cabinet shunt pair required for the proper monitoring of multiple Load shunts use the ED83311 - 30 overhead bus assemblies. Page 44 © Copyright 2021 ABB. All rights reserved.

  • Page 45: Distributed Architecture

    Refer to Figure 6 - 5 for this procedure Intercabinet DC Power Bus Connections Step Action Install the intercabinet bus bars as shown. Install the bus bar shield as shown. Torque connections as specified in Figure 6 - 5. Page 45 © Copyright 2021 ABB. All rights reserved.
  • Page 46 Wide Cabinet Kits for 4827: 1800A (1600225620A) and 5000A (7000244838A) Note that 434 Supplemental Bays come standard with 1800A bay to bay kit. All other bays require interconnect kits, see ordering guide Page 46 © Copyright 2021 ABB. All rights reserved.

  • Page 47: Intercabinet Alarm And Serial Bus Connections

    Note: Remove and discard any resistors that are blocking access to J6 or J5 connection points, except for those in J5 of the last cabinet. Figure 6 - 6: BLJ2 or BLJ3 Board Connections, Millennium Controller Page 47 © Copyright 2021 ABB. All rights reserved.

  • Page 48: Blj2/3 To Bic10 Or Bic10 To Bic10 (Millennium Ii Controller)

    RS485 termination jumper to the 2 - 3 position in the BIC 10 of the last cabinet in the system. Figure 6 - 7: BIC 10 Intercabinet Alarm and Serial Bus Wiring Page 48 © Copyright 2021 ABB. All rights reserved.

  • Page 49: Blj2/3 To Bic11 Or Bic11 To Bic11 (Millennium Ii Controller)

    BLJ2/3 board. Set the RS485 termination jumper to the 2 - 3 position in the BIC11 of the last cabinet in the system. Figure 6 - 8: BIC11 Intercabinet Alarm and Serial Bus Wiring Page 49 © Copyright 2021 ABB. All rights reserved.

  • Page 50: Bay Id And Shunt Size Configuration

    If the Software Configured Shunt Size is selected, proceed to the next section on configuration of it using the Millennium II controller web pages. BICJ/BIC9 Shunt Circuits Figure 6-9: BLJ2/3 DIP Switch Settings When Using a Millennium II Controller Page 50 © Copyright 2021 ABB. All rights reserved.

  • Page 51: Bic10 (Millennium Ii Controller)

    If the Software Configured Shunt Size is selected, proceed to the next section on configuration of it using the Millennium II controller web pages. Figure 6 - 10: BIC 10 Bay ID and Shunt Size Configuration Page 51 © Copyright 2021 ABB. All rights reserved.

  • Page 52: Bic11 (Millennium Ii Controller)

    If the Software Configured Shunt Size is selected, proceed to the next section on configuration of it using the Millennium II controller web pages. Figure 6 - 11: BIC11 Bay ID and Shunt Size Configuration Page 52 © Copyright 2021 ABB. All rights reserved.

  • Page 53: Millennium Ii Controller Configuration Of Bic Shunt Channels

    3. All BIC Current inputs should be listed. Those with current values (including zero) are installed and active. The BIC current monitoring channels are identified by “BCMxxyy” where “xx” is the input channel number and “yy” is the ID number set for the BIC. Page 53 © Copyright 2021 ABB. All rights reserved.
  • Page 54 Shunts” checkbox there must be selected. Set both to NONE · Click the “Submit Channel” button to ensure all changes are saved. · Repeat for all BIC monitored software configured Shunt channels. Page 54 © Copyright 2021 ABB. All rights reserved.

  • Page 55: Ac Connection And Wiring

    7. AC Connection and Wiring Safety Read Section 2, Safety, carefully before connecting AC to the Galaxy Power System. Wire Sizing and Ampacity Table 7-A: Wire Sizing and Ampacity NEC Table 310.15(B)(16) Standard Ga Metric (mm (Formally Table 310.16) see Note Note: For NEC code compliance, all conductor sizing calculations for derating due to ambient temperature and the number of conductors in a conduit are made assuming 90°C rated...

  • Page 56: Gps 4830:Gp100 Rectifiers(48V, 100A)

    One feed for one, two, or three rectifiers. External circuit overload protection, must be provided by customer. Note: All wire sizes are based on the US National Electric Code. Page 56 © Copyright 2021 ABB. All rights reserved.

  • Page 57: Ac Cable Routing

    At the cabinet, route the AC cables through the access holes in the top of the cabinet. Install terminal lugs (if applicable) to cables. Connecting AC Conduit Conduit 1” 1-1/2” 2” Figure 7-1: Attaching AC Conduit Page 57 © Copyright 2021 ABB. All rights reserved.

  • Page 58: Rectifier Positions

    Rectifier Positions Figure 7-2: GPS 4848/100 Dual Shelf Rectifier Positions Page 58 © Copyright 2021 ABB. All rights reserved.
  • Page 59 A Suffix: Left most breaker feeds bottom shelf A Suffix: One feed for two rectifiers B Suffix: Left most breaker feeds bottom two B Suffix: One feed for four rectifiers shelves C Suffix: One feed per rectifier Page 59 © Copyright 2021 ABB. All rights reserved.
  • Page 60 Breakers are Numbered from left to right. Terminal Strips are Numbered from left to right. Left most breaker starts with bottom shelf. Left most Terminal Strip starts with bottom shelf . Page 60 © Copyright 2021 ABB. All rights reserved.

  • Page 61: Ac Input Panels Cross Reference

    208/240 G324 208/240 G325/325C 208/240 G331/331C 208/240 G329 208/240 G333, G433 G326 G327/327C G330/330C G328 G332, G432 Distribution Only Panels, no AC 1200A None G28, G428 4800A None G29, G429, G430 Page 61 © Copyright 2021 ABB. All rights reserved.
  • Page 62 G3; 6-J G386A AC Terminal Strip Panels – GP100 Series Rectifiers G521 G364A G522 G364C G521 G366A G522 G366C G521 G368A G522 G368C G521 G370A G522 G370C G521 G372A G522 G372C Page 62 © Copyright 2021 ABB. All rights reserved.
  • Page 63 AC Terminal Strip Panels – NE075AC48ATEZ Rectifiers 208/240 6@60A G036 12@25/30A 277+N 6@50A 208/240 12@60A G037 (W) 277+N 25/30A 12@50A 208/240 18@60A G038, G038W 25/30A 277+N 18@50A 208/240 16@60A G308, G308W 25/30A 277+N 16@50A Page 63 © Copyright 2021 ABB. All rights reserved.

  • Page 64: Ac Input Panels

    *Torque to 62 in-lbs (7 Nm) Figure 7-5: ED83142-30 Group 2 (H569-434 G322: AC Input Panel for 595A or LTA Series Rectifiers or H569-4830 G334A or G334B: AC Input Panel for GP100 Series Rectifiers) Page 64 © Copyright 2021 ABB. All rights reserved.

  • Page 65: Wiring Options For Ed8314230 Group 3

    *Torque to 62 in-lbs (7 Nm) Figure 7-6: ED83142-30 Group 3 (H569-434 G320: AC Input Panel for 595B or LTB Series Rectifiers or H569-4830 G346A or G346B: AC Input Panel for GP100 Series Rectifiers) Page 65 © Copyright 2021 ABB. All rights reserved.

  • Page 66: Wiring Options For Ed8314230 Group 4A

    Wiring Options for ED8314230 Group 4A *Torque to 62 in-lbs (7 Nm) Figure 7-7: ED83142-30 Group 4A (H569-434 G321 or G323: AC Input Panel for 595A, B, LTA, or LTB Series Rectifiers) Page 66 © Copyright 2021 ABB. All rights reserved.

  • Page 67: Wiring Options For Ed8314230 Group 7

    AC Input Panels (continued) Wiring Options for ED8314230 Group 7 *Torque to 62 in-lbs (7 Nm) Figure 7-8: ED83142-30 Group 7 (H569-4827 G021 or G031:AC Input Panel for NE050AC48ATEZ or NE075AC48ATEZ Series Rectifiers) Page 67 © Copyright 2021 ABB. All rights reserved.

  • Page 68: Wiring Options For Ed8314230 Group 10

    AC Input Panels (continued) Wiring Options for ED8314230 Group 10 *Torque to 62 in-lbs (7 Nm) Figure 7-9: ED83142-30 Group 10 (H569-434 G370: AC Input Panel for 595A or LTA Series Rectifiers) Page 68 © Copyright 2021 ABB. All rights reserved.

  • Page 69: Wiring Options For Ed8314230 Group 11

    AC Input Panels (continued) Wiring Options for ED8314230 Group 11 *Torque to 62 in-lbs (7 Nm) Figure 7-10: ED83142-30 Group 11 (H569-434 G371: AC Input Panel for 595A or LTA Series Rectifiers) Page 69 © Copyright 2021 ABB. All rights reserved.

  • Page 70: Wiring Options For Ed8314230 Group 18

    *Terminal block connections: Max Torque 19.5 in-lbs (2.2 Nm) View Figure 7-11: ED83142-30 Group 18 (H569-434 G324, G325, G326, or G327: AC Input Panel for 595A, B, LTA, or LTB Series Rectifiers) Page 70 © Copyright 2021 ABB. All rights reserved.

  • Page 71: Wiring Options For Ed8314230 Group 20

    (H569-4827 G026, G027, G028, G036, G037, G037W, G038, G038W, G308, or G308W: AC Input Panel for NE050AC48ATEZ or NE075AC48ATEZ Series Rectifiers) Note: To minimize phase imbalance voltage potentials between each 3W+PE and 3W+N+PE field-wiring terminal block group, use feeds from the same transformer source. Page 71 © Copyright 2021 ABB. All rights reserved.

  • Page 72: Wiring Options For Ed8314230 Group 24 & 25

    *Spacing between the studs - 0.75” *Torque to 62 in-lbs (7 Nm) Figure 7-13: ED83142-30 Groups 24 or 25 (H569-434 G334 or G335: AC Input Panel for 595LTA or LTB Series Rectifiers) Page 72 © Copyright 2021 ABB. All rights reserved.

  • Page 73: Wiring Options For Ed8314230 Group 26

    AC Input Panels (continued) Wiring Options for ED8314230 Group 26 Figure 7-14: ED83142-30 Group 26 (H569-434 G328, G329, G332, G333, G432, or G433:AC Input Panel for 595LTA, or LTB Series Rectifiers) Page 73 © Copyright 2021 ABB. All rights reserved.

  • Page 74: Wiring Options For Ed8314230 Group 27

    *Terminal block connections: Max Torque 16 in-lbs (1.8 Nm) Figure 7-15: ED83142-30 Groups 27 (H569-4827 G026, G027, G028, G036, G037, G037W, G038, G038W, G308, or G308W: AC Input Panel for NE050AC48ATEZ or NE075AC48ATEZ Series Rectifiers) Page 74 © Copyright 2021 ABB. All rights reserved.

  • Page 75: Wiring Termination For Ed8314230 Group 20 And 27

    Figure 7-16: Wire Termination for ED83142-30 Groups 20 or 27 (H569-4827 G026, G027, G028, G036, G037, G037W, G038, G038W, G308, or G308W: AC Input Panel for NE050AC48ATEZ or NE075AC48ATEZ Series Rectifiers) Page 75 © Copyright 2021 ABB. All rights reserved.

  • Page 76: Wiring Options For Ed8314230 Group 28

    AC Input Panels (continued) Wiring Options for ED8314230 Group 28 *Torque to 62 in- (7 Nm) Figure 7-17: ED83142-30 Group 28 (H569-4827 G022 or G032: AC Input Panel for NE050AC48ATEZ or NE075AC48ATEZ Series Rectifiers) Page 76 © Copyright 2021 ABB. All rights reserved.

  • Page 77: Wiring Options For Ed8314230 Group 518

    View Figure 7-18: ED83142-30 Group 518 (H569-4830 G304A/B to G312A/B: AC Input Panel for GP100 Series Rectifiers; A=1:2, B=1:4) Note: For A Suffix, B Suffix see page 57 – Suffix definition Page 77 © Copyright 2021 ABB. All rights reserved.

  • Page 78: Wiring Options For Ed8314230 Group 520 And 522

    (Group 520 - H569-4830 G304C to G312C, AC Input Panel for GP100 Series Rectifiers; A=1:2, B=1:4. Group 522 - H569-4830 G364C - G372C & G734C, AC Input Panel for GP100 Series Rectifiers; A=1:2, B=1:4) Note: For C Suffix see page 57 – Suffix definition Page 78 © Copyright 2021 ABB. All rights reserved.

  • Page 79: Wiring Options For Ed8314230 Group 521

    *Terminal block connections: Max Torque 16 in-lbs (1.8 Nm) View Figure 7-20: ED83142-30 Group 521 (H569-4830 G364A-G372A & G734A, AC Input Panel for GP100 Series Rectifiers; A=1:2, B=1:4) Note: For A Suffix see page 57 – Suffix definition Page 79 © Copyright 2021 ABB. All rights reserved.

  • Page 80: Field Modification Of The 1-Phase Circuit Breaker Ac Panel For Use With Phase-Neutral Input Circuits - Ed83142-30 G7 Or G28

    Figure 7-21: Neutral AC Input for ED83142-30 Groups 7 or 28 (H569-4827 G31 or G32 with 480V 3-Phase, 4-wire (3W + N + PE) AC Input) *Phase-to-Neutral Kits Comcode ED83142-30 848233862 848698783 Page 80 © Copyright 2021 ABB. All rights reserved.

  • Page 81: Wiring Charts For Gps 4827

    Wiring chart for GPS 4827 Table 7-C1: AC Input Recommendations – GPS 4827 Page 81 © Copyright 2021 ABB. All rights reserved.

  • Page 82: Wiring Charts For Gps 434

    Wiring chart for GPS 434 Table 7-C2: AC Input Recommendations – GPS 434 Page 82 © Copyright 2021 ABB. All rights reserved.
  • Page 83 Wiring chart for GPS 434 (continued) Table 7-C2: AC Input Recommendations – GPS 434 (Continued) Page 83 © Copyright 2021 ABB. All rights reserved.

  • Page 84: Wiring Charts For Gps 4830

    Wiring chart for GPS 4830 Table 7-C3: AC Input Recommendations – GPS 4830 (480V) Page 84 © Copyright 2021 ABB. All rights reserved.
  • Page 85 Wiring chart for GPS 4830 (continued) Table 7-C4: AC Input Recommendations – GPS 4827 (200-240V) Page 85 © Copyright 2021 ABB. All rights reserved.

  • Page 86: Bottom Cable Feed Options For Gps 4848/100 Systems

    Through bottom of cabinet Through bottom of cabinet Through bottom of cabinet Through top of cabinet Through top of cabinet Through bottom of cabinet Figure 7-22: Bottom Cable Feed Option for GPS4848/100 Page 86 © Copyright 2021 ABB. All rights reserved.

  • Page 87: Completing The Ac Connection

    Completing the AC Connection Completing the AC Connection Step Action Notes Page 87 © Copyright 2021 ABB. All rights reserved.

  • Page 88: Dc Distribution Assembly And Connections

    LED that indicates an operated protector. Note: Panels for DC distribution are white; battery connection panels are blue. Warning Turn off dc breaker and remove dc fuses before making connections. Page 88 © Copyright 2021 ABB. All rights reserved.

  • Page 89: Dc Distribution Panels Cross Reference

    DC Distribution Panels Cross Reference Table 8-A: DC Distribution Panels Cross Reference Height H569-434 H569-4827 H569-4830 Fuse or CB Pos. ED83143-31 (in.) GPS4848/ 100 GPS 4827 GPS 4830 Page 89 © Copyright 2021 ABB. All rights reserved.

  • Page 90: Connecting Loads

    To use the Capacitor Charge Unit, follow the instructions silk-screened on the unit. Figure 8-1: Installation of Large Circuit Breakers and Capacitor Charge Unit Page 90 © Copyright 2021 ABB. All rights reserved.

  • Page 91: Mounting Large Circuit Breakers

    Caution: Turn OFF breaker before beginning procedure. Mounting Large Circuit Breakers Step Action Mounting Small Plug-in Circuit Breakers and Fuses Mounting Small Plug-in Circuit Breakers and Fuses Step Action Page 91 © Copyright 2021 ABB. All rights reserved.

  • Page 92: Distribution Panels

    Jumper straps (J1 to J3) on the CLR card shall be left in the factory default 5 - 12 position for use with ABB Power Shunt RPM monitoring. Move these jumper straps to the “Bypass” 1 - 8 position to permit shunt monitoring with non- ABB equipment.
  • Page 93 Distribution Panels (continued) ED83143-31 Group 2 Figure 8-3: ED83143-31 Group 2 (H469-434/4827/4830 G42/A, G106/A, G107/A, G108/A, or G109/A) 600A DC Distribution Panel Page 93 © Copyright 2021 ABB. All rights reserved.
  • Page 94 405347923 Note Jumper straps (J1 to J3) on the CLR card shall be left in the factory default 5-12 position for use with ABB Power Shunt RPM monitoring. Move these jumper straps to the “Bypass” 1-8 position to permit shunt monitoring with non-ABB equipment.
  • Page 95 406700609 407098474 406700617 407098482 406700625 407098490 406700633 407245448 406700641 407098516 406700658 407098524 406700674 407098532 406700682 407098540 407098557 407098565 407098573 Figure 8-5: ED83143-31 Group 11 (H469-434/4827/4830 G11) 14-position 400A DC Distribution Panel Page 95 © Copyright 2021 ABB. All rights reserved.
  • Page 96 847301702* 847867124 load provided 847659620* 847867124 load provided 847301447* 847867124 load provided 848111175* 847867124 *2-position lug kits include double-hole load and return lugs and associated hardware, and adapter bus bar. Page 96 © Copyright 2021 ABB. All rights reserved.
  • Page 97 406700609 407098474 406700617 407098482 406700625 407098490 406700633 407245448 406700641 407098516 406700658 407098524 406700674 407098532 406700682 407098540 407098557 407098565 407098573 Figure 8-6: ED83143-31 Group 12 (H469-434/4827/4830 G12) 22-position 400A DC Distribution Panel Page 97 © Copyright 2021 ABB. All rights reserved.
  • Page 98 847301702* 847867124 load provided 847659620* 847867124 load provided 847301447* 847867124 load provided 848111175* 847867124 *2-position lug kits include double-hole load and return lugs and associated hardware, and adapter bus bar. Page 98 © Copyright 2021 ABB. All rights reserved.
  • Page 99 Distribution Panels (continued) ED83143-31 Group 15 Figure 8-7: ED83143-31 Group 15 (H469-434/4827/4830 G96, 96A) 10-position 510A DC Distribution Panel Page 99 © Copyright 2021 ABB. All rights reserved.
  • Page 100 200A and 250A three-pole breakers require an adapter bus kit, 848745662, jumper three positions together prior to lug termination. Figure 8-8: ED83143-31 Group 16 14-position (H469-434/4827/4830 G97, 97A) and Group 17 22-position (H469-434/4827/4830 G98, 98A) 600A DC Distribution Panels Page 100 © Copyright 2021 ABB. All rights reserved.
  • Page 101 1/0*** 70*** provided 407817550 2/0*** 1/0*** 70*** 848201919 407817576 load 2/0*** provided 407817576 2/0*** 848201919 ***Only 5 return lugs of the indicated size will fit on the internal panel return bus. Page 101 © Copyright 2021 ABB. All rights reserved.
  • Page 102 Distribution Panels (continued) ED83143-31 Group 21 Figure 8-9: ED83143-31 Group 21 (H469-434/4827/4830 G68, 68A) 1200A (800A e/w LVLD) DC Distribution Panel Page 102 © Copyright 2021 ABB. All rights reserved.
  • Page 103 Distribution Panels (continued) ED83143-31 Group 22 Figure 8-10: ED83143-31 Group 22 (H469-434/4827/4830 G67, 67A) b600A DC Distribution Panel Page 103 © Copyright 2021 ABB. All rights reserved.
  • Page 104 Distribution Panels (continued) ED83143-31 Group 53 Figure 8-11: ED83143-31 Group 53 (H469-434/4827/4830 G52, 52A) 600A DC Distribution Panel Page 104 © Copyright 2021 ABB. All rights reserved.
  • Page 105 Distribution Panels (continued) ED83143-31 Group 54 Figure 8-12: ED83143-31 Group 54 5-position (H469-434/4827/4830 G54, 54A) 1125A (800 e/w LVLD) DC Distribution Panel Page 105 © Copyright 2021 ABB. All rights reserved.
  • Page 106 600A / 50mV Shunt TB1-1 Upper Fuse – TB1-2 Upper Fuse + Order fuse head and fuse separately Figure 8-13: ED83143-31 Group 55 (H469-434/4827/4830 G53, 53A) 1000A (800A e/w LVLD) DC Distribution Panel Page 106 © Copyright 2021 ABB. All rights reserved.
  • Page 107 Cables must be the same length and terminate at a common at each end. ** 800A Fuse only available with G72 Figure 8-14: ED83143-31 Group 56 (Deactivated) 1200A or Group 72 1280A (H469-434/4827/4830 G59, 59A) DC Distribution Panel Page 107 © Copyright 2021 ABB. All rights reserved.
  • Page 108 (Class B) (Class I) Wire Size (mm (Grade 2) load 406332940 load 406338665 load 405348228 load 405348236 load 406021725 load 405348251 847073731 load 405347923 load 407890763 load 407890748 load 406335141 load 407890730 Page 108 © Copyright 2021 ABB. All rights reserved.
  • Page 109 GMT Fuses for Group 58 Comcode Size (A) Wire Ga (min) 405006222 0.25 406976894 405673146 1.33 405181983 406976985 406159061 405725433 Figure 8-15: ED83143-31 Group 58, 6-position GMT, (H469-434/4827/4830 G58) 15A DC Distribution Panel Page 109 © Copyright 2021 ABB. All rights reserved.
  • Page 110 Class gL – Class gG 14x51mm Fuse ABB 270 Series 1–63A Circuit Breaker ABB 290 Series 8–125A Circuit Breaker Figure 8-16: ED83143-31 Groups 71 (H469-434/4827/4830 G60/A, G61/A, G65/A, or G66/A) 600A DC Distribution Panel Page 110 © Copyright 2021 ABB. All rights reserved.

  • Page 111: Low Voltage Load Disconnect Feature

    “3” (those that are changed). These voltage levels will be set during the controller setup. Figure 8-17: EBV Circuit Pack for Load Disconnect Page 111 © Copyright 2021 ABB. All rights reserved.

  • Page 112: Remote Peripheral Monitoring

    For the 214A Control Relay module, the maximum relay contact voltage is 110Vdc and maximum current is 0.3Adc. Wiring depends on the voltage, current, local building codes, and various other characteristics of the controlled point. Page 112 © Copyright 2021 ABB. All rights reserved.

  • Page 113: Mounting Locations

    Overview (continued) Mounting Locations Figure 9-1: Possible RPM Mounting Locations Page 113 © Copyright 2021 ABB. All rights reserved.

  • Page 114: Rpm Installation

    (See Figures 9-2, 9-3, and 9-4.) TB102 is used for communications input/output within the connection units. Use ONLY ABB shielded twisted pair cable per Comcode 407377704 to wire the communications bus as shown in Figure 9-5. This cable is designed to the specific impedance necessary for optimum use in this bus wiring application.
  • Page 115 GPS load panel connections. 100K Ring Type Probes Cable tie and Connecting Cable Shown in Figure 10-3. CLR Assembly (847540424) Generic Monitoring Connection Figure 9-2: Connection of Voltage, Shunt, Transducer, and Binary Modules Page 115 © Copyright 2021 ABB. All rights reserved.
  • Page 116 RPM Installation (Continued) 100K Thermistor 1/2” Ring Type Probe (847917879) or 5/16” Ring Type Probe (848528881) Figure 9-3: Connection of Temperature Module Page 116 © Copyright 2021 ABB. All rights reserved.
  • Page 117 RPM Installation (Continued) Figure 9-4: Connection of Control Relay Module Page 117 © Copyright 2021 ABB. All rights reserved.
  • Page 118 RPM in the chain, is 100 meters or less. For bus lengths between 100 meters and 300 meters (maximum bus length), the number of RPMs on that bus must be reduced. See the RPM product manual (167-790-063). Page 118 © Copyright 2021 ABB. All rights reserved.
  • Page 119 RPM Installation (Continued) Set address per job site Documentation Rotate module top and connect to base Snap spring clips around module top Figure 9-6: RPM Module Assembly Page 119 © Copyright 2021 ABB. All rights reserved.

  • Page 120: Notes

    Notes Page 120 © Copyright 2021 ABB. All rights reserved.

  • Page 121: 10. Battery Connection Panels

    They do, however, provide a convenient way to disconnect the batteries from the system bus for maintenance. Note: Panels for battery connection are blue; dc distribution panels are white. Page 121 © Copyright 2021 ABB. All rights reserved.

  • Page 122: Battery Connection Panels Cross Reference

    2 x 1,500A 2 x NH4 fuse G084 G084 1 x 3,000A with 36 Off Line Equalize Panels 3 x 600A fuse 1,200A 3 x 1,000A 3 x 600A fuse 3 x 1,000A Page 122 © Copyright 2021 ABB. All rights reserved.

  • Page 123: Additional Battery Leads

    (Max. 4/0 AWG) 1600098086A Kit contains (2) 8600097665P Bus Bars and hardware. Provides 16 output terminations (on 1.25” centers) Provides 10 output terminations (on 1.80” centers) Figure 10-1: Additional Battery Leads Page 123 © Copyright 2021 ABB. All rights reserved.

  • Page 124: Battery Connection Panel Options

    Battery Connection Panel Options ED83143-31 G30 1500A Shunt ED83143-31 G30A 3000A Shunt ED83143-31 G30B 6000A Shunt Figure 10-2: H569-434 and H569-4830 Battery Connection Panel Options Page 124 © Copyright 2021 ABB. All rights reserved.

  • Page 125: Connecting (+) And (-) Conductors

    Battery (+) conductors are connected to the battery return bus. See Figures 10-2 and 10-3 to locate the battery connection panels and battery return bus. Also see Figures 4 and H3 in the T83314-30 drawing for additional information. Page 125 © Copyright 2021 ABB. All rights reserved.

  • Page 126: Installing Battery Connection Panels

    If the battery connection panel is equipped with contactors, do not place the forced-off switches (SW100 and SW200) on the BJN board in the NORMAL position at this time. See Figure 10-4. Page 126 © Copyright 2021 ABB. All rights reserved.

  • Page 127: Contactor Control Board

    If the battery connection panel is equipped with circuit breakers, they should be installed but left in the OFF position. Note: The batteries will be connected in Section 13, Power Up and Installation Completion. Page 127 © Copyright 2021 ABB. All rights reserved.

  • Page 128: Notes

    Notes Page 128 © Copyright 2021 ABB. All rights reserved.

  • Page 129: 11. Fascia Cover Installation

    Optional on Centralized Architecture Cabinets Step Action Install each fascia cover using the four 8-32 nuts provided. Fascia panels are optional on the left and right ends Figure 11-1: Fascia Cover Installation Page 129 © Copyright 2021 ABB. All rights reserved.

  • Page 130: 12. Connection Of Office Alarms

    Figure 12-2: Millennium II Controller with Wire Wrap Alarm Board Route wires (installer provided, 22-gauge maximum) from the office alarm block back to the controller by Millennium II Figure 12-1: Millennium II Controller with Insulation Displacement Alarm Board Page 130 © Copyright 2021 ABB. All rights reserved.
  • Page 131 Connecting Controller Alarms (continued) Millennium II Figure 12-2: Millennium II Controller with Wire Wrap Alarm Board Page 131 © Copyright 2021 ABB. All rights reserved.

  • Page 132: Power Up And Installation Completion

    Controller Front Panels Illustrations Refer to the following figures for illustrations of the controller front panels: Figures 13-1 Millennium II Controller Figure 13-1: Galaxy Millennium II Controller Front Panel, Round Page 132 © Copyright 2021 ABB. All rights reserved.

  • Page 133: Initial Power Up Of The System

    When installing a single 595LTA or 595LTB on a shelf, install an Air Dam to block vacant right or left rectifier position. Rectifier Shelf Cover (848680211) - Covers both left and right rectifier positions Air Dam (848754358) - Covers the left or right rectifier position Page 133 © Copyright 2021 ABB. All rights reserved.

  • Page 134: Installing The First Rectifier

    If the controller has alpha-character capability, verify that the text on the display is in English. If Spanish text is required, follow instructions on the Help menu to make the change. Page 134 © Copyright 2021 ABB. All rights reserved.

  • Page 135: Set Rectifier Id

    Note: Abandoning this process before the display stops blinking will default the rectifier to the Follow Step 2 to 5 to install the remaining rectifiers, and follow Step 9 (GPS 4848) to set their ID numbers. Page 135 © Copyright 2021 ABB. All rights reserved.

  • Page 136: Installing Rectifiers

    Installing Rectifiers Figure 13-2: Installing 595A/B Rectifier Carriers Page 136 © Copyright 2021 ABB. All rights reserved.
  • Page 137 Installing Rectifiers (Continued) Note: Remove keying plate for single rectifier shelf only. Figure 13-2A: Installing 595LTA and 595LTB Rectifiers Page 137 © Copyright 2021 ABB. All rights reserved.
  • Page 138 5. Following initialization of the rectifier module, verify its green LED and only its green LED and only its green LED is on. 6. If this isn’t the case, see the troubleshooting section. Page 138 © Copyright 2021 ABB. All rights reserved.

  • Page 139: Lamp Test

    Verify that the Very High and High alarm thresholds are set at least 0.5V above the float voltage to be specified in Step 3. Use the adjust keys to set the system float voltage. Enter the following M2 key sequence: Page 139 © Copyright 2021 ABB. All rights reserved.

  • Page 140: Setting The System Shunt

    To change, move the jumpers on the associated EBV contactor drive boards as shown in Figure 8-15. Next, set the controller’s BICXX and LVLD2 configuration to Load with the desired thresholds as described above. Page 140 © Copyright 2021 ABB. All rights reserved.

  • Page 141: Connecting Batteries

    If any installed rectifiers are missing or are not sharing load, perform the following M2 reboot process to have all the rectifiers reinitialized into the system. When the current has stabilized or dropped to a level equal to several amperes per string, proceed to the next section. Page 141 © Copyright 2021 ABB. All rights reserved.
  • Page 142 Connecting Batteries (Continued) Figure 13-5: Battery Connection Panel Page 142 © Copyright 2021 ABB. All rights reserved.

  • Page 143: Testing Rectifiers And Load Share

    Action Testing Additional Alarms Alarm operation may be verified while the system operates at float voltage. Testing Additional Alarms Step Action Testing the BD Alarm Testing the BD Alarm Step Action Page 143 © Copyright 2021 ABB. All rights reserved.

  • Page 144: Millennium Ii Controller System Alarm Test

    For additional information, consult the Millennium Controller product manual. Millennium II Controller System Alarm Test Step Action Connecting to Load The system is ready to connect to equipment loads. Install or turn on load protectors when needed. Page 144 © Copyright 2021 ABB. All rights reserved.
  • Page 145 BW (14) 429/430 at 900A at 1000A at 1800A 032/032W H5694827 at 2000A at 900A at 1000A at 1800A 037/037W at 2000A at 2700A 038/038W at 3000A at 2400A 308/308W at 2667A Page 145 © Copyright 2021 ABB. All rights reserved.
  • Page 146 312C GZ15 346B GZ42 364A GZ57 364C GZ44 366A GZ58 366C GZ46 368A GZ59 368C H5694830 GZ48 370A 208v GZ60 370C GZ50 372A GZ61 372C GZ52 384A GZ54 386A GZ56 746A Page 146 © Copyright 2021 ABB. All rights reserved.
  • Page 147 – 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 document.

This manual is also suitable for:

Gps 4848/100Gps 4827Gps 4830Gps 434

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