ABB J2012001 User manual

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3U DIN Distribution Shelf - 19 in Rack Mount
J2012001 - multiple models - See SPS, NE, or CP Brochure for details of
models
• Wire cutters and strippers
• Cable crimpers
• Torque wrench (0-40Nm)
• Screw Drivers - Phillips and flat
• Sockets - metric and inch
The distribution shelf may be installed as a component of a power systems or as a stand-alone remote distribution
(cabled input power). Some models include battery connections. Some models include battery connections and
battery contactors.
Controller: All power systems have a controller. It may be located in the primary rectifier shelf or in the distribution
shelf. If the power system has a primary rectifier shelf (with controller), install the distribution shelf immediately
above it.
Refer to SPS, Infinity S (NE S), or CPL Brochure for details, circuit breakers, and accessories.
11” deep Shelf (SPS compatible)
17” deep Shelf (NE & CP compatible)

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Step 1 - Mount Shelf
Prepare the shelf for mounting to the frame.
1. Reposition mounting ears as required - 3 screws each.
Torque to 2.8Nm (25 in-lb) - Phillips screwdriver.
2. Position the shelf immediately above the rectifier shelf
with controller (if present).
3. Install Inter-Shelf brackets between adjacent shelves
(optional).
Torque to 2.8Nm (25 in-lb) - Phillips screwdriver.
Mount the shelf to the frame.
1. Attach shelf to the frame using a minimum of four
screws (two on each side) - 12- 24 (provided).
Torque to 4Nm (35 in-lb) - 5/16” (8mm) socket.
Step 2 - Ground Chassis
Notes:
1 Lug landings are M5 on 5/8” (16mm) centers (lug not
provided)
2 6mm2 (10AWG) recommended.
3 Some applications may rely on frame mounting screws
for shelf ground omitting the shelf ground cable
Torque to 4Nm (35 in-lb) - 8mm (8mm) socket.
Step 3 - Connect System DC Reference
(CO) Ground
Make one connection to a power system (SPS, NE, CPL,
etc.). No connection to a stand-alone, remote distribution
shelf. Connections are to the left-most position on the
Load Return bus - M6 lug ( not provided).
10mm2 recommended
Torque to 4.0 Nm (35 in-lb) - 10 mm socket.
Step 4 - Connect Shelf DC Input
Connections are on the rear under covers.
Bus Connection - to an adjacent rectifier shelf
Install inter-shelf buses joining -48V and RETURN bus
connections of all adjacent shelves.
Cable Connection - Stand-alone Shelf
CAUTION: Verify battery voltage and polarity with a
voltmeter before proceeding.
Lug Landings - 2 x 1/4” on 5/8” center, 0.7” (18mm) max.
tongue width. Connect cables with suitable lugs to -48V &
RETURN. Torque to 4Nm (35in-lb) - 8mm (8mm)socket.
Frame Ground (left rear)
Mounting Ears
Inter-Shelf Bracket
Rectifier Shelf
DC Reference
(CO) Ground
Dual Lug Landings
(stand-alone Shelf)
-48V bus Connections
covers removed
Inter-shelf bus
RETURN bus Connections
covers shown
2 Adjacent
shelves

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Step 5 - Reposition Battery Breaker Bus Bars
Skip if battery breakers are installed or batteries are not present
Battery breaker positions are on the left end of the DIN rail.
Battery breaker bus bars can be positioned for two 3 or 4 pole breakers or for four 1 or 2 pole breakers.
1. Verify that Battery Breaker Bus Bars are properly positioned for the breakers to be installed.
2. Reposition both Battery Breaker Bus Bars to positions for the breakers to be installed.
a Remove screws (2) securing each Battery Breaker Bus Bar to the main bus bar - #2 Phillips.
b Position each Battery Breaker Bus Bars as required.
Secure with screws. Torque to 2 Nm (18 in-lb) - #2 Phillips.
Step 6 - Connect Batteries - Skip if not present
Battery breaker positions are on the left end of the DIN rail.
Batteries connect to Battery Breakers - light gray
Battery Returns connect to the Battery Return bus behind the breakers.
Use lugs suitable to lug landings (lugs not provided).
A. Install Battery Breaker Kits - skip if battery breakers are installed or batteries
are not present
1. Connect alarm wire to battery breaker (wires provided)
Connect Fastons to breaker terminals.
Terminal 11 - Red
Terminal 12 - Black
Battery Breaker Bus Bars - top view
1 or 2 Pole Battery Breaker
3 or 4 Pole Battery Breaker
Bus Bars Positions
Battery Breaker Positions
(Left Breaker Positions)

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2. Mount breaker to DIN rail
a Verify that breaker is OFF.
b Fully open the connections at breaker bottom - #2 Philips
c Slide breaker over bus tabs and engage top DIN rail fully. IMPORTANT - Verify top DIN rail engagement.
d Tighten the breaker bottom connection - #2 Philips. Hold firmly downward and torque as labeled.
3. Connect alarm wires to Alarm Card HDR3
BAT1 Aux + Red
BAT1 Aux - Black
a Run wires to HDR3
b Cut wires
c Strip 12 mm (1/2”)
d Push release lever, Insert wire, Release lever, Pull wire to verify
4. Repeat for additional Battery Breakers, BAT2, etc.
B. Connect Batteries
1. Connect Battery Return Cable to Battery Return Bus
Battery Return Lug Landings - M8, 25.4mm (1”) apart. Torque to 18 Nm (13 ft-lb) - 13mm socket
2. Verify that breaker is OFF.
CAUTION: Verify battery voltage and polarity with a voltmeter before proceeding.
3. Connect Battery Cable to lug adapter (factory assembled to breaker)
Battery Lug Landings - M8, 25.4mm (1”) apart for adapters with .2 landings
Torque to 18 Nm (13 ft-lb) - 13mm socket
4. Repeat for additional Battery connections.
Break off Cable Entry Tabs as necessary.
Battery Connection
Alarm Card HDR3
Battery Return
Connection
Release Levers
Push to release
DIN Rail
Engagement
Bus Tabs
Battery
Return Bus
Breaker Bottom
Connections
Lug Adapter
Alarm Wires

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Alarm Wire
Secured along side
the load wire
Bus Tabs
Load Return
Connection
Load Wire
Breaker Bottom
Connection Screw
DIN Rail
Engagement
Step 7 - Connect Loads (Outputs)
Load breaker positions are on the right side of the DIN
rail. Loads connect to Load Breakers - black.
Load returns connect to the load return bus behind the
breakers - M6 lugs (not provided).
1. Connect load return wire to the Load Return bus - M6 lug
(not provided)
Torque 4.0 Nm (35 in-lb) - 10 mm socket.
2. Verify that breaker is OFF.
3. Mount breaker to DIN rail
a. Fully open the connection at breaker bottom - #2
Philips
b. Slide breaker over bus tab and fully engage top DIN
rail.
IMPORTANT - Verify top DIN rail engagement.
a. Tighten the breaker bottom connection - #2 Philips.
Hold firmly downward and torque as labeled.
4. Connect alarm wire to load breaker
Note: This wire will be secured to the breaker along
side the load wire.
a. Fully open the connection at breaker top- #2 Philips
b. Choose any wire from the bundle of black wires behind
the breakers Cut wire. Strip 10 mm (3/8”) Insert wire
into breaker load connection. Do not tighten the
breaker connection.
5. Connect load wire to breaker
a. Strip the load wire 10mm (3/8”)
b. Insert load wire into breaker load wire connection
alongside the alarm wire.
c. Tighten the breaker top connection - #2 Philips.
Assure both the load wire and the alarm wire are
secured.
6. Repeat for additional loads.
Step 8 - Label Connections
ID label is in front of the breakers or on the door.
Mark each connected circuit identification on the ID label.
Breaker Top
Connection Screw
ID Label Example

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Step 9 - Set Jumpers - LAN Port and Relay per Galaxy Pulsar Edge Controller
Quick Start Guide - Skip if no Controller
See Galaxy Pulsar Edge Controller Quick Start Guide
1. Set Jumpers - LAN Port and Relay
Step 10 - Install Controller - Skip if no Controller
Controller installs to Controller Backplane - inside
on the right.
1. Remove nut - 8mm (5/16)
2. Align Controller with the backplane connector.
3. Slide controller firmly to the left.
CAUTION: DO NOT press on LEDs or LCD.
4. Secure with nut - 8mm (5/16)
Step 11 - Set Shelf IDs per Galaxy Pulsar Edge Controller Quick Start Guide
Skip if Stand-alone Distribution
Step 12 - Install Controller Communications Cables - Skip if Stand-alone Distribution
Controller in Rectifier Shelf
1. Connect the communication cable between Distribution Shelf and adjacent Rectifier Shelf (cable provided).
2. Install other controller communications cables (alarm, LAN, etc.) per Rectifier Shelf Quick Start Guide.
Controller in Distribution Shelf
1. ABB Device Comm cable
a. Route cable out of the shelf through the Control Cable Bushing.
b. Connect cable to the adjacent Rectifier Shelf.
2. Controller Backplane connections.
a. J1-2 Alarms - detachable block - Wire to office alarms and signals.
See Information: Alarm Connections for alarm connection details
b. J5 LAN - Connect to Ethernet network.
Controller Backplane
Controller
Nut

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Controller in Rectifier Shelf
Controller Cable Bushing
Communication Cable
Distribution Shelf to
Rectifier Shelf
Rectifier Shelf
with controller
typical
J2 Alarm Inputs
J4 TEMP Probe
Controller Backplane
J5 LAN
J1 Alarm Outputs
Rectifier Shelf without
controller typical
Controller Cable Bushing
ABB Device Comm Cable
Distribution Shelf to
Rectifier Shelf
ABB Device Comm Cable - to Rectifier Shelf
Bottom View
ABB Device Comm Cable
ABB Device Comm Cable - a shipped
Controller in Distribution Shelf

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Step 13 - Install 1-Wire Battery Temp and Voltage Monitor - Optional - skip if Stand-alone
Distribution
See Information: 1-Wire Battery Temp and Voltage Monitor in Galaxy Pulsar Edge Controller Quick Start Guide
Controller in Rectifier Shelf - Install per Rectifier Shelf Quick Start Guide.
Controller in Distribution Shelf
Controller Backplane connection
1. J4 TEMP Probe - Connect to 1-Wire Battery Temp and Voltage Monitor
Step 14 - Initial Power Up - skip if Stand-alone Distribution
Controller in Rectifier Shelf - Initial Power up per Rectifier Shelf Quick Start Guide.
Controller in Distribution Shelf
Verify that all DC and Alarm connections are complete and secure.
Initial Power up per Rectifier Shelf Quick Start Guide.
If there are no alarms, make required adjustments in the default settings on the controller for this installation.
Step 15 - Configure Controller per Galaxy Pulsar Edge Controller Quick Start
Guide - Skip if Stand-alone Distribution
Controller in Rectifier Shelf - Craft Port per Rectifier Shelf Quick Start Guide.
Controller in Distribution Shelf - Craft Port - USB
Information: Alarm Connections - Shelves with controller only
Connections on controller backplane card behind the shelf front door.
Change alarm descriptions via LAN port (Web pages) or Craft port (EasyView2) when required.
1 Only with 6 relay controllers (...6R…).
2 Returns for R1 and R4 are bridged. Other returns are isolated.
Pin/ Connector Alarm Outputs Alarm Inputs
Input: SPD Fail

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Information: Clear Breaker Alarm
The Alarm Card monitors all breakers that were once ON.
Breaker Alarms, PMJ and FAJ, occur while breakers are OFF or TRIPPED.
Clear Breaker Alarm
Turn the breaker ON
or
Press the Alarm Reset button to ignore all breakers that are OFF or TRIPPED, until they are again ON.
Specifications and Application
• Specifications and ordering information are in the brochures listed in Reference Documents
• Equipment and subassembly ports:
1. are suitable for connection to intra-building or unexposed wiring or cabling;
2. can be connected to shielded intra-building cabling grounded at both ends.
• Grounding / Bonding Network – Connect to an Isolated Ground Plane (Isolated Bonding Network) or an Integrated
Ground Plane (Mesh- Bonding Network or Common Bonding Network).
• Installation Environment - Install in Network Telecommunication Facilities, OSP, or where NEC applies.
• Battery return may be either Isolated DC return (DC-I) or Common DC return (DC-C).
These documents are available at abbpowerconversion.com
Document Title
CC848815341
850035894
Alarm Reset
Galaxy Pulsar Edge Quick Start Guide SPS Brochure
Infinity S (NE S) Brochure
Compact Power Line (CPL) Brochure
Pulsar Edge Controller Family Product Manual

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Safety Statements
• Do not install this equipment over combustible surfaces.
• Rules and Regulations - Follow all national and local rules and regulations when making field connections.
• Compression Connectors
• U. S. or Canada installations - use Listed/Certified compression connectors to terminate Listed/Certified
field-wire conductors.
• 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.
• Electrical Connection Securing: Torque to the values specified on labels or in the product documentation.
• Cable Dress - dress to avoid damage to the conductors and undue stress on the connectors.
• Circuit Breakers and Fuses
• Use only those specified in the equipment ordering guide.
• Size as required by the National Electric Code (NEC) and/or local codes.
Safety Tested Limits - Refer to the equipment ratings to assure current does not exceed
Continuous Load (List 1) - 60% of protector rating
Maximum Load (List 2 - typically end of discharge) - 80% of protector rating.
• GMT Style Fuses - Use only fuses provided with safety caps.
• Field-wired Conductors - Follow all National Electric Code (NEC) and local rules and regulations.
• Insulation rating: 90°C minimum; 105°C (minimum) if internal to enclosed equipment cabinets.
• Size AC field-wired conductors with 75°C ampacity (NEC) equal to or greater than their panel board circuit
breaker rating.
• AC and DC input disconnect/protection - Provide accessible devices to remove input power in an emergency.
• Alarm Signals - Provide external current limiting protection. Rating 60V, 0.5A unless otherwise noted.
• Grounding - Connect the equipment chassis directly to ground. In enclosed equipment cabinets connect to the cabinet
AC service ground bus. In huts, vaults, and central offices connect to the system bonding network.

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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.
• 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 that can shock or cause serious injury. When equipped
with ringer modules, hazardous voltages will be present on the ringer output connectors.
• 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.
• 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.

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© 2021 ABB. All rights reserved.
ABB
601 Shiloh Rd.
Plano, TX USA
abbpowerconversion.com
We reserve the right to make technical changes or modify the
contents of this document without prior notice. With regard to
purchase orders, the agreed particulars shall prevail. ABB AG does
not accept any responsibility whatsoever for potential errors or
possible lack of information in this document.
We reserve all rights in this document and in the subject matter
and illustrations contained therein. Any reproduction, disclosure
to third parties or utilization of its contents–in whole or in
parts – is forbidden without prior written consent of ABB.
Copyright© 2021 ABB
All rights reserved