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Critical Power

Product Manual

128HP
MODULAR +24 VDC, 1200 AMP -48VDC, 40 AMP
Switchmode Rectifier System

Service and Assistance - +1 877 546 3243 PE.TechSupport@ge.com


2015 General Electric Company. All rights reserved. www.gecriticalpower.com
438129BDPD Issue 26 May 2015 Page 1
GE Critical Power. 128HP Installation Manual

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Page 2 Issue 26, May 2015


GE Critical Power. 128HP Product Manual

TABLE OF CONTENTS
TABLE OF CONTENTS ................................................................................................................................ 3
CONCTACT INFORMATION ......................................................................................................................... 4
PRODUCT INFORMATION .......................................................................................................................... 4
WARNINGS................................................................................................................................................... 5
CAUTIONS.................................................................................................................................................... 5
ACRONYMS.................................................................................................................................................. 8
SECTION 1: GENERAL ............................................................................................................................... 9
SECTION 2: INSTALLATION..................................................................................................................... 15
SECTION 3: SPECIFICATIONS ................................................................................................................. 25
SECTION 4: TROUBLE SHOOTING .......................................................................................................... 29
SECTION 5: J-DRAWING.............................................................................................................. 438128HP
SECTION 6: T-DRAWING ....................................................................................................... 439128HPT-1
SECTION 7: RECTIFIER SHELF MANUAL ................................................................................ 4380229PD
SECTION 8: SM100H24D MANUAL............................................................................................ 4380425PD

REFERENCE DOCUMENTATION

PHOENIX DIGITAL PLANT CONTROLLER MANUAL ............................................................... 4380400PD


Separately bound manual

SCHEMATIC DIAGRAM ........................................................................................................438128HPSD-1

Issue 26, May 2015 Page 3


GE Critical Power. 128HP Installation Manual

CONTACT INFORMATION
Phone: +1 877 546-3243

Email: PE.TechSupport@ge.com

Web site: www.gecriticalpower.com

PRODUCT INFORMATION
Please take a moment when the product is new to fill in this information.

First, locate the product information label. This is typically located on the upper front of the equipment
frame, or on the rear of the frame. Fill in the part number, as it appears on the label, in the space
below.

PART NUMBER DATE CODE:

SERIAL NUMBER ECN LEVEL: 860 _ _ _ _ P

Page 4 Issue 26, May 2015


GE Critical Power. 128HP Product Manual

WARNINGS CAUTIONS
1. 1. Follow proper grounding instructions.
Electrical shock hazard. Do not attempt to
remove, maintain, or install this equipment with Suivre fonder correctes les instructions.
power applied. Personnel that attempt to work
on this equipment with the power applied may
subject themselves or others to electrical shock 2. If connecting batteries, remove the battery-
that may cause serious injury or death. box-fuse or trip the circuit breaker. Check
batteries and connections for proper polarity
Le danger lectrique de choc. Pas la tentative and power before connecting the batteries to
pour enlever, maintenir, ou installer cet the system.
quipement avec le pouvoir appliqu. Le
personnel qui tente traiter cet quipement avec Si connectant des piles, enlever la pile-bote-
le pouvoir appliqu peut s'exposer ou les autres le fusible ou trbuche le disjoncteur. Vrifier
au choc lectrique qui peut causer la blessure des piles et des connexions pour la polarit et
ou la mort srieuse le pouvoir correcte avant de connecter les
piles au systme.

2. 3. To remove the circuit breakers or fuses, the


DC and/or AC input to the system will need to
The use of this equipment by unauthorized or be disconnected, thereby disabling the system
untrained personnel should not be attempted. output to the load(s). Take the necessary
Personnel that work on this equipment without precautions and inform the plant engineer that
the proper training may subject themselves or the system output power to the loads will be
others to electrical shock that may cause disabled.
serious injury or death.
Pour enlever les disjoncteurs ou les fusibles,
L'usage de cet quipement par le personnel les donnes de courant alternatif de et/ou de
inautoris ou sans formation ne devrait pas tre DC au systme auront besoin d'tre
tent. Le personnel qui traite cet quipement dbranch, de cette faon rendant infirme la
sans l'entranement correct peut s'exposer ou production de systme au chargement (les
les autres au choc lectrique qui peut causer la chargements). Prendre les prcautions
blessure ou la mort srieuse ncessaires et informer l'ingnieur de plante
que le pouvoir de production de systme aux
chargements seront rendus infirme.

3. Do not attempt to work on this equipment if it is, 4. Before performing any maintenance, ensure
or has been, exposed to a high moisture AC or DC power is not applied to the system.
condition. It is recommended the equipment be
returned to GE to be properly tested. Working Avant d'excuter n'importe quel entretien,
on this equipment during a high moisture assurer que le pouvoir de courant alternatif ou
condition subjects the user to electrical shock DC n'est pas appliqu au systme.
that may cause serious injury or death.

Pas la tentative pour traiter cet quipement si 5. Fuse holders, fuses, and circuit breakers are
c'est, ou a t, expos une haute condition not to be loaded to more than 80 percent of
d'humidit. Il est recommand l'quipement their ampere rating.
s'est retourn GE deux tre convenablement
essay. Traiter cet quipement pendant une Fondez les supports, fusibles, et des
haute condition d'humidit expose l'utilisateur disjoncteurs ne doivent pas tre chargs
au choc lectrique qui peut causer la blessure plus de 80 pour cent de leur estimation
ou la mort srieuse. d'ampre.

Issue 26, May 2015 Page 5


GE Critical Power. 128HP Installation Manual

4. Use of an attachment other than one approved


by GE will void any and all warranties, implied
or other, and will increase risk of fire, or may
possibly cause electrical shock, injury, or death
to personnel.

L'usage d'un attachement autrement qu'un


approuv par GE annulera n'importe quel et
toutes garanties, implicites ou autres, et
augmentera le risque de feu, ou probablement
peut causer le choc lectrique, la blessure, ou
la mort au personnel.

5. Do not operate this equipment if it has been


dropped or otherwise damaged. Trying to
operate this equipment if it has been damaged
subjects yourself or others to electrical shock
that may cause serious injury or death.

L'usage d'un attachement autrement qu'un


approuv par GE annulera n'importe quel et
toutes garanties, implicites ou autres, et
augmentera le risque de feu, ou probablement
peut causer le choc lectrique, la blessure, ou
la mort au personnel.

6. Before you proceed, ensure the input source is


not live and the input circuit breaker(s)/fuse(s)
has been tripped or removed. If these
procedures have not been followed and the
input/output power is live, serious personnel
injury or death may occur.

Avant que vous procdez, assurez que la


source d'entre n'est pas en vie et le circuit
d'entre breaker(s)/fuse(s) a t trbuch ou a
t enlev. Si ces procdures n'ont pas t
suivies et le pouvoir input-output est la blessure
de personnel ou la mort en vie et srieux peut
arriver

Page 6 Issue 26, May 2015


GE Critical Power. 128HP Product Manual

7. A rack/shelf may contain several operating


systems. If there is another system in the
general area you want to install this system, be
cautious of any exposed connectors or wires
and, with permission, remove power to the other
systems. Failure to take the necessary safety
precautions subjects the installer or
maintenance personnel to severe electrical
shock that may cause serious injury or death.

Une tagre/tagre peut contenir plusieurs


systmes d'exploitation. S'il y a un autre
systme dans le secteur gnral que vous
voulez installer ce systme, tes prudent de
connecteurs ou de fils exposs et, avec la
permission, enlevez le pouvoir aux autres
systmes. L'chec pour prendre les prcautions
de sret ncessaires exposent le personnel
d'installateur ou entretien au choc lectrique
svre qui peut causer la blessure ou la mort
srieuse

8. This equipment may connect to lead-acid


batteries. Battery posts, terminals, and related
accessories contain lead and lead compounds,
chemicals known to the state of California to
cause cancer and birth defects or other
reproductive harm. Wash hands after
touching batteries.

Cet quipement peut connecter des piles


mener-acides. Les postes de pile, les
terminaux, et les accessoires apparents
contient l'avance et les premiers composs,
les produits chimiques connus l'tat de
Californie pour causer les dfauts de cancer
et naissance ou l'autre mal reproducteur.
Laver des mains aprs avoir touch des
piles.

Issue 26, May 2015 Page 7


GE Critical Power. 128HP Installation Manual

ACRONYMS
ABS Alarm Battery Supply LUD Local User Display
ACF AC Fail LV Low Voltage
ACO (Audible) Alarm Cut Off LVD Low Voltage Disconnect
ALM Alarm MJ Major
AO Analog Output MN Minor
AWG American Wire Gauge MP Mid Point
BAT Battery MON Monitor
BC Battery Current NC Normally Open
BCX Battery Current (x represents any number) NO Normally Open
BD Battery Disconnect OC Over Current
BOD Battery On Discharge PE Power Earth (Earth Ground)
BS Branch Shunt PL Partial Load
BTC Battery Temperature Compensation PMJ Power Major
CBS Control Battery Supply PMN Power Minor
CFA Converter Fail Alarm PMNR Power Major Return
COF Charger Off (GND Signal) PMJR Power Minor Return
COM Common PNL Panel
CON Charger On (GND Signal) RCC Remote Charger Control
DCA Distribution Current Alarm REMEQ Remote Equalize
DFA Distribution Fuse Alarm RFA Rectifier Fail Alarm
DFAR Distribution Fuse Alarm (Return) RFA J Rectifier Fail Alarm Major
DO Digital Output RFA N Rectifier Fail Alarm Minor
EBD Emergency Battery Disconnect RFAR Rectifier Fail Alarm Return
ECS End Cell Switch RS Rectifier Restart
EPO Emergency Power Off RSR Rectifier Restart Return
EQ/EQL Equalize RXD Receive
FA Fuse Alarm SG Signal Ground
GND Ground SH Shunt
HHVA High High Voltage Alarm SHG Shield Ground
HVA High Voltage Alarm TB Terminal Block
HVS High Voltage Shutdown TCA Total Current Alarm
LCA Low Current Alarm TR Rectifier Turn On/Off
LLV Low Low Voltage TRR Rectifier Turn On/Off Return
LMR Limited Recharge TS Terminal Strip
LOA Low Output Alarm TXD Transmit
LOAR Low Outputt Alarm return VM Volt Meter
LSO Load Share Out WD Watch Dog

Page 8 Issue 26, May 2015


GE Critical Power. 128HP Product Manual

SECTION 1: GENERAL
1.1 GENERAL PRODUCT INFORMATION
The 128HP Power Plant offers up to 1200 Amps of +24VDC power in a compact, low profile design.
Additionally, up to (2) shelves of DC to DC converters can be added. Each converter provides 10A for
a total of 80A at -48VDC.

Power for the equipment load, distribution, alarms, and monitoring are all contained within the Power
Plant using a minimum of rack space. The 128HP power system's modular design enables users to
add power capacity and protection devices as the load requirements increase.

Each modular rectifier and/or converter may be inserted or removed while the Power Plant remains
energized.

This Power Plant is designed to supply +24VDC nominal power to a Telecom grade load while
simultaneously floating batteries. In the event of a commercial AC failure, the system seamlessly
powers the load from the batteries. When the commercial AC returns, the rectifiers can contribute up
to 103% of their rated value to recharge the batteries and supply current to the equipment load.

Features
48 and 80 position distribution heads are available
NEBS Level 3 certified
1200 Amps @ 24VDC
80 Amps @ -48VDC (Optional) with 8 dedicated fuse or breaker positions
100 Amp Switchmode rectifiers
10 Amp @ -48VDC converter modules
Circuit protection from 5 to 250A
Plug in fuses or breakers
24 status LEDs, 16 alarm relays
Front access rack mount battery trays available
Optional battery disconnect (EPO)
Controlled battery recharge
Battery temperature compensation
Battery string current variance alarm
High float current alarm
Full relay rack mount or rack for battery mount
Rectifier test jacks

Issue 26, May 2015 Page 9


GE Critical Power. 128HP Installation Manual

1.2 System Options


1.2.1 48 and 80 Position Distribution

128HP
48 distribution position head
DC return bus positions 53-64 are
vertically orientated two hole in. hole,
5/8 in center positions for larger cables.

DC return bus positions 65-68 are


vertically orientated two hole 3/8 in. hole
one in. center positions for larger cables

(8) -48V positions are center mounted

Flex cable is recommended for cables


larger than N0. 2 AWG

Adaptors are required for 2 and 3 pole 128HP


protection devices

Use narrow tongue lugs for cables larger


than No. 2 AWG

128HP-80
80 distribution position head
DC return bus positions 44-62 are
vertically orientated 3/8 in. hole, one
center positions for larger cables

All in hole, 5/8 in. center positions are


angled for managing larger cables

(8) -48V positions are center mounted

Flex cable is recommended for cables


larger than 1/0

Use narrow tongue lugs for cables larger


than No. 2 AWG

Adaptors are required for 2 and 3 pole


protection devices
128HP- 80

Page 10 Issue 26, May 2015


GE Critical Power. 128HP Product Manual

Adaptors for Multi Pole Devices

1.2.2 +24V Rectifier and Modular Rectifier Shelves

SM100H24D rectifiers output 100A at


+24V with 220VAC input, 103A at current Bus
limit splices

Rectifier shelves can be added in the field


by splicing the shelves together, setting CAN
the addressing dip switches and cable
extending the CAN cable multiple multiple
If the Power Plant is equipped with a Shelf Addition
converter shelf, contact GE Field
service prior to attempting to add a
rectifier shelf

Rectifiers are numbered from left to right


and from top to bottom

Test Jacks are located at the bottom

A wiring kit is required to extend


Individual Rectifier Fail Alarms (RFA)
See J438128HP for ordering information Rectifier Numbering

Table 1-1 provides wiring information for Rectifier


individual RFA extension status
LEDs
Factory default for individual RFA wiring
is Normally Open

Normal operation
o AC OK = Green
o DC OK = Green Rectifier Test Jacks
Rectifier fail
o RFA = Red
NOTE: Do not connect RFA Com leads
when wiring individual RFA leads

Issue 26, May 2015 Page 11


GE Critical Power. 128HP Installation Manual

TABLE 1-1: RFA OUTPUTS


Individual RFA Wiring Chart
Pin # Description Rect # Color
1 RFA 1 RECT 1 GREEN
Shelf #1 4 RFA 2 RECT 2 RED
2 RFA 3 RECT 3 BROWN
Shelf #2
5 RFA 4 RECT 4 BLUE
Shelf #3 3 RFA COM ORANGE
6 RFA COM YELLOW

1.2.3 +24V to -48V Converter Shelf & Module

Up to (2) converters shelves are optional


totaling 80A at -48V Converter
Status LEDS
Each SM48P10A-D converter provides
10A at -48V Voltage
adjustment
Illuminated GREEN (OP OK) LED for Factory
denotes normal operation 10A Converter Module use only
Illuminated RED (CFA) denotes converter
module failure

Illuminated RED (FF) denotes that a fuse


failure has occurred on the module

First Illuminated GREEN capacity LED


denotes 50% of module capacity has
been reached

Second Illuminated GREEN capacity


LED denotes 100% of module capacity
has been reached
(3) Rectifier shelves, (1) factory wired
converter shelf

1.2.4 Low Voltage Disconnect / Battery Disconnect

128HP
Optional Low Voltage Disconnect or
Manual Battery Disconnect

Low Voltage Disconnects are activated


via the Phoenix Controller.

Disconnects can be activated when a


voltage threshold is reached or a time
interval has elapsed

Page 12 Issue 26, May 2015


GE Critical Power. 128HP Product Manual

Disconnects for load A and for load B can


be set separately allowing flexibility when
load shedding is required to extend run
Manual
time for critical equipment
Battery
Disconnect
The manual disconnect disengages the
reserve batteries from the power plant

The manual disconnect is activated buy Low


using the optional slide switch on the front Voltage
of the Phoenix controller Disconnects
Load A & B

Rear View 128HP

1.2.5 Relay Rack Mounted Battery Trays

Relay Rack configuration options are


depicted in J438128HP

Battery trays can be equipped with


optional disconnect devices

Battery disconnects are available in 100A


and 200A versions

Foam strips are provided to provide


airflow between batteries

Hold-down clamps are available for


Earthquake Zone 4 applications

Front and rear brackets are available for


deeper batteries

1.2.6 Battery Temperature Compensation Probes

Temperature Probe position 1 on the Ambient Temperature


interface circuit board is factory wired to Temp Probe Comp Probe
monitor ambient temperature

Temperature Probe position 2 is for field


wired battery temperature monitoring

The Ambient temperature probe is


mounted inside the distribution head
Interface Card
Probe extension cables are available in
various lengths See J 438128HP for
ordering information

Issue 26, May 2015 Page 13


GE Critical Power. 128HP Installation Manual

GE recommends placing the battery


temperature probe on the mid cell of the
battery string.

GE recommends the Ambient Ambient Temperature Probe


temperature probe remain in inside the
distribution head of the power plant

Battery Temperature Probe

Page 14 Issue 26, May 2015


GE Critical Power. 128HP Product Manual

SECTION 2: INSTALLATION
2.1 Sequence of Installation
Step 1 Placing Equipment Bay

Locate relay rack per floor plan


assignment

Mark floor per anchoring hole


dimensions

inch mounting holes in the floor plate


will accommodate up to 5/8 in. floor
anchors

Install floor anchors per customer


standards

GE recommends minimum of 1 ft. 6 in.


space at the rear of the bay
Frame Base Mounting Hole Locations
Floor isolation kits are available for
isolated ground plane

Issue 26, May 2015 Page 15


GE Critical Power. 128HP Installation Manual

Step 2 Frame Ground to Office Ground Bar

On each corner at the top of the


equipment rack there are mounting
positions with in. threaded holes on
5/8 in. centers for frame ground
connections

Run and terminate grounding conductor


from one of the power plants ground
positions to office ground bar or properly
sized aisle ground feeder

Minimum of No. 6 AWG cable should be


run and landed on the office ground bar

Torque in. nuts to 75 in. lbs (6.25 ft


lbs)

Torque 3/8 in. nuts to 144 in. lbs (12 ft


lbs)
NOTE: Failure to properly ground the
Frame Ground
power plant is hazardous to site
personnel and can damage the power
plant circuit cards, rectifiers and
converter modules. It may void the
power plant warranty

NOTE: Land DC return equalization lead


and frame ground lead in adjacent
landing positions on the office ground
bar (or back to back on the bar if
customer standards permit

Step 3 COG connection to Main Ground Bar

Run and terminate equalization lead from


DC return bus to office ground bar

This lead should be sized equal to the


Power Plants ultimate output current
capacity

in. studs on 5/8 in. ctrs, Torque to 75 in.


lbs.
NOTE: Land DC return equalization lead
and frame ground lead in adjacent landing
positions on the office ground bar (or Office Ground Bar Termination on DC
back to back on the bar if customer Return Bus
standards permit

NOTE: Failure to properly ground the


power plant will void the power plant
warranty

Page 16 Issue 26, May 2015


GE Critical Power. 128HP Product Manual

Step 4 Run and Terminate AC Connections

25A AC breaker is required per rectifier

With AC breakers in the off position,


run and terminate AC wiring to AC
termination box on power plant

GE recommends that a licensed


Electrician Terminating all AC
connections

Existing conduit positions for (3) 1 inch,


(3) 1 inch, and (3) 1 conduits Factory AC Wiring to Rectifiers

Rectifiers are factory wired from the AC


box to the rectifiers

Rectifiers are numbered from left to


right and from the top shelf down

Both top and side mount AC access is AC Termination Layout


available

Directly feeding the rectifiers requires


ring lug terminations and proper
conduit support

Maximum wire gage is 10AWG

GE recommends 25A (2) pole


breaker per rectifier

NOTE: Inadequate surge protection is


hazardous to site personnel and can
damage the power plant circuit cards, Side Mount AC Option
rectifiers and converter modules.

Failure to properly protect the power


plant from transient surge will void the
power plant warranty.

Direct Feed Option

Issue 26, May 2015 Page 17


GE Critical Power. 128HP Installation Manual

Step 5 Run and Terminate Alarm cabling

Run and land alarm cabling

See Table 2 for wiring color codes

GE supplied alarm cables have


connectors on one end and are 24AWG

Connector positions are marked on the


protective cover and on GE supplied
Alarm Cable
alarm cables
connector
fields
See Table 2 for wiring color code

Alarm Card Connector

Step 6 Verify Output Relays Are Set per


Customer Standards

Check alarm output relay jumpers meet


customer standards (normally open or
normally closed position)
o GE factory default is Open on
Alarm
o CPU fail alarm is factory set to
Open on Alarm
Alarm
The output relays and their associated extension
alarm are stenciled on the cover to the jumpers
alarm card

Power Major Green on normal operation

Alarm Extension Jumpers

Page 18 Issue 26, May 2015


GE Critical Power. 128HP Product Manual

Step 7 Power Plant Preparation for Startup

Prior to any battery connections to the


plant battery bus, the user must remove
Fuse F1
F1 (CONTROL fuse) from the plant
interconnect card located within the
distribution head. The F1 fuse is a 3-
amp GMT fuse.
Interface Card Fuse Positions

Run and Terminate DC Supply and


Step 8
Return cables

Run and land load cabling

Start load terminations from the bottom


Common
of the power plant working up.
DC return
DC return bus positions 53-64 are
vertically orientated 5/8 in. center +24V
positions for larger cables Supply

DC return bus positions 65-68 are


vertically orientated 3/8 in. center
positions for larger cables -48V
Supply
Land cables 2/0 and above in the
vertically oriented DC return positions
Distribution Positions
If the power plant is equipped with
converters, (8) supply cable landings
are available in the center on the floor
of the power plant

+24V and -48V share the common DC


return bus in the center of the bay

Issue 26, May 2015 Page 19


GE Critical Power. 128HP Installation Manual

Step 9 Battery Connections

Run and land battery cabling

These connections are on the rear of the


power plant

(4) landing positions are 3/8 in. studs on


1 in. ctrs Battery Connection Area
(16) landing positions are 5/8 in. studs
on 5/8 in. ctrs

Verify polarity using Digital Volt Ohm


Meter prior to landing cables

NOTE: Crossing polarity will damage


circuit packs and rectifiers

Step 10 Energize Power Plant

Remove all rectifiers and converter


modules from the power plant if All LEDs
previously installed illuminate at
initial startup
Turn each battery string breaker ON
(one string at a time) if equipped. This
will apply battery potential to the power
plant
Initial Turn Up
Once all battery string disconnect
breakers are ON, replace F1
(CONTRL fuse) into the plant
interconnect card This will start the LEDs cycle
digital controller initialization / self-test on and off
process within 30 seconds during self
test mode
The Phoenix digital controller
initialization / self-test will start within 30
seconds
Self Test
Audible alarm will sound during self test

All status LEDs will illuminate and cycle


SYSOK
during self test mode
and
FLOAT
Verify that all Red and Amber status
LEDs are
LEDs extinguish on controller front
illuminated
panel
after self
test mode
Normal operation completes
o SYSOK LED = Green Normal Operation
o FLOAT = Green

Page 20 Issue 26, May 2015


GE Critical Power. 128HP Product Manual

Step 11 Install Rectifier Modules

Insert rectifier modules


Normal
operation
Rectifiers can be added or removed with
the power plant energized

GE recommends setting the RM Retaining


count to zero ( 0 ) for full plug and play thumb
operation screw
Rectifier Normal Operation
Normal operation
o AC OK = Green
o DC OK = Green

Step 12 Install Converter Modules

Move cutoff switch on Converter


module to OFF position prior to
inserting or remove modules Convert On
/ Off switch
After module installation, move switch
to ON position.
Normal
operation
GE recommends setting CM count to
( 0 ) for full plug and play mode
Normal Operation Retaining
Normal operation thumb
o OP OK = Green screw

Issue 26, May 2015 Page 21


GE Critical Power. 128HP Installation Manual

Step 13 System Verification and Alarm


Extension Verification
Using the Phoenix Controller:

Verify that only SYSOK and FLOAT


LEDs are illuminated

Verify that the no alarms are reported

Verify status of all rectifiers and


converters are communicating properly

Verify that the Rectifiers are load


sharing within 0.5A

Verify that the plant voltage displayed is


within 0.05V of voltage measured
between +24V bus and DC Return
using a calibrated Volt Ohm Meter

Using Phoenix controller, verify all


extended alarms with the Alarm Center

See Phoenix Controller Quick start


guide shipped with this product

See Phoenix Controller Manual


4380800PD, section 4.8 shipped with Quick Start Guide
this product

NOTE: Alarms will be extended to the


Network Alarm Center

Page 22 Issue 26, May 2015


GE Critical Power. 128HP Product Manual

Step 14 Verify Power Plant Set Points

Using Phoenix controller, verify all


Power Plant set points are per customer
standards

See Phoenix Controller Quick start


guide shipped with this product

See Phoenix Controller Manual


4380400PD, section 4.4.4, shipped with
this product

Quick Start Guide

Issue 26, May 2015 Page 23


GE Critical Power. 128HP Installation Manual

Step 15 Install Fuses / Breakers

Install circuit breakers or fuses for loads

Breakers must be inserted correctly to


maintain alarm pin contact

Incorrect breakers will not extend a fuse


fail alarm

This diagram is also inside the power


plant on the door.

Leave one position vacant between


100A and larger protection devices

Do not exceed 60A protection devices


in -48V converter positions

NOTE: Circuit breakers and fuse blocks


are keyed for this power plant. DO NOT
use circuit breakers that have a tie from
the alarm connection to the BAT bus. See
J-438128HP for ordering information
Fuse / Breaker Insertion

NOTE 1: Equipment grounding conductor size (Frame or Chassis) is based on the


recommendations of the National Electric Code Table 250.122 for copper wire. #6 AWG
is minimum size recommended.

NOTE 2: Fuse or circuit breaker protection external to the system for commercial AC is to be
provided by the customer or contractor and should meet National Electrical Code
standards.

NOTE 3: DC wire sizes are based on the voltage drop considerations and the National Electric
Code Table 310-16 for copper wire.

NOTE 4: Installation of the system should be in an area that is accessible to qualified


personnel only.

Page 24 Issue 26, May 2015


GE Critical Power. 128HP Product Manual

SECTION 3: SPECIFICATIONS
3.1 Terminal Block Connections for the 6200666P Alarm Card
TABLE 3-1: TERMINAL BLOCK CONNECTIONS FOR THE 6200666P ALARM CARD
6370457P-xx
Plant Alarm Factory Relay
Pin # Color Codes Acronym Contact
(Condition) Contact State #
(Optional)

TB66-8 WH / BL ALARM OUT


Rectifier Major RFAJ Open on Alarm K1
TB64-8 BL / WH COMMON

TB66-7 WH / OR ALARM OUT


Rectifier Minor
RFAN Open on Alarm K2
TB64-7 OR / WH COMMON

TB66-6 WH / GR ALARM OUT


AC Fail ACF Open on Alarm K3
TB64-6 GR / WH COMMON

TB66-5 WH / BR ALARM OUT


High Voltage
HVA Open on Alarm K4
Alarm
TB64-5 BR / WH COMMON

TB66-4 WH / SL ALARM OUT


Low Voltage
LVA Open on Alarm K5
Alarm
TB64-4 SL / WH COMMON

TB66-3 R / BL ALARM OUT


Low Low Voltage
LLVA Open on Alarm K6
Alarm
TB64-3 BL / R COMMON

TB66-2 R / OR ALARM OUT


Low Voltage
LVD Open on Alarm K7
Disconnect
TB64-2 OR / R COMMON

TB66-1 R / GR ALARM OUT


Converter Fail Open on
CFA K8
Alarm Alarm
TB64-1 GR / R COMMON

Issue 26, May 2015 Page 25


GE Critical Power. 128HP Installation Manual

6370457P-xx
Plant Alarm Factory Relay
Pin # Color Codes Acronym Contact
(Condition) Contact State #
(Optional)

TB67-8 R / BR ALARM OUT


Open on
Temperature TEMP K9
Alarm
TB65-8 BR / R COMMON

Battery Alarm /
TB67-7 R / SL Battery Fuse ALARM OUT
Alarm / Open on
BAT K10
Battery Alarm
TB65-7 SL / R Disconnect Alarm COMMON

High High
TB67-6 BK / BL Voltage ALARM OUT
(indicates a High
Voltage HHVA Open on
K11
Shutdown (HVSD) Alarm
TB65-6 BL / BK (HVSD) COMMON
condition)

TB67-5 BK / OR ALARM OUT


Battery On Open on
BOD K12
Discharge Alarm
TB65-5 OR / BK COMMON

TB67-4 BK / GR ALARM OUT


Distribution Fuse Open on
DFA K13
Alarm Alarm
TB65-4 GR / BK COMMON

TB67-3 BK / BR ALARM OUT


Open on
Power Minor PMN K14
Alarm
TB65-3 BR / BK COMMON

TB67-2 BK / SL ALARM OUT


Open on
Power Major PMJ K15
Alarm
TB65-2 SL / BK COMMON

TB67-1 Y / BL ALARM OUT


Open on
Controller Fail P Fail K16
Alarm
TB65-1 BL / Y COMMON

Page 26 Issue 26, May 2015


GE Critical Power. 128HP Product Manual

3.2 Factory Default Settings and Ranges


TABLE 3-2: FACTORY DEFAULT SETTINGS AND RANGES
Description Default Range Resolution
Battery on Discharge 26.0 VDC 20-30 VDC 100mV
Plant High Voltage Alarm 28.25 VDC 20-30 VDC 100mV
Low Voltage Alarm 26.0 VDC 20-30 VDC 100mV
Plant Low Low Voltage Alarm 23.0 VDC 20-30 VDC 100mV
Low Voltage Load Disconnect (A B C) 21.0 VDC 20-30 VDC 100mV
Low Voltage Reconnect (A B C) 24.5 VDC 20-30 VDC 100mV
Low Voltage Disconnect Time 4h .1-10h .1h
Total Current Alarm (% Applied Globally) 100% 0-100% 1%
Ambient Temperature Alarm (Threshold 1) 10C 0C to 100C 1C
Ambient Temperature Alarm (Threshold 2) 40C 0C to 100C 1C
Plant Float* 27.0 VDC 23.5 28.5 VDC 100 mV
Plant Equalize* 27.0 VDC 23.5 28.5 VDC 100mV
Rectifier Max Current 103 ADC 0 103 ADC 0.1 ADC
Rectifier HVSD 28.5 VDC 27.5 32.5 VDC 100mVDC
Temperature Compensation Slope 36mV per C 0-120 mV per C 1mV per C
Distribution Current Alarm 80% 0-120% 1%
Battery Temperature Alarm (Threshold 1) 10C -40C to 100C 1C
Battery Temperature Alarm (Threshold 2) 50C -40C to 100C 1C
Rectifier Current Imbalance .25 .10 1.0 1%
Rectifier Temp Max 80C 0-100C 1C
Limited Recharge Setting 80% 50-100% 1%
Max Alarm Test Time 15 Min. 1-255 Min. 1 Min.
Float Current Limit 750mADC 0-10000mADC 1mADC
Float Current Alarm Delay 12h 1-24h 1h
Plant Equalize Time Setting 24 hours 0-36 hours .1 Hr
Plant High Voltage Shutdown 29.0 VDC 20-30 VDC 100mV
Recharge Control Minimum 24 VDC 23.5 24.5 VDC .1
Recharge Rate Factor .20 .05 - .25 .01
Battery Current Variance .20 0 - 1.0 .01
Variance Inhibit Minimum .10 .05 .25 .01
High Float Current Factor .05 .02 .25 .01

*Actual setting will depend on type of batteries being used. Consult battery manufacturers
specifications.

Issue 26, May 2015 Page 27


GE Critical Power. 128HP Installation Manual

SYSTEM RATINGS
 SPECIFICATIONS
Input Environmental
Voltage Range 120 / 208 / 240VAC Storage Ambient -40F to +185F (-40C to +85C)
176 265VAC Operating Ambient +23F to +122F (-5C to +50C)
Frequency 45 65Hz Humidity < 95% non-condensing
Current 13A AC typical, Heat Dissipation 750 BTU/hr per rectifier module at full load
19A AC maximum per rectifier 315 BTU/hr per converter module at full
Customer Provided 25A, 2-Pole CB per rectifier load
Protection
Mechanical 48 positions 80 positions
Output Dimensions, Fully 36.8H x 22D x 23 45.5H x 22D x 23
Voltage Range 23.5 28.5VDC Equipped mounting width mounting width
Current 100A per rectifier Weight 450 lbs. 590 lbs.
(50A per rectifier @ 120VAC) Cooling Front to rear Front to rear
Efficiency 90% full load variable speed fans variable speed fans

Noise Documentation
Voice Band < 32dBrnc (with battery) Product Manual 438128HPPD-1
Wide Band 100 mVrms (10 20MHz)/ J Drawing 438128HP
< 250 mV peak to peak (0
100MHz)
Acoustic < 55dB

NOTES:

Shock: This equipment, in its shipping container, withstands shock developed while
transporting without physical damage or degradation of the electrical performance

Vibration: This equipment, in its shipping container, withstands vibration encountered


while transporting without physical damage or degradation of the electrical performance.

Ventilation: System Ventilation openings should not be blocked and the ambient
temperature of the air entering the system should not exceed 50C (122F)

Page 28 Issue 26, May 2015


GE Critical Power. 128HP Product Manual

SECTION 4: TROUBLE SHOOTING


4.1 GENERAL --- Field Service 1-888-317-1216 for Emergency Service
ALARM ALARM
ALARM NAME Plant Condition
ACRONYM LED
NORMAL OPERATION
SYSOK System OK Green Power Plant is functioning normally
FLOAT Float Mode Green Power Plant is functioning normally
STATUS LEDS
RFAJ Rectifier Major Red Two or more rectifier failures
RFAN Rectifier Minor Amber One rectifier failure
BAT Battery Monitor Battery fuse, Battery disconnect, Battery Midpoint, Battery Current
Amber
Variance Alarm, Battery temperature alarm
DFA Distribution Fuse Red A circuit breaker has tripped or a fuse has blown
DCA Distribution Current Amber Power Plant total current is within 80% of capacity

LLVA Low Low Voltage Red Power Plant output is below 23V / Battery on Discharge
LVA Low Voltage Amber Power Plant output is below 26Vdc
HVA High Voltage Red Power Plant output voltage has reached 28.25V
HHVA High High Voltage Red Plant has reached 29V / High voltage shutdown
CFA Converter Fail Red Converter module failure
Low Voltage
LVD Red Low voltage disconnect has activated
Disconnect

TCA Total Current Power Plant current is in excess of 100% rated current (rectifier
Amber
current limit is 103%)
ACF AC Fail Amber Alternating Current (AC) energizing the rectifiers is not present
TEMP Temp High/Low Power Plant ambient temperature is above 50 degrees ( C ) or
Amber
below 10 degrees ( C )
EQL** Equalize Mode** Power Plant has been changed from FLOAT mode to Equalize
Amber
Battery mode
BTC BTC Active Amber Battery temperature compensation is activated.
LMR Limited Recharge When Power Plant load current has exceeded the user set
Amber
percentage of the total current capacity of the power plant
In a CPU Fail condition, the Backup Controller monitors the CBS
Control Battery
CBS Red function. The associated CBS LED indicator, and audible signal will
Supply
be active
Battery On
BOD Red Power Plant is energizing load using batteries
Discharge
PMJ Power Major Red Any / All listed Red LED alarms also activate PMJ
PMN Power Minor Amber Any / All listed Amber LED alarms also activate PMN
CPU FAIL Controller Failure Red Power Plant controller is not functioning
Illuminated when Power Plant has an active alarm and the
ACO Audible Alarm Cutoff Amber
associated audible has been silenced

** Some Valve Regulated Battery (VRLA) manufactures will void product warranty if equalization charge is
placed on the battery string. Consult battery manufactures charging specifications before using this function.

Issue 26, May 2015 Page 29