ABB Galaxy Millennium J2011002 User manual

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© Copyright 2023 ABB. All rights reserved. Millennium SC_MAN Rev 2.0
PRODUCT MANUAL
Galaxy Millennium® SC Controller
J2011002
Product Manual
Ordering code: 850015641

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© Copyright 2023 ABB. All rights reserved. Millennium SC_MAN Rev 2.0
Notice:
The information, specifications, and procedures in this manual are subject to change without notice.
ABB assumes no responsibility for any errors that may appear in this document.
© 2012 abbpowerconversion.com
All International Rights Reserved
Printed in U.S.A.

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© Copyright 2023 ABB. All rights reserved. Millennium SC_MAN Rev 2.0
List of Contents
List of Figures.........................................................................................................................................5
List of Tables ..........................................................................................................................................7
Introduction............................................................................................................................................10
Product Description...............................................................................................................................12
Overview.........................................................................................................................................................12
Feature Summary..........................................................................................................................................15
Standard System Features ................................................................................................................15
Front Panel User Interface.................................................................................................................16
Local Serial Access..............................................................................................................................17
Remote Access ....................................................................................................................................17
Battery Management .........................................................................................................................18
Integrated Monitoring Inputs...........................................................................................................19
Integrated Outputs.............................................................................................................................19
Hardware........................................................................................................................................................20
Chassis............................................................................................................................................................20
Controller Cards ..................................................................................................................................21
Supporting Documents ...............................................................................................................................25
Front Panel .....................................................................................................................................................26
Default Display ....................................................................................................................................26
LCD ........................................................................................................................................................27
LEDs ......................................................................................................................................................27
Push-Button Keys................................................................................................................................28
Test Jacks.............................................................................................................................................28
Serial (PC) Port ....................................................................................................................................28
Alarm Buzzer........................................................................................................................................29
Contrast Adjust ...................................................................................................................................29
Display Menus................................................................................................................................................30
Configuration Menus..........................................................................................................................30
Control and Operations Menus ........................................................................................................32
History Menus .....................................................................................................................................33
Statistics Menus..................................................................................................................................33
Status Menus.......................................................................................................................................34
Installation..............................................................................................................................................36
Preparation ....................................................................................................................................................36
Safety and Precautions......................................................................................................................36
Installation Materials..........................................................................................................................36
Plan Rectifier Interface Cards First ID Settings .............................................................................36
Plan Wiring Transfer from Existing Controller ...............................................................................39
Prepare Galaxy SC Configuration File for MSC Use.......................................................................40
Record Customer Specified Minimum Configuration ..................................................................40
Remove Existing Controller.........................................................................................................................41
Galaxy SC Controller Removal...........................................................................................................42
MCS Controller Removal ....................................................................................................................60
Other Controller Removal ..................................................................................................................68

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© Copyright 2023 ABB. All rights reserved. Millennium SC_MAN Rev 2.0
Install Controller ........................................................................................................................................... 75
Mount the MSC ................................................................................................................................... 75
Remove Controller Fuses................................................................................................................... 76
Install Circuit Cards............................................................................................................................ 77
Install Cabling...................................................................................................................................... 81
Remote Peripheral Monitoring (RPM) ............................................................................................. 92
Power-Up the Controller.................................................................................................................... 94
Configure Settings............................................................................................................................. 94
Install Parallel Rectifiers Regulation Fuses..................................................................................... 112
Acceptance Test............................................................................................................................................ 113
Introduction......................................................................................................................................... 113
Tools and Test Equipment ................................................................................................................ 113
Test Precautions ................................................................................................................................. 113
Test Sequences................................................................................................................................... 114
Troubleshooting .................................................................................................................................... 121
Controller Circuit card ................................................................................................................................. 121
Modem ........................................................................................................................................................... 121
Controller Alarm Descriptions.................................................................................................................... 122
Clear Events................................................................................................................................................... 127
Uninstall Devices .......................................................................................................................................... 127
Specifications ........................................................................................................................................ 128
General ........................................................................................................................................................... 128
Alarm and Control Signals........................................................................................................................... 131
Fuse Alarm Major (FAJ) - BSL-63 ...................................................................................................... 134
Fuse Alarm Minor (FAN) - BSL-65 ..................................................................................................... 134
Open String Alarm (OS) - BSL-72...................................................................................................... 135
Aux Major (AMJ) - BSL-64 .................................................................................................................. 135
Aux Minor (AMN) - BSL-66................................................................................................................. 135
Low Voltage Disconnect Active (LVD1) - BSL-84............................................................................ 135
Low Voltage Disconnect Active (LVD2/LVD2R) - BSL-61/62........................................................ 135
External Boost Option (TFLT/TBST/PBT) - BSL-67-69.................................................................. 135
Rectifier Hold OFF on Engine Option (RO/ROR) - BSL-77-78 ...................................................... 135
Rectifier External Sequence Option (TR1-TR4) - BSL-73/79/85/80........................................... 136
Auxiliary Port - TB1 ....................................................................................................................................... 136
Rectifier Interface......................................................................................................................................... 137
Features Reference................................................................................................................................ 139
Shunt Type..................................................................................................................................................... 139
Threshold Alarms.......................................................................................................................................... 140
Battery Temperature Measurement.......................................................................................................... 141
Load Share..................................................................................................................................................... 141
Mixed Load Share Mode .................................................................................................................... 142
Serial Load Share Mode..................................................................................................................... 143
None Load Share Mode...................................................................................................................... 143
Configuring Load Share Mode ......................................................................................................... 143
Network Access - LAN (Gateway)............................................................................................................... 143
Slope Thermal Compensation.................................................................................................................... 145
Battery Recharge Current Limit................................................................................................................. 145

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© Copyright 2023 ABB. All rights reserved. Millennium SC_MAN Rev 2.0
External Voltage Input (EXT-V) .................................................................................................................. 146
Backup and Restore Configuration........................................................................................................... 147
T1.317 Objects and Attributes .............................................................................................................. 150
User Defined Object Build example ................................................................................................ 179
Factory Defaults .................................................................................................................................... 181
Network Settings ......................................................................................................................................... 181
DIP Switch Settings...................................................................................................................................... 181
Voltage Threshold Ranges and Default Values........................................................................................ 183
Controller Alarm Severity, LED and Relay Default Values....................................................................... 184
Spare and Replacement Parts............................................................................................................... 186
Alarm and Control Signals Cross Reference ........................................................................................ 188
Safety ..................................................................................................................................................... 199
Safety Statements ....................................................................................................................................... 199
Warning Statements and Safety Symbols................................................................................................ 200
Precautions ................................................................................................................................................... 201
Contacts and Warranty ......................................................................................................................... 203
Customer Service Contacts........................................................................................................................ 203
Product Warranty ......................................................................................................................................... 203
Revision History..................................................................................................................................... 205
List of Figures
Figure 1 MSC Chassis ........................................................................................................................................11
Figure 2 MSC Controller Front.........................................................................................................................12
Figure 3 Controller Arrangements..................................................................................................................13
Figure 4 BJC Card Slots ....................................................................................................................................14
Figure 5 Front Panel ..........................................................................................................................................16
Figure 6 Controller Dimensions ......................................................................................................................20
Figure 7 Card Locations....................................................................................................................................21
Figure 8 MCR1B/2B Circuit Card .....................................................................................................................22
Figure 9 MSCB_FB Fuse Card ..........................................................................................................................22
Figure 10 Backplane ..........................................................................................................................................23
Figure 11 Modem BSM6 ....................................................................................................................................23
Figure 12 Alarm Termination Card BSL3_MSC..............................................................................................24
Figure 13 Rectifier Interface Card...................................................................................................................24
Figure 14 Remote Interface Module (RIM).....................................................................................................25
Figure 15 Default Display..................................................................................................................................26
Figure 16 Front Panel ........................................................................................................................................27
Figure 17 Configuration Menus 1 of 2.............................................................................................................30
Figure 18 Configuration Menus 2 of 2 ............................................................................................................31
Figure 19 Control and Operations Menus .....................................................................................................32
Figure 20 History Menus ..................................................................................................................................33
Figure 21 Statistics Menus...............................................................................................................................33
Figure 22 Status Menus 1 of 2..........................................................................................................................34
Figure 23 Status Menus 2 of 2 .........................................................................................................................35

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© Copyright 2023 ABB. All rights reserved. Millennium SC_MAN Rev 2.0
Figure 24 RIC ID Setting ................................................................................................................................. 37
Figure 25 Galaxy SC Controller - Front......................................................................................................... 42
Figure 26 Galaxy SC Controller - Rear........................................................................................................... 42
Figure 27 LVLD Contactor EBV Card SW300 ............................................................................................... 47
Figure 28 LVBD Contactor Control BJN Card SW300 ................................................................................ 48
Figure 29 Galaxy SC Rectifier Fuses ............................................................................................................. 55
Figure 30 Galaxy SC TB2 and TB3.................................................................................................................. 57
Figure 31 Galaxy SC TB1 Plant Connections................................................................................................ 58
Figure 32 Galaxy SC Controller Fuses........................................................................................................... 58
Figure 33 MCS Alarm Circuit .......................................................................................................................... 60
Figure 34 MCS TB1 Alarm Connections........................................................................................................ 62
Figure 35 MCS Auxiliary Board (CP2)............................................................................................................ 64
Figure 36 MSC .................................................................................................................................................. 75
Figure 37 Fuse Card......................................................................................................................................... 76
Figure 38 Cards Front..................................................................................................................................... 77
Figure 39 Cards Rear....................................................................................................................................... 77
Figure 40 Card Connections.......................................................................................................................... 78
Figure 41 RIC ID Setting.................................................................................................................................. 79
Figure 42 Modem Card Wiring....................................................................................................................... 80
Figure 43 Remote Interface Module (RIM) - Side B.................................................................................... 81
Figure 44 Controller Connections Rear ....................................................................................................... 82
Figure 45 Controller Connections Front...................................................................................................... 82
Figure 46 BSL4_MSC Alarm Terminations................................................................................................... 84
Figure 47 Modem Connections ..................................................................................................................... 88
Figure 48 TB100............................................................................................................................................... 89
Figure 49 Shunt Reference Jumper - J5....................................................................................................... 90
Figure 50 Plant Connections Wire-set - 847411824 ................................................................................... 91
Figure 51 Controller Fuses ............................................................................................................................. 94
Figure 52 Controller Drawer .......................................................................................................................... 99
Figure 53 MSC Controller SW202 .................................................................................................................. 100
Figure 54 Rectifier Regulation Fuses ........................................................................................................... 112
Figure 55 DIP Switches................................................................................................................................... 181

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© Copyright 2023 ABB. All rights reserved. Millennium SC_MAN Rev 2.0
List of Tables
Table 1 MSC Standard System Features........................................................................................................15
Table 2 Front Panel User Interface .................................................................................................................17
Table 3 Supporting Documents ......................................................................................................................25
Table 4 Push-Button Key Functionality..........................................................................................................28
Table 5 Rectifier Interface Cards First ID Settings ......................................................................................38
Table 6 Galaxy SC Basic Controller (BJA) HVSD DIP Switch Settings .......................................................43
Table 7 Galaxy SC Basic Controller (BJB) DIP Switch Settings...................................................................44
Table 8 Galaxy SC Intelligent Controller (BJH) DIP Switch Settings .........................................................44
Table 9 Galaxy SC Alarm Threshold Settings................................................................................................45
Table 10 Galaxy SC Plant Shunt Settings.......................................................................................................45
Table 11 Galaxy SC Low Voltage Disconnects Settings...............................................................................46
Table 12 Galaxy SC Slope Thermal Compensation Settings.......................................................................46
Table 13 Galaxy SC Rectifier Setpoints ..........................................................................................................47
Table 14 Galaxy SC High Voltage Shutdown Setting -48V..........................................................................49
Table 15 Galaxy SC High Voltage Shutdown Setting -+/-24V ....................................................................51
Table 16 MCS DIP Switch Settings..................................................................................................................64
Table 17 MCS-BD and LV2 Alarm Settings – S1..............................................................................................65
Table 18 MCS High Voltage Shutdown / Float – S2 .....................................................................................66
Table 19 MCS High Voltage Shutdown / Equalize – S3................................................................................67
Table 20 Other Controller DIP Switch Settings ............................................................................................68
Table 21 Other Controller Alarm Threshold Settings...................................................................................69
Table 22 Other Controller Plant Shunt Settings...........................................................................................69
Table 23 Other Controller Low Voltage Disconnect Settings ....................................................................69
Table 24 Other Controller Slope Thermal Compensation Settings ..........................................................70
Table 25 Other Controller Rectifier Float Setpoints ....................................................................................70
Table 26 MSC Interface Reference..................................................................................................................83
Table 27 Thermal Probe Types.........................................................................................................................85
Table 28 P3 Compatible Temperature Probe Cables...................................................................................85
Table 29 ABS Pin Numbers...............................................................................................................................86
Table 30 Minimum Configuration...................................................................................................................106
Table 31 Modem Settings Configuration.......................................................................................................110
Table 32 Network Settings Configuration.....................................................................................................111
Table 33 Controller Alarm Descriptions.........................................................................................................122
Table 34 MSC Specifications - General ..........................................................................................................128
Table 35 Alarm and Control - Signal Names and BSL Pins..........................................................................131
Table 36 Alarm - Descriptions, BLS Pins, and Signal Names......................................................................132
Table 37 Alarm and Control Inputs - Descriptions, BLS Pins, and Signal Names....................................134
Table 38 TR Leads and Associated Rectifiers...............................................................................................136
Table 39 Auxiliary Port - TB1.............................................................................................................................136
Table 40 Rectifier Cables..................................................................................................................................137
Table 41 Commercial Rectifier Wiring (H285-226 G62) ...............................................................................138
Table 42 Threshold Alarms...............................................................................................................................140
Table 43 Battery Temperature Source Priority.............................................................................................141
Table 44 Load Share Modes.............................................................................................................................141
Table 45 External Voltage Input Resistors ....................................................................................................146

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© Copyright 2023 ABB. All rights reserved. Millennium SC_MAN Rev 2.0
Table 46 System Objects and Attributes...................................................................................................... 151
Table 47 DC Distribution Objects and Attributes........................................................................................ 153
Table 48 AC Distribution Objects and Attributes........................................................................................ 153
Table 49 Alarm Test Objects and Attributes................................................................................................ 154
Table 50 Plant Objects and Attributes .......................................................................................................... 154
Table 51 Bay Interface Card (BIC) Objects and Attributes ......................................................................... 157
Table 52 Boost Objects and Attributes ......................................................................................................... 157
Table 53 Rectifier Objects and Attributes .................................................................................................... 158
Table 54 Converter Objects and Attributes.................................................................................................. 160
Table 55 Ringer Objects and Attributes........................................................................................................ 161
Table 56 Battery Objects and Attributes ...................................................................................................... 162
Table 57 Disconnect Contactor Objects and Attributes ............................................................................ 164
Table 58 Standard Alarm Objects and Attributes ....................................................................................... 165
Table 59 Single Threshold Alarm Objects and Attributes.......................................................................... 167
Table 60 Dual Threshold Alarm Objects and Attributes............................................................................. 168
Table 61 Events Objects and Attributes........................................................................................................ 169
Table 62 Alarm Input Objects and Attributes............................................................................................... 170
Table 63 Data Switch Objects and Attributes.............................................................................................. 171
Table 64 Remote Peripheral Monitor Objects and Attributes................................................................... 172
Table 65 Distribution Current Objects and Attributes............................................................................... 173
Table 66 Controller Analog Input Objects and Attributes ......................................................................... 174
Table 67 Other Measurement Objects and Attributes ............................................................................... 174
Table 68 Reporting Objects and Attributes ................................................................................................. 175
Table 69 Remote Communication Objects and Attributes........................................................................ 176
Table 70 Configurable Statistics Objects and Attributes.......................................................................... 177
Table 71 TL1 Management Objects and Attributes ..................................................................................... 178
Table 72 System Objects and Attributes ...................................................................................................... 179
Table 73 MSC DIP Switch Settings ................................................................................................................. 182
Table 74 Enhanced Remote Security Features............................................................................................. 182
Table 75 Voltage Threshold Ranges and Default Values ............................................................................ 183
Table 76 Controller Alarm Severity, LED and Relay Default Values........................................................... 184
Table 77 Rectifier Alarm Defaults ................................................................................................................... 186
Table 78 MSC Spare and Replacement Parts................................................................................................ 186
Table 79 Galaxy SC Wiring Plan & Cross Reference ..................................................................................... 189
Table 80 MCS/CCS Wiring Plan & Cross Reference..................................................................................... 192
Table 81 ECS - 12U Wiring Plan & Cross Reference ...................................................................................... 194
Table 82 Wiring Transfer Plan - Other Controller......................................................................................... 195

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© Copyright 2023 ABB. All rights reserved. Millennium SC_MAN Rev 2.0
Introduction
The Galaxy Millennium® SC controller (MSC) brings next generation features of the controller to
plants with legacy rectifiers. It provides integrated control and monitoring of plants with a mixture of
rectifier technologies by interfacing with parallel rectifiers (legacy, non-serial rectifiers) as well as all
Galaxy Protocol (GP) serial rectifiers and converters. It provides control, monitoring, and alarm
monitoring functions over a multi-drop serial interface that interconnects Galaxy Protocol (GP)
rectifiers, GP converters, Bay Interface Cards (BICs), and other serial devices. Galaxy Protocol
communication is via robust RS-485 serial buses. MSC has a plethora of I/O and monitoring options.
It can monitor and control battery plants containing up to 72 GP serial rectifiers, up to 16 serial
converters, up to 32 BICs, and up to 16 parallel rectifiers. A maximum combination of 90 GP nodes can
be directly managed on the rectifier serial bus. MSC performs many functions described more
thoroughly in following sections.
Feature Summary
• Alarm Detection, Identification, and Reporting
• System and Component Status
• System and Feature Configuration
• System Alarm Thresholds
• Battery Management (Slope Thermal Compensation/Recharge Current Limit)
• Battery discharge testing
• Reserve Time Prediction
• Selective high/low voltage shutdown
• Float/Boost Mode Control
• Low Voltage Disconnect Management
• Remote Access Control And Multiple Level Password Security
• Control and Operation
• Plant
• Rectifiers
• Parallel - Legacy ABB and non-ABB Ferro, SCR, and ABB ECS Switch Mode
• Serial GP Protocol - ABB Switch Mode
• History
• Statistics
Abbreviations
• MSC - Galaxy Millennium® SC controller
• SC - Galaxy® SC controller
• M2 - Galaxy Millennium® II controller
• GP - Galaxy Protocol (RS-485)