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ABB Galaxy Power System User Manual

ABB Galaxy Power System
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© Copyright 2021 ABB. All rights reserved.
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.

Table of Contents

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ABB Galaxy Power System Specifications

General IconGeneral
EfficiencyUp to 96%
Frequency50/60 Hz
TypeUninterruptible Power Supply (UPS)
TopologyDouble Conversion (Online)
Parallel CapabilityYes
Protection LevelIP20
Operating Temperature0 to 40 °C
Cooling MethodForced Air
Communication InterfaceModbus, SNMP
DimensionsVaries by model
WeightVaries by model

Summary

Introduction to Galaxy Power Systems

Product Documentation

Lists related documents like ordering guides, drawings, and manuals for the Galaxy Power System.

Safety Precautions and Information

Safety Statements

General safety instructions, warnings, and compliance information for Galaxy Power Systems.

Warning and Safety Symbols

Explains hazard symbols and signal words used in the manual for user safety.

Precautions

Outlines essential safety precautions for working with the equipment.

Special Installation Notes

Provides specific installation notes and warnings for different regions and languages.

Getting Started with Installation

Tools and Hardware

Lists necessary tools, hardware, and supplies for installation.

Torque Settings for Hardware

Provides specific torque values for various screw sizes used in installation.

Unpacking and Location Preparation

Details site requirements and checks before unpacking and positioning equipment.

System Electrical Architecture Overview

Introduction to System Architecture

Overview of system architecture, connections, and physical considerations.

Bonding Network

Explains suitability for Common Bonding Network (CBN) or Isolated Bonding Network (IBN).

Facility Requirements

Describes suitable installation locations and facility requirements.

Single-Cabinet Distributed System

Illustrates and describes a single-cabinet distributed system configuration.

Distributed Architecture

Explains how multiple cabinets form larger distributed systems.

Centralized Architecture

Describes how components connect to a single DC bus in centralized systems.

Cabinet Floor Mounting and Grounding

Cabinet Installation Procedure

Details the process of installing cabinets, including mounting hardware.

Mounting Dimensions for 24-inch Cabinets

Provides footprint diagrams and dimensions for 24-inch wide cabinets.

Mounting Dimensions for 36-inch Cabinets

Provides footprint diagrams and dimensions for 36-inch wide cabinets.

Mounting Dimensions for 30-inch Cabinets

Provides footprint diagrams and dimensions for 30-inch wide cabinets.

Cabinet Installation Procedure Steps

Step-by-step guide for cabinet installation and anchoring.

Cabinet and Central Office Grounding

Explains procedures for grounding cabinets and system ground connections.

Cabinet Grounding Procedure

Specific steps for grounding the cabinet framework.

Central Office Grounding Procedure

Steps for connecting the system ground to the building's principal ground point.

Recommended Cable Rack Layout

Illustrates various cable rack arrangements for optimal routing.

Centralized and Distributed Architecture Connections

Multiple Cabinet Installation Requirements

Covers special requirements for systems with more than one cabinet.

Centralized Architecture Connections

Details DC power connections to the central bus bar.

Remote Sense and Shunt for BLJ/BIC9 Bay Board

Procedures for external sense and shunt with BLJ/BIC9 bay boards.

Remote Sense and Shunt for BIC10 Bay Board

Procedures for external sense and shunt with BIC10 bay boards.

Remote Sense and Shunt for BIC11 Bay Board

Procedures for external sense and shunt with BIC11 bay boards.

BIC 11 Terminal Block Positions

Table detailing terminal block assignments for BIC 11.

Ground Terminal Strip in Distribution-only Cabinets

Wiring of return circuits for BIC/controller in distribution-only cabinets.

Distributed Architecture Connections

Details inter-cabinet DC power bus connections.

Intercabinet DC Power Bus Connections

Describes the procedure for connecting DC power buses between cabinets.

Intercabinet Alarm and Serial Bus Connections

Covers alarm and serial bus connections between cabinets.

BLJ2/3 to BLJ2/3 Connections

Procedure for connecting BLJ2/3 boards between cabinets.

BLJ2/3 to BIC10 Connections

Procedure for connecting BLJ2/3 to BIC10 or BIC10 to BIC10 boards.

BLJ2/3 to BIC11 Connections

Procedure for connecting BLJ2/3 to BIC11 or BIC11 to BIC11 boards.

Bay ID and Shunt Size Configuration

Explains how to configure bay ID and shunt size settings.

BLJ2/3 Shunt Size Configuration

Configuration steps for BLJ2/3 boards, including DIP switches.

BIC10 Shunt Size Configuration

Configuration steps for BIC10 boards, including rotary switches.

BIC11 Shunt Size Configuration

Configuration steps for BIC11 boards, including rotary switches.

Millennium II Controller Shunt Channel Configuration

Steps to configure shunt channels via the Millennium II controller web pages.

Software Configured Shunt Channel Configuration

Details setting shunt size and type through the controller interface.

AC Connection and Wiring Procedures

AC Connection Safety

Reminder to review safety precautions before AC connection.

Wire Sizing and Ampacity Guidelines

Provides NEC table for wire sizing and ampacity calculations.

AC Input Schemes Overview

Details AC input configurations for GPS 4848/100, 4830, and 4827.

GPS 4848/100 Rectifier Input/Output

Input/output voltages for 595 and 595LT rectifiers.

GPS 4830 Rectifier Input/Output

Input/output voltages for GP100 series rectifiers.

GPS 4827 Rectifier Input/Output

Input/output voltages for NE series rectifiers.

AC Cable Routing Instructions

Steps and cautions for routing AC cables to the cabinet.

Connecting AC Conduit

Illustrates how to attach AC conduit to the cabinet.

GPS 4848/100 Rectifier Positions

Shows rectifier positions for GPS 4848/100 dual shelf.

GPS 4830 Rectifier Positions

Shows rectifier positions for GPS 4830 with different AC feeds.

GPS 4827 Rectifier Positions

Shows rectifier positions for GPS 4827 with different AC feeds.

AC Input Panels Cross Reference (GPS 4848/100)

Cross-reference table for GPS 4848/100 AC input panels.

AC Input Panels Cross Reference (GPS 4830)

Detailed cross-reference table for GPS 4830 AC input panels.

AC Input Panels Cross Reference (GPS 4827)

Detailed cross-reference table for GPS 4827 AC input panels.

AC Input Panel Wiring Options (Group 2)

Specific wiring diagrams for ED8314230 Group 2 AC input panels.

AC Input Panel Wiring Options (Group 3)

Specific wiring diagrams for ED8314230 Group 3 AC input panels.

AC Input Panel Wiring Options (Group 4A)

Specific wiring diagrams for ED8314230 Group 4A AC input panels.

AC Input Panel Wiring Options (Group 7)

Specific wiring diagrams for ED8314230 Group 7 AC input panels.

AC Input Panel Wiring Options (Group 10)

Specific wiring diagrams for ED8314230 Group 10 AC input panels.

AC Input Panel Wiring Options (Group 11)

Specific wiring diagrams for ED8314230 Group 11 AC input panels.

AC Input Panel Wiring Options (Group 18)

Specific wiring diagrams for ED8314230 Group 18 AC input panels.

AC Input Panel Wiring Options (Group 20)

Specific wiring diagrams for ED8314230 Group 20 AC input panels.

AC Input Panel Wiring Options (Groups 24 or 25)

Specific wiring diagrams for ED8314230 Groups 24/25 AC input panels.

AC Input Panel Wiring Options (Group 26)

Specific wiring diagrams for ED8314230 Group 26 AC input panels.

AC Input Panel Wiring Options (Group 27)

Specific wiring diagrams for ED8314230 Group 27 AC input panels.

Wire Termination for AC Input Panels

Illustrates wire termination for specific AC input panel groups.

AC Input Panel Wiring Options (Group 28)

Specific wiring diagrams for ED8314230 Group 28 AC input panels.

AC Input Panel Wiring Options (Group 518)

Specific wiring diagrams for ED8314230 Group 518 AC input panels.

AC Input Panel Wiring Options (Group 520 and 522)

Specific wiring diagrams for ED8314230 Groups 520/522 AC input panels.

AC Input Panel Wiring Options (Group 521)

Specific wiring diagrams for ED8314230 Group 521 AC input panels.

Field Modification for Phase-Neutral Input

Procedure to modify AC panels for phase-to-neutral connections.

GPS 4827 AC Input Wiring Chart

AC input recommendations and wiring for GPS 4827.

GPS 434 AC Input Wiring Chart

AC input recommendations and wiring for GPS 434.

GPS 4830 AC Input Wiring Chart

AC input recommendations and wiring for GPS 4830.

Bottom Cable Feed Options for GPS 4848/100

Details bottom cable feed configurations for GPS 4848/100.

Completing the AC Connection

Final steps for completing the AC connection process.

DC Distribution Assembly and Connections

Overview of DC Distribution Panels

Describes DC distribution panels, fuses, circuit breakers, and alarm cards.

DC Distribution Panels Cross Reference

Cross-reference table for different DC distribution panel types.

Connecting Loads to DC Distribution

Procedures for connecting loads to the DC distribution system.

Cable Routing Strategy for DC

Guidelines for routing AC and DC cables for optimal performance.

Capacitor Charge Unit Installation

Information on installing and using the Capacitor Charge Unit.

Mounting Large Circuit Breakers

Steps for mounting large circuit breakers onto panels.

Mounting Small Plug-in Breakers and Fuses

Steps for mounting small plug-in breakers and fuses.

ED83143-31 Group 1 Distribution Panel

Specific information on the ED83143-31 Group 1 distribution panel.

ED83143-31 Group 2 Distribution Panel

Specific information on the ED83143-31 Group 2 distribution panel.

ED83143-31 Group 5 Distribution Panel

Specific information on the ED83143-31 Group 5 distribution panel.

ED83143-31 Group 11 Distribution Panel

Specific information on the ED83143-31 Group 11 distribution panel.

ED83143-31 Group 11 Lugs and Hardware

Lugs and hardware table for ED83143-31 Group 11.

ED83143-31 Group 12 Distribution Panel

Specific information on the ED83143-31 Group 12 distribution panel.

ED83143-31 Group 12 Lugs and Hardware

Lugs and hardware table for ED83143-31 Group 12.

ED83143-31 Group 15 Distribution Panel

Specific information on the ED83143-31 Group 15 distribution panel.

ED83143-31 Group 16 Distribution Panel

Specific information on the ED83143-31 Group 16 distribution panel.

ED83143-31 Group 16 Lugs and Hardware

Lugs and hardware table for ED83143-31 Group 16.

ED83143-31 Group 21 Distribution Panel

Specific information on the ED83143-31 Group 21 distribution panel.

ED83143-31 Group 22 Distribution Panel

Specific information on the ED83143-31 Group 22 distribution panel.

ED83143-31 Group 53 Distribution Panel

Specific information on the ED83143-31 Group 53 distribution panel.

ED83143-31 Group 54 Distribution Panel

Specific information on the ED83143-31 Group 54 distribution panel.

ED83143-31 Group 55 Distribution Panel

Specific information on the ED83143-31 Group 55 distribution panel.

ED83143-31 Group 56 Distribution Panel

Specific information on the ED83143-31 Group 56 distribution panel.

ED83143-31 Group 56 Lugs and Hardware

Lugs and hardware table for ED83143-31 Group 56.

ED83143-31 Group 58 Distribution Panel

Specific information on the ED83143-31 Group 58 distribution panel.

ED83143-31 Group 71 Distribution Panel

Specific information on the ED83143-31 Group 71 distribution panel.

Low Voltage Load Disconnect Feature

Details the Low Voltage Load Disconnect (LVLD) feature and EBV circuit pack.

EBV Circuit Pack for Load Disconnect

Information on the EBV circuit pack for load disconnect functionality.

Remote Peripheral Monitoring (RPM)

Overview of RPM Modules

Introduces RPM modules for data acquisition and control.

RPM Modules and Connection Units

Lists available RPM modules and their functions.

Current Limiting Resistors

Explains the requirement and availability of current limiting resistors.

RPM Module Mounting Locations

Illustrates possible mounting locations for RPM modules.

RPM Installation Procedures

Step-by-step guide for installing RPM modules.

Battery Connection Panels

Connecting and Disconnecting Batteries

Procedures for connecting and disconnecting batteries.

Overview of Battery Connection Panels

Explains battery connection panels, shunts, and controller interaction.

Battery Connection Panels Cross Reference

Cross-reference table for various battery connection panel types.

Additional Battery Leads Options

Options for connecting more than eight battery leads.

Battery Connection Panel Options

Illustrates different battery connection panel configurations.

Connecting Battery Conductors

Procedures for connecting positive and negative battery conductors.

Installing Battery Connection Panels

Step-by-step guidelines for installing battery connection panels.

Contactor Control Board Details

Details the Contactor Control Board and its switches/LEDs.

Battery and Alarm Fuses/Circuit Breakers

Guidance on installing battery and alarm fuses/breakers.

Fascia Cover Installation

Introduction to Fascia Covers

Introduces the installation procedure for fascia covers.

Installing Fascia Covers

Procedures for installing front and end-of-line fascia covers.

Connection of Office Alarms

Introduction to Alarm Connections

Explains the procedure for connecting office alarms.

Connecting Controller Alarms

Details connecting controller alarms using alarm boards.

Power Up and Installation Completion

Initial System Checkout

Steps for system checkout before installing rectifiers.

Pre-Installation Checks for Rectifiers

Pre-installation checks for rectifier shelves.

Safety Reminder for Power Up

Reminder of safety precautions during power-up procedures.

Controller Front Panel Illustrations

Illustrations of the Millennium II controller front panel.

Initial System Power Up Procedure

Procedure for turning on the system with default firmware.

Rectifier Installation Notes

Notes regarding rectifier installation and shelf covers.

Installing the First Rectifier

Step-by-step guide for installing the first rectifier module.

Controller Verification Steps

Steps to verify controller setup and operation after rectifier installation.

Setting Rectifier ID Numbers

Procedures for setting the ID number for each rectifier.

General Rectifier Installation

General instructions for installing rectifier modules.

Lamp Test Procedure

Procedure to test controller and rectifier LEDs.

Voltage Calibration Procedure

Procedure to calibrate the controller's voltage display.

Setting the System Float Voltage

Steps to set the system's float voltage.

Setting the System Shunt Configuration

Procedure to configure shunt types and sizes.

Setting Low-Voltage Battery Disconnect

Steps to enable and configure the LVBD feature.

Setting Low-Voltage Load Disconnect

Steps to enable and configure the LVLD feature.

Connecting Batteries to the System

Procedures for connecting batteries to the system.

Testing Rectifiers and Load Share

Procedures to test rectifier performance and load sharing.

Testing Additional Alarms

Procedure to test system alarms.

Testing the BD Alarm

Procedure to test the BD (Battery Disconnect) alarm.

Millennium II Controller System Alarm Test

Procedure for testing system alarm relays and wiring.

Connecting to Equipment Loads

Final step to connect equipment loads to the system.

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