ABB GPS4827 User manual

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© Copyright 2021 ABB. All rights reserved.
PRODUCT MANUAL
GPS4827 Infinity Power System
User’s Guide
Product Manual
Ordering Code 850022019
Issue 1
January 2012

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© Copyright 2021 ABB. All rights reserved.
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 2021 ABB. All rights reserved.
PRODUCT MANUAL
GPS4827 Infinity Power System
User’s Guide
Table of Contents
1. Introduction ··································································································································· 5
GPS4827················································································································································ 5
Customer Service Contacts···············································································································6
2. System Description······················································································································· 7
Overview ··············································································································································· 7
Architecture·········································································································································· 9
3. Galaxy Millennium II Controller ·································································································· 13
4. Rectifiers ······································································································································17
NE050AC48ATEZ ································································································································17
5. AC Input Panels ··························································································································· 21
Overview ·············································································································································· 21
6. Battery Connection Panels········································································································· 23
7. DC Distribution Panels ··············································································································· 25
Function ·············································································································································· 25
8. External Return Bars ··················································································································· 31
Overview ············································································································································· 31
9. Millennium II Controller Operation ···························································································· 35
Controller Connections ···················································································································· 37
Installing Circuit Packs ·····················································································································38
Thermal Probes··································································································································42
USB Interface ·····································································································································43
Local Port············································································································································43
Wiring Alarm Outputs·······················································································································43
Wiring Alarm and Control Inputs ····································································································46
Fuses ···················································································································································50
Front Panel Display···························································································································· 51
Controller Defaults····························································································································54
Controller Display Menu Maps ········································································································ 61

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10. Acceptance Testing······················································································································71
Introduction ········································································································································71
Tools and Test Equipment ················································································································71
Test Precautions·································································································································71
Test Sequences·································································································································· 72
11. Circuit Boards······························································································································ 81
Overview ············································································································································ 81
12. Specifications···························································································································· 83
Rectifier··············································································································································85
13. Safety········································································································································· 87
Safety Statements···························································································································· 87
14. Maintenance and Replacement ································································································ 89
Requirements····································································································································89
Rectifier Installation and Replacement Procedures ···································································89
15. Troubleshooting Procedure······································································································ 91
Preliminary········································································································································· 91
Troubleshooting Procedure············································································································92
16. Product Warranty························································································································· 93
17. Revision ······································································································································· 95

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1. Introduction
GPS4827
ABB Power developed the Galaxy Power System GPS 4827 to support -48 volt telecommunications
powering solutions in worldwide markets. The GPS 4827 combines 50-ampere, fan-cooled,
switchmode 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 1,800-ampere maximum capacity, distribution flexibility, and universal ac input capability, the
GPS 4827 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.
The Millennium controller provides 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

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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 1-877-546-3243 (877 ABB) or for all other countries, please call 1-972-244-9288. 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
Power Systems product manuals and software are available on-line. Software includes Easy View and
SNMP MIB.

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2. System Description
Overview
Block Diagram
A basic block diagram of the Galaxy Power System 4827 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 GPS4827
System Components
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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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.

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Architecture
Configurations
The GPS 4827 is a 7-foot cabinet that can provide up to 1800 amps of DC power in single or multiple
cabinets. Shown in Figures 2-2, 2-3 and 2-4.
Cabinets can contain ac distribution, dc distribution, a battery connection panel, rectifiers, and a
system controller. Cabinets can also be ordered as rectifier only or distribution only cabinets.
Illustrations
Figure 2-3 shows how supplemental cabinets may be added to grow the system for more distribution.
The rectifier output buses are interconnected to permit the cabinet to share current and ensure
common voltage references for all system rectifiers. The total system ampacities must not exceed
1800A.
Figure 2-2 Cabinet schematic

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Figure 2-3 Schematic of Two-cabinet System Architecture 1800A Maximum per system.
Figure 2-3 Schematic of Two-cabinet System Architecture 1800A Maximum per system.
Shared DC Power
Battery String
To Loads
AC
AC
Ground Cabinet
Ground
Shared DC Power AC
Battery String
Battery String
AC
System (CO)
Ground
Cabinet
Ground
AC
Ground
Cabinet
Ground
AC
Ground
To Loads
To Loads
Controller
Rectifier
Battery
Distribution
Cabinet
Rectifier
Battery
Distribution
Cabinet
Rectifier
Battery
Distribution
Cabinet

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Figure 2-5 GPS4827 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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3. Galaxy Millennium II Controller
Overview
Introduction
The GPS 4827 comes equipped with the Galaxy Millennium II Controller. This section describes the
controller operation and detailed 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.
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
Figure 3-1 illustrates the front panel.

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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, the status LED that lights will indicate the
most severe active alarm.
• 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.

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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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Reference Material
Controller Product Manuals
A The Galaxy Millennium Controller product manual (Select Code 167-792-180) is furnished with every
GPS 4827. Refer to this manual for information regarding configuration and operation.
RPM System Product Manual
Refer to the Galaxy Remote Peripheral Monitoring System product manual (Select Code 167-790-063)
for additional information regarding module operation.

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4. Rectifiers
NE050AC48ATEZ
Overview
The NE050AC48ATEZ Series rectifier (50A) operates from single-phase ac service with a phase-
to-phase voltage within the range of 95 to 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 NE050AC48ATEZ 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.

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Features
Output Current “Walk-in”
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.
Output Protection
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.
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.
Fan Alarm and Control
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.
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.

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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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