ABB GPS2436 User manual

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© Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3
PRODUCT MANUAL
GPS2436 (H5692436) User’s Guide
GPS2436 is available with Galaxy Millennium II or Galaxy Pulsar Plus controllers.
This manual is based on and includes information specific to the Galaxy
Millennium II controller.
Refer to these documents for information specific to the Galaxy Pulsar Plus
controller
• Galaxy Pulsar Plus Product Manual CC848815341
• GPS2436 Ordering Guide H5692436.
Product Manual
Ordering Code
850022020
Notice:
The information, specifications, and procedures in this manual are subject to change without notice.
ABB Power assumes no responsibility for any errors that may appear in this document.

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© Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3
Table Of Contents
1 Introduction ............................................................................................................................................5
GPS2436.............................................................................................................................................................. 5
Customer Service Contacts............................................................................................................................. 6
2 System Description ................................................................................................................................ 7
Overview ..............................................................................................................................................................7
Architecture........................................................................................................................................................ 8
3 Galaxy Millennium II Controller ............................................................................................................ 11
Overview ............................................................................................................................................................11
4 Rectifiers............................................................................................................................................... 15
NE100AC24ATEZ...............................................................................................................................................15
5 AC Input Panels ..................................................................................................................................... 17
Overview ............................................................................................................................................................ 17
6 Battery Connection Panels .................................................................................................................. 19
Overview ............................................................................................................................................................19
7 DC Distribution Panels ......................................................................................................................... 21
Function .............................................................................................................................................................21
8 External Return Bars............................................................................................................................. 27
Overview ............................................................................................................................................................27
9 Millennium II Controller Operation ..................................................................................................... 31
Controller Connections .................................................................................................................................. 33
Installing Circuit Packs ................................................................................................................................... 34
Thermal Probes.................................................................................................................................................37
USB Interface.....................................................................................................................................................37
Local Port...........................................................................................................................................................37
Wiring Alarm Outputs..................................................................................................................................... 38
Wiring Alarm and Control Inputs ..................................................................................................................40
Fuses..................................................................................................................................................................44
Front Panel Display..........................................................................................................................................44
Controller Defaults.......................................................................................................................................... 47
Controller Display Menu Maps ...................................................................................................................... 53
10 Acceptance Testing.............................................................................................................................63
Introduction ..................................................................................................................................................... 63
Tools and Test Equipment ............................................................................................................................. 63
PRODUCT MANUAL
GPS2436 (H5692436) User’s Guide

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© Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3
Table Of Contents (Continued)
Test Precautions.............................................................................................................................................. 63
Test Sequences................................................................................................................................................ 63
11Circuit Boards....................................................................................................................................... 71
Overview ............................................................................................................................................................71
12 Specifications ..................................................................................................................................... 73
GPS2436............................................................................................................................................................ 73
Rectifier............................................................................................................................................................. 75
13 Safety................................................................................................................................................... 77
Safety Statements........................................................................................................................................... 77
14 Maintenance and Replacement..........................................................................................................79
Requirements................................................................................................................................................... 79
Rectifier Installation and Replacement Procedures .................................................................................. 79
15 Troubleshooting Procedure ............................................................................................................... 81
Preliminary........................................................................................................................................................ 81
Troubleshooting Procedure........................................................................................................................... 82
16 Product Warranty................................................................................................................................83
17 Revision ...............................................................................................................................................85

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© Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3
GPS2436
ABB Power developed the Galaxy Power System GPS2436 to support +24 volt telecommunications
powering solutions in worldwide markets. The GPS2436 combines 100-ampere, fan-cooled, switch
mode rectifiers, microprocessor control technologies, battery and load disconnect/reconnect options,
and a comprehensive line of fuse and circuit breaker dc distribution options in a modular front-access
design. This modularity ensures easy access, simplified installation and maintenance, and allows the
system to expand in capacity as power needs grow. With 2000-ampere maximum capacity,
distribution flexibility, and universal ac input capability, the GPS2436 supports switching,
transmission, and wireless applications in central office locations and environmentally controlled
remote sites (huts or vaults).
The main emphasis of this manual is to provide a general product description that will familiarize the
user with the main components of the system and to provide guidelines for the basic maintenance of
this Galaxy Power System. GPS2436 is available with Galaxy Millennium or Galaxy Pulsar Plus
controllers. Both controllers provide many advanced functions and features, including;
• 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
• Float/Boost Mode Control
• Low Voltage Disconnect Management
• Remote Access Control And Multiple Level Password Security
• History
• Statistics
This manual is based on and includes information specific to the Galaxy Millennium II controller.
Refer to these documents for information specific to the Galaxy Pulsar Plus controller
• Galaxy Pulsar Plus Product Manual CC848815341
• GPS2436 Ordering Guide H5692436.
1 Introduction

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© Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3
Power Systems product manuals and software are available on-line. Software includes Easy View and
SNMP MIB.
Customer Service Contacts
Customer Service, Customer Training, Technical Support, Product
Repair and Return, and Warranty Service
For customers in the United States, Canada, Puerto Rico, and the US Virgin Islands,
please dial [phone] or for all other countries, please call [phone]. This number is
staffed from 7:00 am to 5:00 pm USA Central Time Zone (GMT-6), Monday through Friday, on normal
business days. At other times, this number is still available, but for emergencies only. Services provided
include initiating the spare parts procurement process, ordering documents, product warranty
administration, and providing other product and service information.
For other customers worldwide the 800 number may be accessed after first dialing the direct country
code for the country where the call is originating, or you may contact your local field support center or
your sales representative to discuss your specific needs.
On-Line Power Systems Product Manuals and Software

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© Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3
2 System Description
Overview
A basic block diagram of the Galaxy Power System 2436 is shown in Figure 2-1. It illustrates the
arrangement and interconnection of the system components from the ac input to the dc output.
Figure 2-1 Block Diagram of the GPS2436
Block Diagram
System
The power system accepts alternating current from the commercial utility or a standby ac power
source and rectifies it to produce dc power for the using equipment. The system’s control and alarm
functions interact with the rectifiers and the office. In addition, the system provides overcurrent
protection and charge, discharge, and distribution facilities. Battery reserve is connected in parallel
and automatically provides a source of dc power if the commercial or standby ac fails. Battery reserve
can be engineered to supply dc power for a specific period of time. In normal practice, battery capacity
is sized to provide 3 to 8 hours of reserve time.

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© Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3
Components
AC Input connects the commercial and/or standby ac power sources to the rectifiers within the system
and provides overcurrent protection. In some applications the ac service is wired directly to the
rectifiers and overcurrent protection is provided at the service panel.
Rectifiers convert an ac source voltage into the dc voltage level required to charge and float the
batteries and to power the using equipment.
Controller provides the local and remote control, monitoring, and diagnostic functions required to
administer the power system.
Batteries provide energy storage for an uninterrupted power feed to the using equipment during loss
of ac input or rectifier failure.
DC Distribution Panel provides overcurrent protection, connection points for the using equipment, and
bus bars used to interconnect the rectifiers, batteries, and dc distribution.
Battery Connection Panel provides connection points for the battery strings through battery
disconnect fuses or contactors and current monitoring shunts.
Architecture
The GPS2436 is a 7-foot cabinet that can provide up to 3600 amps of DC power in a single cabinet.
Figures 2-1 and 2-2 show diagrams of single cabinets.
Each cabinet contains ac distribution, dc distribution panels, a battery connection panel, rectifiers,
termination points for load circuits, and a system controller.
Configurations
Illustrations
Figure 2-3 shows a block diagram of a two cabinet system. One supplemental cabinet may be added to
grow the system to 2,700 amperes. The rectifier output buses are interconnected to permit the cabinet
to share current and ensure common voltage references for all system rectifiers.
Figure 2-2 Cabinet schematic

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© Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3
Figure 2-3 Schematic of two-cabinet system architecture
Controller Rectifier
Battery Distribution
Cabinet
Rectifier Battery
Distribution
Cabinet
Rectifier Battery
Distribution
Cabinet
Figure 2-4 Schematic of Three-cabinet System Architecture 1800A Maximum per system.

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© Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3
Figure 2-5 GPS2436 Six shelf cabinet with door removed
Rectifier Shelves 3,6 or 9
AC Panel
Circuit Breakers or
Terminal strip
Miscellaneous DC Distribution
Panels

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© Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3
3 Galaxy Millennium II Controller
Overview
Introduction
The GPS2436 comes equipped with the Galaxy Millennium II Controller. This section describes the
controller operation and general information about the features of the front panel keys, LEDs, and
display.
The Galaxy Millennium II Controller provides advanced local and remote monitoring and data
acquisition features. The controller monitors system parameters; such as, system voltage and current,
and components; such as rectifiers, and distribution circuits. The controller reports the status and
issues appropriate alarms in the event a failure occurs.
Each cabinet is equipped with a bay interface card (BIC). The BIC acts as an interface to the cabinet
control and alarm signals.
User Interface and Display
The Millennium II’s primary user interface is a backlit LCD front panel display that can be viewed in
English or Spanish, two rows of LEDs, an array of pushbutton keys, and a pair of test jacks.
Figure 3-1 illustrates the front panel.
Default Display
The default display shows basic system status; system voltage, load current, and plant state. The
controller returns to this display approximately three minutes after a key is pressed. The information
on the screen is updated automatically approximately every two seconds. The default screen displays
the following: The first line shows the number of alarms and warnings present in the system, the date,
and the time. The next two lines show the system voltage and the system load. The last line shows the
system mode, which can be one of the following:
• FLOAT
• BOOST
• STC (Slope Thermal Compensation)
• BATT TEST

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© Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3
LEDs
Two rows of LEDs show the source and severity of various alarms. An alarm lights one status LED and
one or more alarm LEDs. If more than one alarm LED lights, only the status LED of the most severe
alarm will light.
• The first row includes four LEDs, labeled Alarm Status. They indicate the severity of the reported alarm:
Critical
Major
Minor
Normal
The Battery on Discharge LED is also in this row.
• The second row has seven LEDs, labeled Equipment Status. They indicate the source of the alarm:
AC System
Battery
Controller
Distribution Rectifier
Remote Modules
The Modem LED illuminates when the internal modem is in use.
Test Jacks
A pair of test jacks allows direct measurement of the dc bus sense voltage being monitored by the
controller.
Pushbutton Keys
A group of pushbutton keys below the backlit LCD display provides the primary user interface with the
controller. These keys are used singly or in combination to navigate through the controller’s menus.
The following is a general description of the pushbutton keys:
• ESCAPE: Return to the immediate higher level menu.
• HELP: Displays limited on-line help information.
• MENU: View the MAIN menu.
• ENTER: Select a menu item.
• Up arrow: Moves the cursor up one line.
• Down arrow: Moves the cursor down one line.
• Left arrow: Moves the cursor left one field.
• Right arrow: Moves the cursor right one field.
• + and -: Increase or decrease parameter values.
• Lamp test: Tests the controller’s circuit board LEDs and front panel LEDs. It will also test the indicators of serially
connected rectifiers.
Access Panel
A rubber flap can be opened to access the local port connector. The DB-9 local port connector
supports standard RS232 serial communication. Refer to the Galaxy Millennium II Controller product
manual for additional details on port configuration and isolation.

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© Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3
Reference Material
Controller Product Manuals
The Galaxy Millennium II Controller product manual (Ordering Code 108994645) is available. Refer to
this manual for information regarding configuration and operation.
RPM System Product Manual
Refer to the Galaxy Remote Peripheral Monitoring System product manual (Ordering Code 107570517)
for additional information regarding RPM module operation.

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© Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3
4 Rectifiers
NE100AC24ATEZ
Overview
The NE100AC24ATEZ Series rectifier (100A) operates from single-phase ac service with a
phase-to-phase voltage within the range of 95-275Vac.
The rectifiers are shipped separately from the cabinets for quick and straightforward installation into
rectifier shelves at the site. Interconnections to ac input, dc output, and control signals occur
automatically during insertion. No settings or adjustments to potentiometers are necessary.
The NE100AC24ATEZ rectifiers are UL Recognized for both the U. S. and Canada, comply with UL1950
(Information Technology Equipment), and meet EN60950 requirements.
Front Panel Display
Status Indicators
Three LEDs on the rectifier’s faceplate indicate the rectifier’s condition.
• The Norm LED is green and is lit when the rectifier has AC input present and is working properly.
• The ACF LED is amber and is lit when there is no AC input present to the rectifier.
• The Fail LED is red and is lit if there is a failure in the rectifier.
Lamp Test
To test the LEDs on the rectifier front panel, press the Lamp Test button on the controller.
Features
Output Current “Walk-in”
Output Protection
This circuit controls the time (up to eight seconds) required for the rectifier to reach normal operating
conditions after it is turned on. This feature minimizes the starting surge on the customer's power
source.
Rectifier is equipped with an internal fuse for plant protection if a fault occurs in a rectifier.
Electronic Current Limit
When the output current tends to increase above the current limit set point, the current limit circuit
overrides the voltage regulating signal and safely limits the output current of the rectifier, thus
preventing damage to itself or the load.

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© Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3
High Voltage Shutdown (HVSD)
The rectifier senses the voltage at its output terminals. If this voltage is too high, the rectifier will shut
down to prevent the high voltage from damaging itself or the load.
Restart
Upon shutdown, the rectifier will attempt to restart. The rectifier will also accept a restart command
from the controller for a remote restart. The rectifier will attempt to restart three times before issuing
a rectifier fail alarm to the controller.
The rectifier contains a cooling fan. The fan’s speed, which is based on ambient temperature and
output power level, is lowered during low-load and low-temperature conditions to minimize audible
noise and maximize fan life.
Fan Alarm and Control
Thermal Alarm
The rectifier senses the internal operating temperature and will issue a thermal alarm if the internal
temperature exceeds a safe operating level. Ambient temperatures above the maximum rating will
result in a rectifier shutdown and the issuing of a thermal alarm (TA).
Autonomous Operation
Rectifiers will continue to power the load if the controller fails or if communication is lost.
Controller Communications Alarm
When communications between the rectifier and controller are interrupted, the rectifier continues to
operate and the red Fail LED on the rectifier blinks.
Connectorized
The rectifiers provide the controller with a full complement of status and alarm signals. The rectifier
status and alarm signals, ac input, and dc output are all connectorized for easy installation and
maintenance. System connections are made when the rectifier is plugged into the shelf. No additional
connections are required.
“Forced” Load Sharing
Internal rectifier circuitry will allow rectifiers to share load in the event communication to the controller
is lost or the controller malfunctions.

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© Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3
5 AC Input Panels
Overview
The ac input panel provides the facility to terminate 3-phase ac service to the GPS2436 system or to
distribute individual 1-phase ac supplies to each of the system rectifier positions.
Depending upon the option ordered, the panel will connect 3-wire (three phases), 4-wire (three phases +
neutral), or individual 2-wire (single phase, either 2 hot leads or 1 hot lead and neutral) input ac service.
Some options provide circuit breakers to protect the conductors providing ac service to the individual
rectifiers. Other systems contain a terminal strip and the conductors are protected by circuit breakers
located in the building’s ac service panel.
Note: All wire sizes based on the US National Electric Code.
AC Service
Figure 5-1: AC Input Terminal strip Panel
Figure 5-2: AC block.
Factory wiring from AC block to rectifier shelf shown.

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© Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3
Figure 5-3: AC Input circuit Breaker Panel
CB1 CB2 CB3 CB4 CB5 CB6 CB7 CB8 CB9 CB10 CB11 CB12
G11 G12 G21 G22 G31 G32 G41 G42 G51 G52 G61 G62
G13 G14 G23 G24 G33 G34 G43 G44 G53 G54 G63 G64
Figure 5-4: AC circuit breaker wiring and rectifier positions

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© Copyright 2023 ABB. All rights reserved. GPS2436_MAN Rev. 1.3
6 Battery Connection Panels
Overview
Function
Batteries are connected to the GPS2436 cabinets on battery connection panels located in the cabinet
directly below or behind the ac input panel. All panels include the battery shunt and an alarm card that
communicates with the controller to provide battery current and status information. The panel
includes a low voltage battery disconnect/reconnect (LVBD/R) contactor. When equipped with
contactors, a contactor control card provides local/manual control of the contactors and a shunt to
monitor battery charge/discharge current.
Illustrations
Battery connection panel is shown in Figures 6-1.
Note: Battery connection panels are blue; dc distribution panels are white.
Figure 6-1: H5692436 G39 (ED83143-31 G36) Panel is equipped with a Low Voltage Battery Disconnect/Reconnect
contactor rated at 2000 amps, and a 3000 amp shunt to monitor battery charge/discharge current.

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