ABB Integritas User manual

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Page 1 Version 6.0
© 2021 ABB. All rights reserved.
Read and follow all safety statements, warnings, and precautions in this guide.
Basic Features:
All DC outputs are floating - not referenced to ground.
DC output Ground Fault Detection. Set at factory default adjustable at site, if necessary.
Monitored class II AC input surge device included in addition to surge capability of IP rectifier units.
Monitored Class III output surge device included.
Full-featured charger control unit.
Wall Mount
Bracket
(top and
bottom)
Door Latch
(Lock option)
Control Panel
Door Latch
(Lock option)
Drip/Drop Shield
Input Box
Output Box
IO Module
IP Rectifier
slots (3)
Air Filter
DC Output
Box
Chassis
Ground Lug
Signal Wire Knockouts
(top and bottom)
Controller
IO Module
slot
Air Filter
IP Rectifier
slots (3)
Output
Signal Unit
Input
Box
Output
Signal Unit
Output Ground
Fault Unit
Controller slot
Output
Ground faiult
Bottom Feed Charger with BATT & DC Load Breakers Top Feed Charger with 2 DC Breakers
IntegritasTM Battery Charger
8600092587P

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Page 2 Version 6.0
© 2021 ABB. All rights reserved.
Contents
Safety and Precautions..............................................……………………................. 3
Installation ......................................................................................................... 4
1Set External Shunt Jumper—Option..............................................................4
2Mount the Charger............................................................................................5
2 Wall ...................................................................................................................5
2 Rack ..................................................................................................................5
3Ground the Chassis.........................................................................................6
4Connect AC Input.............................................................................................6
4A Single Phase................................................................................................7
4B Three (3) Phase 200/240V~ Three Phase...............................................8
5Connect Loads...................................................................................................9
6Connect Batteries .............................................................................................10
7Connect External Distribution (optional)......................................................11
8Connect Controller Signals and Bias............................................................11
8A Pulsar XL Controller...................................................................................11
8B Nebula Controller.......................................................................................12
9Connect Output Signals Unit Signals ............................................................13
10Install Rectifiers.................................................................................................14
11 Initial Start Up....................................................................................................14
12 Configure Controller.........................................................................................14
13 Apply Power to Loads.......................................................................................15
Information:
Controller - View and Change Parameters and Alarm Severity……………...15
Controller - Controller - LAN Port - Local / Network........................................16
Controller Alarm Relay Jumpers..........................................................................16
IP843G Controller Basic Operation.....................................................................16
IP943G Controller Basic Operation.....................................................................18
Battery Monitoring Connections - for use with VRLA batteries only............19
Interlock Cable Recommendations.....................................................................19
Signal Connections................................................................................................19
Alarm Outputs........................................................................................................19
Alarm Inputs ...........................................................................................................20
System Communications Ports...........................................................................20
Power Units ............................................................................................................20
Maintenance....................................................................................... ................ 21
Troubleshooting ................................................................................ ................ 21
Parts List ............................................................................................ ................ 21
Specifications & Application............................................................. ................ 22
Reference Documents ....................................................................... ................ 22
Notes………………………………………………………………....... ……................ 23

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Page 3 Version 6.0
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Precautions
• Install, service, and operate equipment only by professional, skilled and qualified personnel who have the necessary
knowledge and practical experience with electrical equipment and who understand the hazards that can arise when working
on this type of equipment.
• Disconnect batteries from outputs and/or follow safety procedures while working on equipment. Batteries may be
connected in parallel with the output of the rectifiers. Turning off the rectifiers will not necessarily remove power from the
bus.
• Batteries may produce explosive gas. Do not create arcs, smoke, or use an open flame in the vicinity.
• Do not disconnect permanent bonding connections unless all power inputs are disconnected.
• Verify that equipment is properly safety earth grounded before connecting power. High leakage currents may be possible.
• Exercise care and follow all safety warnings and practices when servicing this equipment. Hazardous energy and voltages
are present in the unit and on the interface cables and connectors that can shock or cause serious injury.
• Use safe lifting practices. The equipment is heavy. Lifting devices are recommended.
• Use the following precautions in addition to proper job training and safety procedures:
• Use only properly insulated tools.
• Remove all metallic objects (key chains, glasses, rings, watches, or other jewelry).
• Follow Lock Out Tag Out (LOTO) procedures: customer specified, site specific, or general as appropriate.
Disconnect all power input before servicing the equipment. Check for multiple power inputs.
• Wear safety glasses.
• Follow Personal Protective Equipment requirements: customer specified, site specific, or general as appropriate.
• Test circuits before touching.
• Be aware of potential hazards before servicing equipment.
• Identify exposed hazardous electrical potentials on connectors, wiring, etc.
• Avoid contacting circuits when removing or replacing covers;.
• Use a personal ESD strap when accessing or removing electronic components.
• Follow all warning and precautionary battery instructions, including proper replacement and disposal procedures, to
minimize risk of injury. External batteries, if applicable, are to be installed in accordance with all national and local rules and
regulations, including CEC, part 1.
• Personnel with electronic medical devices need to be aware that proximity to DC power and distribution systems, including
batteries and cables, typically found in telecommunications utility rooms, can affect medical electronic devices, such as
pacemakers. Effects decrease with distance.
Important Safety Instructions
1. SAVE THESE INSTRUCTIONS – This document contains important safety and operating instructions for the Integritas
battery charger.
2. Before using battery charger, read all instructions and cautionary markings on battery charger, battery, and all connected
equipment.
3. Rules and Regulations - Follow all national and local rules and regulations when making field connections.
4. Field-wired Conductors - Follow all National Electric Code (NEC) and local rules and regulations.
a. Insulation rating: 90°C minimum; 105°C (minimum) if internal to enclosed equipment cabinets.
b. Size AC field-wired conductors with 75°C ampacity (NEC) equal to or greater than their panel board circuit breaker
rating.
c. Size DC field-wired conductors with 90°C ampacity (NEC) equal to or greater than circuit breaker/fuse rating.
5. AC and DC input disconnect/protection - Provide accessible devices to remove input power in an emergency.
6. Compression Connectors
a. U. S. or Canada installations - use Listed/Certified compression connectors to terminate Listed/Certified field-wire
conductors.
b. All installations - apply the appropriate connector to the correct size conductor as specified by the connector
manufacturer, using only the connector manufacturer’s recommended or approved tooling for that connector.
7. Electrical Connection Securing: Torque to the values specified on labels or in the product documentation.
8. Cable Dress - dress to avoid damage to the conductors and undue stress on the connectors.
9. Alarm Signals - Provide external current limiting protection. Rating—60V (125V for 125V charger), 0.5A unless otherwise
noted.
10. Grounding - Connect the equipment chassis directly to ground.
11. WARNING: Equipment does not provide battery discharge control and protection. To be provided by external battery
source.
12. WARNING: A battery can present a risk of electrical shock, burn from high short circuit current, fire or explosion from
vented gases. Observe proper precautions.

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Page 4 Version 6.0
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Installation
Regulations, standards, site engineering instructions etc. take precedence over these general installation
instructions.
Step 1 - Set External Shunt Jumper - 0ption
The charger is factory configured for an internal shunt.
Set the Shunt Jumper to External if an external shunt is used.
1. Remove charger rear panel—6 screws: 3 each top and bottom.
2. Move both Shunt Jumpers HDR11 and HDR12 to RMT (External) position—pins 2-3.
3. Replace charger rear panel. Secure with 6 screws.
Tools required:
• Wire cutters and strippers • Torque wrench - 0-65 in-lb (0-10 Nm) • Screwdrivers - Philips and Flat
• Cable crimpers • Sockets - 5/16”, 7/16, etc.
Jumpers in External (RMT Positions

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Page 5 Version 6.0
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Step 2 - Mount the Charger
The charger may be mounted on a wall or in a rack, in an area free of flammable/explosive materials.
Recommended clearance above and below the charger: 2 inches (5 cm). Recommended clearance in front of the
charger: 36” (914 mm).
Hot air exits the top - do not locate temperature sensitive equipment above the charger.
CAUTION: Use safe lifting practices. The charger is heavy - up to 154 lb (70 kg). Lifting devices are recommended.
Wall Mount - follow Step 2A Wall.
Rack Mount - follow Step 2B Rack
Step 2A Wall - Mount the Charger to a Wall
CAUTION: Use safe lifting practices. The charger is heavy. Lifting devices are recommended.
The wall and fasteners must safely support 470 lb (3 times the charger weight).
Mount with (8) sets of mounting hardware rated for at least 60 lb. each.
1. Locate the appropriate place for the charger.
2. Secure the bottom wall mount bracket to the wall.
a. Remove the bottom wall mount bracket from the charger - 4 screws.
b. Drill (4) holes in the wall to mount the bottom bracket.
Use the bottom bracket as a template.
c. Secure the bottom bracket to the wall with mounting hardware.
3. Prepare to secure the top wall mount bracket to the wall.
a. Place the charger against the wall, resting on the wall mounted bottom bracket.
b. Temporarily install one screw through the bottom bracket into the charger..
c. Mark (4) holes in the wall for top bracket mounting hardware.
Use the top bracket as a template.
d. Remove the charger, first removing the screw installed in step b.
e. Drill (4) holes in the wall to mount the top bracket.
4. Secure the charger to the wall.
a. Place the charger against the wall, resting on the bottom secured bracket.
b. Secure the top bottom bracket to the wall with mounting hardware.
c. Secure the cabinet to the bottom bracket with the 4 screws removed in step a.
Go to Step 3
Step 2B Rack - Mount the Charger to a Rack
CAUTION: Use safe lifting practices. The charger is heavy. Lifting devices are recommended.
1. Attach Rack Mount Brackets positioned for flush mount or mid-mount.
Secure mounting brackets - 8 screws each.
Torque to 25 in-lb (2.8 Nm)
2. Attach the system to the frame using a minimum of twelve (six on each side) 12-24 screws (provided).
Torque to 35 in-lb (4.0 Nm) using a 5/16” socket wrench.

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Page 6 Version 6.0
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Step 4 - Connect AC Input
AC Input box location: Bottom Feed - bottom left Top Feed - top left
AC knockouts: for 2” conduit.
Danger: Shock Hazard - Turn OFF and lock-out tag-out the AC source before making AC connections.
When connecting to AC mains, follow all local and national wiring rules.
Caution: Ensure that wires do not come in contact with sharp or rough surfaces that may damage insulation and
cause a short circuit.
1. Verify all AC breakers are off - Charger AC1 and external AC feed breaker.
2. Choose the next step to match AC input voltage marked on the charger ratings label.
Step 3 - Ground the Chassis
Chassis ground lug - 1/4” on 5/8” centers (lug provided).
Minimum 6 AWG recommended.
1. Connect ground wire to chassis on top or bottom of cabinet.
1/4-20 screws (2) provided
Torque to 65 in-lb (7.3 Nm) using a 7/16” socket wrench.
AC Input per Charger Label AC Input Option Follow Step
120/240 AC Step 4A Single Phase
200/240 AC Step 4B Three Phase
Screw
Wire Entry
Ground Wire
Lug
Screw
Bottom Feed
Terminal Block for Single AC Feed shown Top Feed
Terminal Block for Single AC Feed shown
Ground
Bar
Top Feed
Chassis Ground Lug
(top or bottom)

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Step 4A Single Phase - Connect 120/240 Single Phase AC Input Section
Sizing external protectors and wire for all rectifier positions (3 or 6) provides full power for all rectifier positions.
Recommended External Protection and Minimum Wire Size - 6 AWG max.
19” 3 rectifier configuration
120V~ Phase to Neutral
(1200W per rectifier
max)
240V~ Phase to Neutral
(2725W per rectifier max)
Single-Phase Rectifiers
Rectifier Positions Powered
Maximum
Rectifiers
per Feed
External
Feed
Protector
Minimum
Wire
External
Feed
Protector
Minimum
Wire
1120A 14AWG 20A 14AWG
2240A 8AWG 40A 8AWG
3 360A 6AWG 60A 6AWG
Recommended External Protection and Minimum Wire Size - 6 AWG max.
23” 6 rectifier configuration
120V~ Phase to Neutral
(1200W per rectifier
max)
240V~ Phase to Neutral
(2725W per rectifier max)
Single-Phase Rectifiers
Rectifier Positions Powered
Maximum
Rectifiers
per Feed
External
Feed
Protector
Minimum
Wire
External
Feed
Protector
Minimum
Wire
1120A 14AWG 20A 14AWG
2240A 8AWG 40A 8AWG
3 360A 6AWG 60A 6AWG
4480A 4AWG 80A 4AWG
55100A 2AWG 100A 2AWG
66120A 1AWG 120A 1AWG

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Step 4A Single Phase - Connect 120/240 Single Phase AC Input Section
(Continued)
1. Verify the charger AC breaker (AC1) is OFF.
2. Verify AC voltage matches AC Input per
charger label with a meter.
3. Bring AC wires into the AC Input Box in
conduit through one of the 2” knockouts
4. Connect Ground wire (green /green-
yellow) to lug.
a. Strip 1/2” (13mm)
b. Insert into ground lug.
c. Tighten lug screw securely.
d. Pull wire to verify.
5. Connect each AC wire to the
terminal block in the AC Input Box.
AC terminal connections are labeled at
each position - Gnd, L, N, L1, and L2.
a. Strip 1/4” (10mm).
b. Insert into terminal block.
c. Torque screw to 13 in-lb (1.5
Nm).
d. Pull wire to verify.
Go to Step 5
Gnd
NL1
Gnd
L2
L1
Gnd
240V 120V
Gnd
L

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Step 4B Three (3) Phase, 3W+PE - Connect 380-480V & 240V 3-Phase AC Input
Section
Recommended External Protection and Minimum Wire Size - 6 AWG max.
19” 3 rectifier configuration 380-480V~ Phase to Phase
(2725W per rectifier max)
Three (3) Phase Rectifiers
Rectifier Positions Powered Maximum
Rectifiers per Feed
External Feed
Protector Minimum Wire
1115A 14AWG
2230A 10AWG
3 340A 8AWG
Recommended External Protection and Minimum Wire Size - 6 AWG max.
23” 6 rectifier configuration 380-480V~ Phase to Phase
(2725W per rectifier max)
Three (3) Phase Rectifiers
Rectifier Positions Powered Maximum
Rectifiers per Feed
External Feed
Protector Minimum Wire
1115A 14AWG
2230A 10AWG
3 340A 8AWG
4450A 6AWG
5560A 6AWG
6670A 4AWG
Recommended External Protection and Minimum Wire Size - 6 AWG max.
19” 3 rectifier configuration 240V~ Phase to Phase
(2725W per rectifier max)
Three-Phase Rectifiers
Rectifier Positions Powered Maximum Rectifiers
per Feed
External Feed
Protector Minimum Wire
1120A 14AWG
2240A 8AWG
3 360A 6AWG

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Step 4B Three (3) Phase, 3W+PE - Connect 380-480V & 240V 3-Phase AC Input
Section (Continued)
Sizing external protectors and wire for all rectifier positions (3 or 6) provides full power for all rectifier positions.
1. Verify the charger AC breaker (AC1) is OFF.
2. Verify AC voltage matches AC Input per Charger Label with a meter.
3. Bring AC wires into the AC Input Box in conduit through one of
the 2” knockouts
4. Connect Ground wire (green /green-yellow) to lug.
5. Strip 1/2” (13mm)
6. Insert into ground lug.
7. Tighten lug screw securely.
8. Pull wire to verify.
5. Connect each AC wire to the
terminal block in the AC Input Box.
AC terminal connections are labeled at
each position - Gnd, L, N, L1, and L2.
a. Strip 1/4” (10mm).
b. Insert into terminal block.
c. Torque screw to 13 in-lb (1.5 Nm).
d. Pull wire to verify.
Go to Step 5
Top Feed
Bottom
Feed
240V
Recommended External Protection and Minimum Wire Size - 6 AWG max.
23” 6 rectifier configuration 240V~ Phase to Phase
(2725W per rectifier max)
Three-Phase Rectifiers
Rectifier Positions Powered Maximum
Rectifiers per Feed
External Feed
Protector Minimum Wire
1120A 14AWG
2240A 8AWG
3 360A 6AWG
4480A 4AWG
55100A 2AWG
66120A 1AWG

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Step 4C Three (3) Phase, 3W+N+PE - Connect 277V 3-Phase AC Input Section
Sizing external protectors and wire for all rectifier positions (3 or 6) provides full power for all rectifier positions.
1. Verify the charger AC breaker (AC1) is OFF.
2. Verify AC voltage matches AC Input per Charger Label with a meter.
3. Bring AC wires into the AC Input Box in conduit through one of
the 2” knockouts
4. Connect Ground wire (green /green-yellow) to lug.
5. Strip 1/2” (13mm)
6. Insert into ground lug.
7. Tighten lug screw securely.
8. Pull wire to verify.
5. Connect each AC wire to the
terminal block in the AC Input Box.
AC terminal connections are labeled at
each position - Gnd, L, N, L1, and L2.
a. Strip 1/4” (10mm).
b. Insert into terminal block.
c. Torque screw to 13 in-lb (1.5
Nm).
d. Pull wire to verify.
Go to Step 5
Top Feed
Bottom Feed
L1 L2 L3 NGND
GND
L1 L3
L1 L3L2 N
Recommended External Protection and Minimum Wire Size - 6 AWG max.
19” 3 rectifier configuration 277V~ Phase to Neutral
(2725W per rectifier max)
Three-Phase Rectifiers
Rectifier Positions Powered Maximum Rectifiers
per Feed
External Feed
Protector Minimum Wire
1120A 14AWG
2240A 8AWG
3 360A 6AWG
Recommended External Protection and Minimum Wire Size - 6 AWG max.
23” 6 rectifier configuration 277V~ Phase to Neutral
(2725W per rectifier max)
Three-Phase Rectifiers
Rectifier Positions Powered Maximum
Rectifiers per Feed
External Feed
Protector Minimum Wire
1120A 14AWG
2240A 8AWG
3 360A 6AWG
4480A 4AWG
55100A 2AWG
66120A 1AWG
277V

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Step 5 - Connect Loads (equipment to be powered)
Load voltage is marked on the charger ratings label.
Load connections are to the terminal blocks in the DC Output Box.
Load terminal block (TB) is behind the Battery terminal block.
Each TB position is marked with its connection: BAT1+, BAT1-, BAT2+, BAT2-, 125V DC+, 125V DC-, 24VDC+, 24VDC
-, 48VDC+, 48VDC-.
1. Verify that equipment being powered accepts the charger output voltage.
2. Verify all DC breakers (DC1, DC2) are OFF.
3. Remove the DC Output Box cover - 4 thumbscrews.
4. Connect Load 1 Positive cable to the Positive terminal block position marked Load 1.
5. Connect Load 1 Negative cable to the Negative terminal block position behind the positive position marked
Load 1.
6. If DC2 Breaker is labeled “Load”, Repeat from 4. for Load 2.
7. Replace the DC Output Box cover - 4 thumbscrews.
Top Feed
with 1 DC Load breaker
Bottom Feed
with 2 DC Load breakers
(Shown as 125VDC)
Battery TB
Screws
Load TB
Behind
Battery TB
Screws
LOAD1+ LOAD1–
Battery TB
BAT 2+

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Step 6 - Connect Batteries
Danger: Energy Hazard - avoid shorting battery wires to ground or to each other.
Caution: Ensure that wires do not come in contact with sharp or rough surfaces that may damage insulation and
cause a short circuit.
Battery voltage is marked on the charger ratings label.
DC Output Box location: Bottom Feed - bottom right Top Feed - top right
DC knockouts: for 2” conduit.
Wire Gauge: 6AWG to 1/0 Strip Length: 1” (24 mm) Torque Screw to 70 in-lb (8 Nm)
1. Measure battery voltage and polarity with a meter.
2. Verify all DC breakers (DC1 and DC2 / BATT if present) are OFF.
3. Remove the DC Output Box cover - 4 thumbscrews.
4. Connect Battery Positive cable to the terminal block position marked BAT1+ (BAT2+ for second battery).
5. Connect Battery Negative cable to the terminal block position marked BAT1– (BAT2– for
second battery).
6. Repeat from 1 for second battery if present.
7. Turn BATT breaker ON if present.
8. Verify the Reverse Polarity LED is not Red and the Ready LED is Green.
If the Reverse Polarity LED is RED, reverse battery cables.
If Ready LED is not Green, verify the voltage on the battery wires.
9. Turn BATT breaker OFF if present.
Top Feed
with 1 DC Load breaker
Bottom Feed
with 2 DC Load breakers
(Shown with +/- 125VDC)
Battery TB
Screws
Screws
Battery TB
Reverse
Polarity LED
Ready LED Output Signal Unit
Output Signal
Unit
BAT1-
BAT1–

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Step 8 - Connect IO Module Signals and Bias
8A - Pulsar XL controller
Connect per site engineering instructions.
Connections are on the front of the IO Module connections unit.
Route wires through routing bend tab and tie wires to wire tie points and wire as
desired.
TB1 - TB21 detachable block - Strip - 0.35” (9 mm) Torque - 2 in-lb (0.25 Nm)
Alarm Outputs and Inputs
TB1 - TB10 Alarms Outputs - Wire to office alarms. See Information: Signal
Connections.
TB11 - TB20 Inputs - Wire to signal sources. See Information: Signal
Connections.
Alt Bias
TB21 Alternative 24V external Bias supply
LAN
LAN Ethernet LAN or local PC connection
1-Wire Battery Temp and Voltage Monitor - Optional
1-WIRE DATA See Information: Battery Monitoring Connections.
IP843G IO Module
Step 7 - Connect External Distribution - future option
ALARM OUTPUTS
RATED 125VDC @ 0.5A
REF FACTORY DEFAULT ASSIGNMENT (SIGNAL – PIN#1; COMMON – PIN2)
TB1 CRITICAL ALARM
TB2 MAJOR ALARM (CHARGER SUMMARY)
TB3 MINOR ALARM
TB4 R1 (RECTIFIER FAIL – RFA/MRFA)
TB5 R2 (AC FAIL – ACF/MACF)
TB6 R3 (LOW VOLTAGE – BD/VLV)
TB7 R4 (GROUND FAULT – GFI)
TB8 R5 (SURGE PROTECTOR – SPD)
TB9 R6 (HIGH VOLTAGE – HVSD/HV)
TB10 R7 (CHECK BATTERY)
ALARM INPUTS
TB11 AUX1 (AIR CONDITIONER FAIL)
TB12 AUX2 (DOOR OPEN)
TB13 AUX3 (HIGH EXTERNAL AMBIENT)
TB14 AUX4 (LOW EXTERNAL AMBIENT)
TB15 CHARGER/PLANT BATTERY TEST (PBT)
TB16 REMOTE RECTIFIER STANDBY (GSTBY)
TB17 AUX9 (AUXILIARY 9)
TB18 AUX8 (AUXILIARY 8)
TB19 OSA1 – (OPENSRING)
TB20 AUX6 (HYDROGEN PRESENT)
DIGITAL PORTS
TB21 RESERVED FOR FUTURE USE
TB22 1-WIRE TEMP PROBES; 1-WIRE SIGNAL ON PIN1; RETURN ON PIN2
TB24 OPTIONAL #24VDC CONTROLLER BACK-BIAS INPUT
ALT-BIAS 24VDC-IN PIN 4; ALT-BIAS 24VDC-IN RTN PIN 5
RECT DATA RS485 / GALAXY PROTOCOL RECTIFIER SERIAL BUS
LAN 10/100 BASE-T ETHERNET

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8B - Nebula controller
Connect per site engineering instructions.
Connections are on the front of the IO Module connections unit.
Route wires through routing bend tab and tie wires to wire tie points and wire
as desired.
TB1 - TB21 detachable block - Strip - 0.35” (9 mm) Torque - 2 in-lb (0.25 Nm)
Alarm Outputs and Inputs
TB1 - TB10 Alarms Outputs - Wire to office alarms. See Information: Signal
Connections.
TB11 - TB20 Inputs - Wire to signal sources. See Information: Signal
Connections.
Alt Bias
TB21 Alternative 24V external Bias supply
1-Wire Battery Temp and Voltage Monitor - Optional
1-WIRE DATA See Information: Battery Monitoring Connections.
IP943G IO Module
ALARM OUTPUTS
RATED 125VDC @ 0.5A
REF FACTORY DEFAULT ASSIGNMENT (SIGNAL – PIN#1; COMMON – PIN#2)
TB1 Power Critical Alarm severity indicator
TB2 Power Major Alarm severity indicator
TB3 Power Minor Alarm severity indicator
TB4 R1 Rectifier Fail (RFA/MRFA)
TB5 R2 AC Fail alarm (ACF/MACF)
TB6 R3 Low Voltage (BD/, VLV)
TB7 R4 Ground Fault (GFI)
TB8 R5 High Voltage (HVSD/HV)
TB9 R6 Multiple Rectifier Fail (MRFA/MFA)
TB10 R7 Check Battery
ALARM INPUTS
(“DRY”, NO VOLTAGE, BINARY CONTACT MONITORS)
TB11 AUX1 (AIR CONDITIONER FAIL)
TB12 AUX2 (DOOR OPEN)
TB13 AUX3 (HIGH EXTERNAL AMBIENT)
TB14 AUX4 (LOW EXTERNAL AMBIENT)
TB15 CHARGER/PLANT BATTERY TEST (PBT)
TB16 REMOTE RECTIFIER STANDBY (GSTBY)
TB17 AUX9 (AUXILIARY 9)
TB18 AUX8 (AUXILIARY 8)
TB19 OSAI – (OPEN STRING)
TB20 AUX6 (HYDROGEN PRESENT)
DIGITAL PORTS
TB21 RESERVED FOR FUTURE USE
TB22 1-WIRE TEMP PROBES; 1-WIRE SIGNAL ON PIN1; RETURN ON PIN2
TB23/24 OPTIONAL #24VDC CONTROLLER BACK-BIAS INPUT
ALT-BIAS 24VDC-IN PIN 4; ALT-BIAS 24VDC-IN RTN PIN 5
RECT DATA RS485 / GALAXY PROTOCOL RECTIFIER SERIAL BUS

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Step 9 - Connect Output Signals Unit Signals
Connect per site engineering instructions.
Connections are on the front of the Output Signals Unit. In the DC Output Box
Detachable blocks - 16 AWG max Strip - 0.35” (9 mm) Torque - 2 in-lb (0.25 Nm)
Route wires through routing bend tab and tie wires to wire tie points and wire as desired.
External Shunt - optional
Jumper on rear of charger must have been moved in Step 1.
Connect with polarity as marked.
Remote Voltage Sense - optional
1. Install current limiting module at the bat-
tery.
Battery Module
125V 847540424
24/48V 848738278
a. Extend wires with butt splices (not provided).
b. Connect to battery + and - posts (terminals not provided).
Stack up: Battery Post, Power terminal, Remote Voltage Sense terminal.
c. Torque per battery specification.
2. Connect current limiting module to the signal unit Remote Voltage Sense detachable block with polarity as
marked.
Extend wires with butt splices (not provided).
Remote Interlock - optional
A factory installed jumper enables the rectifiers without an external signal.
Interlock enables rectifier output.
Enable rectifier output with between pins of Remote Interlock connector.
Open Circuit voltage - 7Vdc. Short circuit current - 1mA per shelf. Max enable voltage - 0.7Vdc.
Cables not provided - see Information Interlock Cable Recommendations.
1. Remove factory installed jumper from Remote Interlock connector.
2. Insert interlock signal cable into Remote Interlock connector.
Output Signal UnitDC Output Box
Bottom Feed shown
To Remote
Voltage Sense
Current Limiting
Module

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Step 11 - Initial Start-up
Rectifiers are keyed allowing only their installation into chargers of the same voltage.
1. Verify that AC and DC connections are complete and secure.
2. Turn on AC input breakers.
a. External feed breaker(s)
b. Charger AC breaker(s) (AC1 and AC2 if present)
Rectifiers will start-up. Then the Controller will start-up.
3. Verify
4. All rectifiers should be indicating green AC and DC LEDs with no red LEDs.
The Controller should be indicating no alarms - display background should be green and no red LEDs.
If alarms are present, see Troubleshooting section.
If there are no alarms, make required adjustments to the default settings on the controller for this installation.
Step 10 - Install Rectifiers
Rectifiers are keyed for input and output voltage, allowing only their installation into compatible
chargers .
Warning: Equipment Damage - Do not Install rectifiers if the Reverse Polarity LED is Red .
1. Verify the Reverse Polarity LED is not Red and the Ready LED is Green.
If the Reverse Polarity LED is RED, reverse battery cables.
If Ready LED is not Green, verify the voltage on the battery wires
2. Slide Rectifier firmly into a Rectifier position - oriented as shown.
3. Secure Rectifier - thumb screws - top and bottom.
4. Repeat for remaining Rectifiers.
5. Secure empty slot fillers in each vacant Rectifier position - thumb screws top and bottom.
Step 12 - Configure Controller
Verify and edit controller basic configuration parameters per site engineering instructions.
See Information: IP843G Controller Basic Operation.
IP843G Product Manual provides additional detail.

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Step 13 - Apply Power to Loads and Batteries Connected through Breakers
Rectifiers are keyed allowing only their installation into chargers of the same voltage.
1. Turn on BATT breaker if present
2. Verify DC output voltage with a meter on VDC+ and VDC– jacks on the Output Signal Unit.
Terminals voltage is output voltage ÷100.
3. Turn on load breaker(s) DC1 (and DC2 if present)
4. Verify No Ground Fault alarm - Ground Fault Unit U LED is Green and F LED NOT Red.
If F LED is Red, adjust values of resistance threshold down (R1 + R2).
Operate Test/Reset button after each adjustment.
If alarm continues, trouble shoot load and battery wiring accordingly.
Output Ground Fault Unit
LEDs
R1 & R2
Test/Reset Button
Output Ground Fault Unit
Bottom Feed shown
Output Signal Unit
Information: Controller - View and Change Parameters and Alarm Severity
View and change system parameters and alarm severity
from the factory defaults via:
A. Front Display
B. LAN port in Local mode via a laptop (web pages)
C. LAN port in Network mode (web pages)
D. Craft Port via laptop and EasyView2 software or HyperTerminal.
Easy View2 (GUI) software can be downloaded from https://abbpowerconversion.com
See Pulsar Plus G3 Controller Product Manual for details.

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Information: Pulsar XL Controller Alarm Relay Jumpers
Jumpers are located on the side top of the controller.
Alarm Relay Jumper Factory Defaults are Open On Alarm.
1. Remove Controller - 2 thumb screws.
2. Position jumpers per site engineering instructions
3. Replace controller - secure with 2 thumb screws.
Information: Pulsar XL Controller - LAN Port - Local / Network
The LAN port is be configured as Local or Network -
controller display menu path Configuration > Communication Ports > Network Settings >
DHCP > mode CLIENT or SERVER
Local (Server): LAN connects to a laptop.
Local (Server) is a temporary setting. When configuration is complete, return LAN
port to Network (Client) mode.
Network (Client): LAN connects to a network. (Default).
CAUTION: Do not connect LAN port to a network when configured as Local.
See Pulsar Plus G3 Controller Product Manual for details.
Information: Pulsars XL (IP843G) Controller Basic Operation
View and change system parameters from the factory defaults via
A. Controller Display
B. Craft Port on front of controller using a laptop with EasyView2 software or HyperTerminal.
EasyView2 (GUI) software can be downloaded from https://abbpowerconversion.com
C. J5 LAN port web pages using a laptop with browser. LAN port Server mode is for local laptop connection. Set
the LAN port to Server: With the controller set to Server enter the default IP address 192.168.2.1 (default) in the
web browser address field.
Warning: Do not connect J5 LAN port to a network when set to Server. Set the controller to Client or Static before
connecting to the network. Static is the factory default setting and the typical setting for most networks.
Controller Alarm Status: The display changes colors; Green = Normal, Amber = Minor Alarm, Red = Critical/Major
Alarm

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Front Display Menu Map
Web Home Page
Control Panel
Status LEDs
Menu
Navigation
LCD
Display
Some alarms may occur during initial installation; example: thermal probe fail or Major/Minor communication fail .
Clear these alarms: Via Controller Display: follow the menu path; Menu > Control/Operation > Clear Events or
Uninstall Equipment.
Via web pages or EasyView2; Select the Maintenance tab > clear latched events and clear
missing devices.
Verify Basic Installation Settings: Date, Time, Battery Type, number of strings and float voltage
Controller Display - Menu > Configuration > System Settings and Menu > Configuration > Batteries.
Web pages or EasyView2 - Installation Tab for Date, Time. Site ID and Site Description.
Settings Tab > Battery Management for Battery Type and number of battery strings installed.