Apc Mge Galaxy 5000 Users Manual 86 174010 00
40130kva c498a556-23b7-4c85-9a5e-542391623040 APC Fan 40 130KVA User Guide |
2015-02-03
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w w w. m g e u p s . c o m MGE Galaxy 5000 40 – 130KVA Installation and User Manual Critical Power and Cooling Services Division Installation and User Manual MGE Galaxy 5000 40 – 130KVA Uninterruptible Power Systems Installation and User Manual Schneider Electric 1660 Scenic Avenue, Costa Mesa, CA 92626, (714) 557-1636 Service Solutions Team: 1-800-438-7373 (Hours: 24/7) Revision History: A00 ECN-005986 5/28/08 B00 ECN-006020 6/20/08 Copyright © 2008 American Power Conversion Corporation. All rights reserved. Printed in U.S.A. 86-174010-00 B00 i MGE Galaxy 5000 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS – This manual contains important instructions for Galaxy 5000 that must be followed during operation and maintenance of the equipment. WARNING Opening enclosures expose hazardous voltages. Always refer service to qualified personnel only. ATTENTION L'ouverture des cellules expose à des tensions dangereuses. Assurez-vous toujours que le service ne soit fait que par des personnes qualifiees. WARNUNG! Das öffnen der Gehäuse legen gefährliche Spannungen bloss. Service sollte immer nur von qualifizierten Personal durchgeführt werden. WARNING As standards, specifications, and designs are subject to change, please ask for confirmation of the information given in this publication. ATTENTION Comme les normes, spécifications et produits peuvent changer, veuillez demander confirmation des informations contenues dans cette publication. WARNUNG! Normen, Spezifizierungen und Pläne unterliegen Anderungen. Bitte verlangen Sie eine Bestätigung über alle Informationen, die in dieser Ausgabe gemacht wurden. NOTE This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at user's own expense. WARNING To reduce the risk of fire or electric shock, install in a controlled indoor environment free of conductive contaminants. This equipment is intended only for installations in a RESTRICTED ACCESS LOCATION. ATTENTION Pour réduire le riske d'inccendie ou d'électrocution, installer dans une enciente intérieure contrôlée en température et humidité et sans contaminants conducteurs. Ce matériel est destiné seulement pour des installations dans un EMPLACEMENT RESTREINT D'ACCES. WARNUNG! Um die Gefahr von Feuer und elektrischem Schock zu reduzieren, muss das Gerät in einem temperatur – und feuchtigkeitskontrollierten Raum, frei von leitungsfähigen Verunreinigungen, installiert werden. Dieses Gerät ist nur für die Installation an einem Ort mit qeingeschränkter Zugangserlaubnis vorgesehen. Diese Ausrüstung ist nur für Anlagen in einem EINGESCHRäNKTEN ZUGRIFF STANDORT bestimmti. ii Important Safety Instructions 86-174010-00 B00 Installation and User Manual WARNING HIGH LEAKAGE CURRENT. Ground connection essential before connecting supply. ATTENTION COURANT DE FUITE ELEVE. Raccordement a la terre indispensable avant le raccordement au reseau. WARNUNG! Hoher Ableitstrom Vor Inbetriebnahme Schutzleiterverbindung herstellen. Certification Standards – Three Phase UPS ◗ ◗ ◗ ◗ ◗ ◗ IEC1004/ANSI C62.41 Standards for Surge Withstand Ability. FCC Part 15, Subpart J, Class A. UL/CUL 1778, Standards for Uninterruptible Power Supply Equipment. NEMA PE 1 - Uninterruptible Power Systems. NFPA 70 – National Electrical Code. ISO 9001. Environment This product has been designed to respect the environment. It does not contain any Chlorofluorocarbon (CFC) or Hydrochlorofluorocarbon (HCFC). UPS recycling at the end of service life: Schneider Electric undertakes to recycle, by certified companies and in compliance with all applicable regulations, all UPS products recovered at the end of their service life (contact your Schneider Electric branch office). Packing: UPS packing materials must be recycled in compliance with all applicable regulations. WARNING: This product may be supplied with lead-acid batteries. Lead is a dangerous substance for the environment if it is not properly recycled by specialized companies. 86-174010-00 B00 Certification Standards, Three Phase UPS, Environment iii MGE Galaxy 5000 (This page left blank intentionally) iv 86-174010-00 B00 Contents IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii Certification Standards – Three Phase UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii Contents CAUTION: Record All Serial Numbers! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VI Section Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VII Introduction 1.0 1.1 1.2 1.3 1.4 1.5 1.6 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 1 Inside the UPS Cabinet, Access to Connections . . . . . . . . . . . . . . . . . . . .1 — 3 UPS Cabinet Bottom View Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 4 User-Machine Interface Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 5 Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 6 Relay Communication Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 7 Setup and Installation 2.0 2.1 2.1.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.8.1 2.9 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 1 Layout of Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 2 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 2 Connection of Power Cables in a Single UPS . . . . . . . . . . . . . . . . . . . . . .2 — 3 Redundant Parallel Configuration (Maximum Two UPS Units for Pn) . . . .2 — 4 Auxiliary Interconnections Between UPSs in Parallel Configurations . . . .2 — 5 Connection of General Shutdown or Remote Emergency Power Off (REPO) Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 7 Adding Communication Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 8 Connection of the Relay Communications Card . . . . . . . . . . . . . . . . . . . .2 — 9 Characteristics of the Contacts on the Relay Communications Card . . . .2 — 10 Routing the Control/Communications Cables . . . . . . . . . . . . . . . . . . . . . .2 — 11 3.0 3.1 3.2 3.3 3.4 3.5 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 1 Shutting Down a Single UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 1 Restarting a Single UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 2 Shutting Down a Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 2 Restarting a Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 3 Operation of Mimic-Panel LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 4 Operation 86-174010-00 B00 Contents I MGE Galaxy 5000 3.6 3.7 3.8 3.9 3.10 3.10.1 3.10.2 3.10.3 Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 5 Load on Battery Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 5 UPS Personalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 6 Display Messages List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 7 Operation of the Relay Communication Card (Dry Contacts) . . . . . . . . . .3 — 8 Standard Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 8 Programmable Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 8 List of Operating Status Conditions That May be Assigned to an SECI Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 9 Maintenance 4.0 4.1 4.2 4.3 4.3.1 4.3.2 4.3.3 4.4 4.4.1 4.4.2 4.4.3 4.5 4.6 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 1 Identification of Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 1 Life Cycle Monitoring (LCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 1 UPS Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 2 UPS Isolation Single UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 2 UPS Isolation Parallel UPS Without External Bypass Cabinet . . . . . . . . .4 — 3 UPS Isolation Parallel UPS With External Bypass Cabinet . . . . . . . . . . . .4 — 4 Return to the Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 5 Return to Normal Single UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 5 Return to Normal Parallel UPS Without External Bypass Cabinet . . . . . .4 — 6 Return to Normal Parallel UPS With External Bypass Cabinet . . . . . . . . .4 — 8 Servicing Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 9 Training Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 9 A1 A2 A3 A4 A5 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A — 1 Maximum Allowable Power for Parallel UPS Units . . . . . . . . . . . . . . . . . .A — 5 UPS Cabinet Major Internal Components . . . . . . . . . . . . . . . . . . . . . . . . .A — 6 Available Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A — 7 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A — 8 Appendices MGE Warranty & Proprietary Rights Statement for Three Phase Products MGE Standard Three Phase Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .W — 1 Proprietary Rights Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .W — 1 Warranty and Product Registration User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .W — 2 Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .W — 2 Warranty Extension (Warranty+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .W — 2 Service Solutions Team — Three Phase Products Technical Support and Product Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S — 1 Who To Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S — 1 Scheduling Field Service Engineer Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S — 1 Return Policy for Repair of Three Phase Products (RGA) . . . . . . . . . . . . . . . . . . .S — 1 Glossary Reorder Form II Contents 86-174010-00 B00 Installation and User Manual Figures 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 MGE Galaxy 5000 UPS Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 2 Single Line Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 2 Inside MGE Galaxy 5000 UPS Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 3 Power Connection Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 4 INTN PCA for Auxiliary Interconnections of Parallel UPSs . . . . . . . . . . . .1 — 4 MGE Galaxy 5000 Cabinet Bottom View Layout . . . . . . . . . . . . . . . . . . . .1 — 4 User-Machine Interface Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 5 Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 6 Relay Communication Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 7 Space Allowance for Installation of UPS . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 1 Layout of Cabinets (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 2 Single UPS With Common Normal and Bypass AC Inputs . . . . . . . . . . . .2 — 3 Single UPS With Separate Normal and Bypass AC Inputs . . . . . . . . . . . .2 — 3 Parallel UPS With Common Normal and Bypass AC Inputs . . . . . . . . . . .2 — 4 Parallel UPS With Separate Normal and Bypass AC Inputs . . . . . . . . . .2 — 4 Redundant Parallel Configuration (Maximum Two UPS) . . . . . . . . . . . . . .2 — 5 Parallel Configuration for Increased Capacity (Four UPSs) . . . . . . . . . . .2 — 6 Fitting the Protection Cover for the Auxiliary Interconnection Cables . . . .2 — 7 Connection of General Shutdown or Remote Emergency Power Off (REPO) Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 7 Adding Communication Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 8 Connection of Relay Communication Card . . . . . . . . . . . . . . . . . . . . . . . .2 — 9 Characteristics of the Contacts on the Relay Communications Card . . . .2 — 10 Routing the Control/Communications Cables for Single UPS . . . . . . . . . .2 — 11 Routing the Control/Communications Cables for Parallel UPS . . . . . . . . .2 — 12 Shutting Down a Single UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 1 Restarting a Single UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 2 Shutting Down a Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 2 Restarting a Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 3 Operation of Mimic-Panel LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 4 Normal (Double Conversion) Operating Mode . . . . . . . . . . . . . . . . . . . . .3 — 5 Load on Battery Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 5 UPS Personalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 6 Life Cycle Monitoring (LCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 1 UPS Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 2 Parallel UPS Configuration Without External Bypass Cabinet . . . . . . . . .4 — 3 Parallel UPS Configuration With External Bypass Cabinet . . . . . . . . . . . .4 — 4 Shutdown and Isolation of all the UPSs . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 4 Return to the Normal Operation for Single UPS . . . . . . . . . . . . . . . . . . . .4 — 5 Parallel UPS Configuration Without External Bypass Cabinet . . . . . . . . .4 — 6 Parallel UPS Configuration With External Bypass Cabinet . . . . . . . . . . . .4 — 8 2-1 4-1 Electrical Specifications for the MGE Galaxy 5000 . . . . . . . . . . . . . . . . . .2 — 2 Identification of Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 1 Tables 86-174010-00 B00 Contents III MGE Galaxy 5000 CAUTION: Record All Serial Numbers! RECORD ALL SERIAL NUMBERS FOR THE MGE GALAXY 5000 AND ACCESSORIES. THESE SERIAL NUMBERS WILL BE REQUIRED IF YOUR SYSTEM NEEDS SERVICE. KEEP THIS MANUAL IN A PLACE WHERE YOU CAN REFERENCE THE SERIAL NUMBERS IF SERVICE IS REQUIRED! UPS SERIAL NUMBER: ____________________________________________________________ BATTERY SERIAL NUMBER: _______________________________________________________ AUXILIARY SERIAL NUMBER: ______________________________________________________ ADDITIONAL SERIAL NUMBERS: ____________________________________ ____________________________________ ____________________________________ ____________________________________ ____________________________________ ____________________________________ ____________________________________ ____________________________________ ____________________________________ ____________________________________ ____________________________________ ____________________________________ ____________________________________ ____________________________________ NOTES: IV Record All Serial Numbers 86-174010-00 B00 Installation and User Manual Safety Rules Safety of persons The UPS must be installed in a room with restricted access (qualified personnel only). A UPS has its own external power source (the battery). Consequently, the power outlets may be energized even if the UPS is disconnected from the AC-power source. Dangerous voltage levels are present within the UPS. It should be opened exclusively by qualified service personnel. The UPS must be properly grounded. The battery supplied with the UPS contains small amounts of toxic materials. To avoid accidents, the instructions below must be observed. ◗ Never operate the UPS if the ambient temperature and relative humidity are higher than the levels specified in the documentation. ◗ Never burn the battery (risk of explosion). ◗ Do not attempt to open the battery (the electrolyte is dangerous for the eyes and skin). ◗ Comply with all applicable regulations for the disposal of the battery. ◗ Caution, wait five minutes before opening the UPS to allow the capacitors to discharge. ◗ Caution, there is high leakage current, the grounding conductor must be connected first. ◗ The product must be installed on a non-inflammable surface (e.g. concrete). ◗ Caution, battery replacement must be carried out by qualified personnel. Product safety A protection circuit breaker must be installed upstream and downstream, and be easily accessible. ◗ Never install the UPS near liquids or in an excessively damp environment. ◗ Never let a liquid or foreign body penetrate inside the UPS. ◗ Never block the ventilation grates of the UPS. ◗ Never expose the UPS to direct sunlight or a source of heat. ◗ When replacing battery cells, use the same type and number of cells. Special precautions ◗ The UPS connection instructions contained in this manual must be followed in the indicated order. ◗ Check that the indications on the rating plate correspond to your AC-power system and to the actual electrical consumption of all the equipment to be connected to the UPS. ◗ If the UPS must be stored prior to installation, storage must be in a dry place. ◗ The admissible storage temperature range is -25°C to +45°C. ◗ If the UPS remains de-energized for a long period, we recommend that you energize the UPS for a period of 24 hours, at least every three months. This charges the battery, thus avoiding possible irreversible damage. ◗ The UPS is designed for normal climatic and environmental operating conditions concerning the altitude, ambient operating temperature, relative humidity and ambient transport and storage conditions. ◗ Using the UPS within the given limits guarantees its operation, but may affect the service life of certain components, particularly that of the battery and its autonomy. The maximum storage time of the UPS is limited due to the need to recharge the battery. ◗ Unusual operating conditions may justify special design or protection measures: - harmful smoke, dust, abrasive dust, - humidity, vapor, salt air, bad weather or dripping, - explosive dust and gas mixture, - extreme temperature variations, - bad ventilation, - conductive or radiant heat from other sources, - strong electromagnetic fields, - radioactive levels higher than those of the natural environment, - fungus, insects, vermin, etc., - battery operating conditions. 86-174010-00 B00 Safety Rules V MGE Galaxy 5000 Symbol Usage Document Icons Danger, these instructions are imperative. Display Icons Move up or down one page Vertical selection Other selection Information, advice, help may Visual indication Action Audio signal Event selection in log by date and time Enter / Confirm Increase Event scroll in log Decrease Page scroll in log Save LED OFF Fast forward LED flashing Forward LED ON Details Settings Ground cables Circular menu Maintenance Other cables Graphical display Control Alarm Status conditions Return to previous display Delete Access to measurements Buzzer off VI Symbol Usage 86-174010-00 B00 Installation and User Manual Section Descriptions 1 Introduction Provides a general description of the MGE Galaxy 5000 system’s intended use, single line, major components, and mechanical specifications. 2 Setup and Installation Guides the user through performing connections required for initial installation. Included are the electrical specifications and connection details. 3 Operation Provides startup, shutdown, and normal operation of the MGE Galaxy 5000 UPS. Describes the operation of the mimic-panel LEDs. 4 Maintenance Identifies alarm conditions, UPS isolation operation, and maintenance and safety information on servicing batteries for the MGE Galaxy 5000. A Glossary provides definitions of abbreviations and terms used in this manual. 86-174010-00 B00 Section Descriptions VII MGE Galaxy 5000 (This page left blank intentionally) VIII 86-174010-00 B00 Introduction Thank you for selecting a Schneider Electric product to protect your electrical equipment. The MGE Galaxy 5000 range has been designed with the utmost care. We recommend that you take the time to read this manual to take full advantage of the many features of your UPS. Schneider Electric pays great attention to the environmental impact of its products. Measures that have made MGE Galaxy 5000 a reference in environmental protection include: ◗ the eco-design approach used in product development, ◗ production in an ISO 14001 certified factory, ◗ recycling of the MGE Galaxy 5000 at the end of its service life. To discover the entire range of Schneider Electric products and the options available for the MGE Galaxy 5000 range, we invite you to visit our web site, www.mgeups.com, or contact your local Schneider Electric representative. All products in the MGE Galaxy 5000 range are protected by patents. They implement original technology not available to competitors of Schneider Electric. To take into account evolving standards and technology, equipment may be modified without notice. Indications concerning technical characteristics and dimensions are not binding unless confirmed by Schneider Electric. This document may be copied only with the written consent of Schneider Electric. Authorized copies must be marked "MGE Galaxy 5000 Installation and User Manual” no. 86-174010-00. We invite you to visit our web site, www.mgeups.com, or contact your local Schneider Electric representative. 1.0 Scope Provides a general description of the MGE Galaxy 5000 system’s intended use, single line major components, and mechanical specifications. 1.1 General Description The MGE Galaxy 5000 is a three phase double conversion uninterruptible power supply (UPS), designed for flexibility to meet a wide range of application requirements. The MGE Galaxy 5000 offers many options to allow you to customize a solution to meet your unique specifications. The options offered include, but are not limited to, adjacent and remote battery cabinets, input and output isolation transformers, distribution options, parallel system bypass cabinets, and a variety of communication cards. 86-174010-00 B00 Introduction 1—1 MGE Galaxy 5000 Figure 1-1: MGE Galaxy 5000 UPS Cabinet. UPS power rating (KVA) Dimensions (H x W x D) 40-130 75” x 28” x 33.4” 1900 x 712 x 850 mm Figure 1-2: Single Line Diagram MGE GALAXY 5000 UPS SYSTEM WITH BATTERY SINGLE LINE DIAGRAM Q3BP Optional Bypass Input 480Y VAC Main Input 480 VAC Bypass Input Main Input KA2 Q4S Q1 Input Fuses KA1 Input Static Switch PFC Boost Rectifier Output Output Static Inverter Fuses Switch Q5N Output To Critical Load Battery Static Switch Battery Charger UPS CB 1—2 Introduction CB CB CB 86-174010-00 B00 Installation and User Manual 1.2 Inside the UPS Cabinet, Access to Connections Figure 1-3: Inside MGE Galaxy 5000 UPS Cabinet (1) Connectors for auxiliary interconnections of parallel UPS units (INTN PCA), optional (2) User-machine interface display (3) Slot for relay communications card (4) Open slots for optional communication cards (5) Open cabinet door (6) Screw-type terminal block for connections of contacts and coils for two external battery circuit breakers XMB07, XMB08 (7) Screw-type terminal block for connection of remote emergency power off (REPO) XMB06 (8) Q1: input switch for normal AC input (9) Q4S: input switch for bypass AC input (10) Q3BP: bypass switch (11) Q5N: UPS output switch (12) Protection cover for power connections (13) Screw-type terminal block for connection of contacts for parallel circuit breakers TB6, optional 86-174010-00 B00 Introduction 1—3 MGE Galaxy 5000 Figure 1-4: Power Connection Terminals (14) Terminals for load output (15) Terminals for bypass AC input (16) Terminals for normal AC input (17) Main grounding connector (22) Connection of external battery (+/- poles) Figure 1-5: INTN PCA for Auxiliary Interconnections of Parallel UPSs (19) DB9 connectors: exchange-current information (20) Screw connectors: position information on Q5N, Q4S and Q3BP switches, from the external bypass (21) DB9 connectors: CAN communication information between UPSs PIN 1 1.3 PIN 1 UPS Cabinet Bottom View Layout Figure 1-6: MGE Galaxy 5000 Cabinet Bottom View Layout 4.04 (102.50) 17.32 (440.00) 1.26 (32.00) swivel casters (2) 29.33 (745.00) 26.81 (681.00) fixed casters (2) levelers (4) 1.08 (27.50) 17.32 (440.00) 1.32 (33.50) 25.39 (645.00) 1—4 Introduction 86-174010-00 B00 Installation and User Manual 1.4 User-Machine Interface Display Figure 1-7: User-Machine Interface Display (30) Graphical display (31) Load protected LED (32) Minor fault LED (33) Major fault LED (34) Help key (35) Function keys (36) Menu key (38) OFF button (37) ON button (42) Load supplied LED (40) UPS ON LED (41) Operation on battery power LED (43) Bypass in operation LED (39) PFC ON LED 86-174010-00 B00 Introduction 1—5 MGE Galaxy 5000 1.5 Display Screens Figure 1-8: Display Screens Frequency measurements Personalization 1—6 Introduction 86-174010-00 B00 Installation and User Manual 1.6 Relay Communication Card Figure 1-9: Relay Communication Card (50) Card cover screws (51) Card screw holes (52) Card cover (53) Cable entry holes (54) Output terminal block (55) Input terminal block (56) Cable clamping screws 86-174010-00 B00 Introduction 1—7 MGE Galaxy 5000 (This page left blank intentionally) 1—8 Introduction 86-174010-00 B00 Setup and Installation 2.0 Scope Guides the user through performing connections required for initial installation. Included are the electrical specifications and connection details. 2.1 Location To ensure correct ventilation, leave nothing on top of the UPS. Leave three feet of free space in front of the UPS for door opening. The UPS cabinet rests on four levelers positioned in the four corners of the cabinet to spread the weight. The UPS must be installed in a room with restricted access (qualified personnel only). Figure 2-1: Installation of UPS 86-174010-00 B00 Setup and Installation 2—1 MGE Galaxy 5000 2.1.1 Layout of Cabinets Figure 2-2: Layout of Cabinets (typical) TOP VIEW DISTRIBUTION 2.2 TRANSFORMER MBC UPS BATTERY Electrical Specifications Table 2-1: Electrical Specifications for the MGE Galaxy 5000 Output Power Rating (0.9 PF) 40KVA 50KVA 60KVA 80KVA 100KVA 130KVA UPS Voltage (input/output) 480/480 480/480 480/480 480/480 480/480 480/480 Input/Output Requirements & Frequency Three phase, Three wire + G, 60Hz Input Phase Rotation A, B, C Clockwise Input Power Factor > 0.98 Input Current/Input Current with Battery 48A/59A 59A/70A 71A/88A 94A/111A 117A/150A 151A/182A Charging Current Maximum Input Current with Charging Current 57A 70A 85A 111A 148A 182A (at low line -10%) Bypass/Output Current 48A 60A 72A 96A 120A 156A Battery Voltage 356VDC End Voltage 432VDC Nominal 490VDC Max. Floating Voltage Max. Battery Current at Battery Voltage 90A 113A 135A 180A 225A 293A (432 VDC at 100% Load) Max. Battery Current at End-Voltage 109A 137A 164A 219A 273A 355A (356 VDC at 100% Load) Battery Disconnect Circuit Breaker Rating 175A, 250A, 400A Input, Bypass, Maintenance Bypass and 125A 250A Output Switch Rating Input and Output Fuse Rating 160A 315A 2—2 Setup and Installation 86-174010-00 B00 Installation and User Manual CAUTION 2.3 Only an authorized electrical professional should access electrical connections. A severe shock hazard exists. Connection of Power Cables in a Single UPS Figure 2-3: Single UPS With Common Normal and Bypass AC Inputs 14.56” 22 To access the connections, remove cover (see Section 1.3). 1 - The grounding conductors must be connected to the UPS grounding-plate connections (17). 2 - Connect the three phases of the normal AC source to connection (15). 3 - Connect the three phases supplying the load to connection (14). 4 - Connect external battery (+/-) to connection (22). 5 - Tie the cables down to the frame. 6 - Put the cover back in place. Figure 2-4: Single UPS With Separate Normal and Bypass AC Inputs To access the connections, remove cover (see Section 1.3). 1 - The grounding conductors must be connected to the UPS grounding-plate connections (17). 2 - Connect the three phases of the normal AC source to connection (16). 3 - Connect the three phases of the bypass AC source to 22 connection (15). 14.56” 4 - Connect the three phases supplying the load to connection (14). 5 - Connect external battery (+/-) to connection (22). 6 - Tie the cables down to the frame. 7 - Put the cover back in place. 86-174010-00 B00 Setup and Installation 2—3 MGE Galaxy 5000 2.4 Redundant Parallel Configuration (Maximum Two UPS Units for Pn) These configurations do not have an external System Bypass Cabinet (SBC). Figure 2-5: Parallel UPS With Common Normal and Bypass AC Inputs UPS 2 UPS 1 14.56” 14.56” 22 22 Ground To Normal / Bypass AC Source To load To Load To access the connections, remove cover (see Section 1.3). 1 - The grounding conductors must be connected to the grounding-plate of each UPS (17). 2 - Connect the three phases of the bypass AC source to connection (15) in each UPS. 3 - Connect the three phases of the supplied loads to connection (14) in UPS1. 4 - Connect (14) in UPS2 to (14) in UPS1 using the three load conductors. 5 - Connect the external battery (+/-) to connections (22) in UPS1 and UPS2. 6 - Tie the cables down to the cabinet frames. 7 - Put the covers back in place. Figure 2-6: Parallel UPS With Separate Normal and Bypass AC Inputs UPS 1 UPS 2 22 22 14.56” 14.56” Ground To Load CAUTION 2—4 To Normal AC Source To Bypass AC Source To access the connections, remove cover (see Section 1.3). 1 - The grounding conductors must be connected to the grounding-plate of each UPS (17). 2 - Connect the three phases of the normal AC source to connection (16) in each UPS. 3 - Connect the three phases of the bypass AC source to connection (15) in each UPS unit. 4 - Connect the three phases of the supplied loads to connection (14) in UPS1. 5 - Connect (14) in UPS2 to (14) in UPS1 using the three load conductors. 6 - Connect the external battery (+/-) to connections (22) in UPS1 and UPS2. 7 - Tie the cables down to the cabinet frames. 8 - Put the covers back in place. If the two UPSs are placed side by side, connect as indicated above. In the other configurations, always make sure that the cables between the UPSs and bypass AC source have the same cross-section and the same length. The same is true for the cables between the UPSs and the load. Setup and Installation 86-174010-00 B00 Installation and User Manual 2.5 Auxiliary Interconnections Between UPSs in Parallel Configurations Figure 2-7: Redundant Parallel Configuration (Maximum Two UPS) 19 21 19 UPS 1 21 19 21 19 21 UPS 2 Red plug Blue plug PCA INTN PCA INTN Exchange-current interconnections (19): Link connectors XMS02 and XMS03 on the two UPS units. CAN // interconnections (21): Fit a blue plug on connector XMS06 on UPS1. Link connector XMS07 on UPS1 to connector XMS06 on UPS2. Fit a red plug on connector XMS07 on UPS2. Note: The supplied cables (33 ft) limit the distance between the two UPS units to approximately 20 ft. 86-174010-00 B00 Setup and Installation 2—5 MGE Galaxy 5000 Figure 2-8: Parallel Configuration for Increased Capacity (Four UPSs) These configurations have an external System Bypass Cabinet (SBC). PCA INTN PCA INTN UPS 2 UPS 1 Blue plug 20 20 SBC Interconnections with the external system bypass cabinet (20): ◗ Interconnect terminals 7, 8, 9, and 10 on the auxiliary terminal block TB2 in the system bypass cabinet to UPS terminal blocks XMS04/XMS05 pins 1, 2, 3, and 4 respectively. ◗ Create a loop connection between the cabinet and the UPSs as shown in Figure 2-8. Details of terminal block connections. TB2 7 8 9 SBC 10 XMS04 / XMS05 TB2 7 4 20 1 Common UPS 3 Red plug 19 2 20 UPS 4 19 3 21 21 Note: The interconnection cables for the SBC are not supplied 19 19 21 21 UPS 2 UPS 1 Blue plug UPS 3 UPS 4 1 2 3 4 8 9 10 Exchange-current interconnections (19): Use the XMS02 and XMS03 connectors to create a loop between the UPSs (all the XMS02 and XMS03 connectors must be used). CAN // interconnections (21): Daisy-chain the UPSs using the XMS06 and XMS07 connectors. Fit a blue plug on the first UPS unit and a red plug on the last UPS (all the XMS06 and XMS07 connectors must be used). Note: The supplied cables are 33 ft long. To ensure sufficient isolation of exchange-current, CAN and external bypass cabinet cables, they must be run separately from the power cables. Red plug 2—6 Setup and Installation 86-174010-00 B00 Installation and User Manual Fitting the Protection Cover for the Auxiliary Interconnection Cables The protection cover supplied with the parallel connected UPS units protects the user against direct contact with voltages other than SELVs and ensures the auxiliary interconnection cables are maintained in position. Figure 2-9: Fitting the Protection Cover for the Auxiliary Interconnection Cables Note: Tie down the cables as indicated in the diagram in Section 2.9. 2.6 Connection of General Shutdown or Remote Emergency Power Off (REPO) Terminal Block Figure 2-10: Connection of General Shutdown or Remote Emergency Power OFF (REPO) Terminal Block XMB08 1 - Remove the wire jumper from terminal block (7). 2 - Connect the general shutdown NC contact to terminals 1 and 2 (SELV). 3 - Tie the cable down as illustrated in Section 2.9. XMB07 XMB06 CAUTION 86-174010-00 B00 Pressing the general shutdown button causes UPS shutdown and opening of the battery circuit breaker (with opening of the bypass static switch depending on personalization settings). The Remote Emergency Power Off (REPO) notion is applicable to installations where pressing the button also causes the upstream Normal AC source and bypass AC source circuit-breakers to open. In parallel configurations, there must be a single general shutdown button with a separate contact for each UPS unit. Setup and Installation 2—7 MGE Galaxy 5000 2.7 Adding Communication Cards Figure 2-11: Adding Communication Cards 2—8 Setup and Installation 86-174010-00 B00 Installation and User Manual 2.8 Connection of the Relay Communications Card CAUTION 1 2 3 4 5 6 7 8 Isolate and lock-out all power sources for this card before making connections. Never connect SELV (safety extra low voltage) and non-SELV circuits to the different outputs of the same card. - Remove the cover (52) secured by the screws (50). - Run the communications cables through the cable entry holes (53). - Connect the conductors to the input (55) and output (54) terminal blocks. - Put the cover back in place and secure it with the screws (50). - Tighten the screws (56) to lock the cables. - Indicate the locations of the power sources on the labels. - Insert the card in its slot. - Secure the card with two screws (51). Figure 2-12: Connection of Relay Communication Card 86-174010-00 B00 Setup and Installation 2—9 MGE Galaxy 5000 2.8.1 Characteristics of the Contacts on the Relay Communications Card Figure 2-13: Characteristics of the Contacts on the Relay Communications Card Characteristics of the output contacts: Permissible voltage: 250V AC, 30V DC. Permissible current: 2 A. Cable: 4 x 0.93 mm2, Ø 6.6 ± 0.3 mm. Low battery warning Load on battery power Characteristics of the input contacts: Switched voltage: 5 V DC Consumption: 10 mA. Cable: 4 x 0.34 mm2, Ø 5 ± 0.5 mm. Load on automatic bypass Load on UPS Battery fault UPS OFF General alarm UPS ON Communications Card Connection Example If a SELV (safety extra low voltage) source is used, it must always be possible to isolate the communications card from the upstream source to ensure the safety of personnel working on the installation. communication card AC Disconnecting device that can be locked 2 — 10 Setup and Installation 86-174010-00 B00 Installation and User Manual 2.9 Routing the Control/Communications Cables Single UPS Figure 2-14: Routing the Control/Communications Cables for Single UPS Separate the control and communication cables from the power cables. Run the cables together in front of the protection panels and tie them to the panels as indicated. Free slots for optional communication cards. See installation drawing for proper card placement. Slot for relay communications card Tie General-shutdown cable (not supplied) and external battery circuit breaker cable must be tied down separately. Ties Cable description Insulation level Location on illustration Relay communication card SELV 3 Optional communication card SELV or LV 4 External battery circuit-breaker cables SELV 6 General-shutdown cable SELV 7 CAUTION 86-174010-00 B00 To ensure sufficient isolation of control and communication cables, they must be run separately from the power cables. Reinforce the insulation of these control and communication cables if any risk of contact with the power cables exists. Setup and Installation 2 — 11 MGE Galaxy 5000 Parallel UPS Figure 2-15: Routing the Control/Communications Cables for Parallel UPS Separate the control and communication cables from the power cables. Run the cables together in front of the protection panels and tie them to the panels as indicated. Parallel-connection cables for connection to the SBC (not supplied). The CAN and current exchange cables are supplied. Free slots for optional communication cards. See installation drawing for proper card placement. Slot for relay communications card Ties General-shutdown cable (not supplied) and external battery circuit breaker cable must be tied down separately. Ties Cable description Insulation level Location on illustration External bypass cabinet cable ELV 1 CAN cables SELV 1 Exchange-current cables SELV 1 Relay communication card SELV 3 Optional communication card SELV or LV 4 External battery circuit-breaker cables SELV 6 General-shutdown cable SELV 7 CAUTION 2 — 12 To ensure sufficient isolation of exchange-current, CAN and external bypass cabinet cables, they must be run separately from the power cables. Reinforce the insulation of these control and communication cables if any risk of contact with the power cables exists. Setup and Installation 86-174010-00 B00 Operation CAUTION 3.0 All operations concerning system start-up and compliance with standards and regulations, including those related to the battery cabinet, must be carried out by trained and certified personnel before using the UPS. Scope Provides startup, shutdown, and normal operation of the MGE Galaxy 5000 UPS. Describes the operation of the mimic-panel LEDs. 3.1 Shutting Down a Single UPS The UPS remains energized unless it is shut down. Figure 3-1: Shutting Down a Single UPS 1 - Press a button to exit sleep mode. 2 - Press the OFF button (38) for 3 seconds. The load is no longer protected by the UPS. It is supplied via the bypass. 3 - Set the battery circuit breaker of the auxiliary cabinets to OFF. 4 - Set the input switch Q1 (8) to OFF. The charger no longer operates to keep the batteries fully charged. 5 - Open the upstream circuit breakers of the Normal AC source and Bypass AC source to completely power off the UPS. 86-174010-00 B00 Operation 3—1 MGE Galaxy 5000 3.2 Restarting a Single UPS Check that switches Q4S (9) and Q5N (11) are closed. If this is the case, continue with this procedure, otherwise refer to Section 4.4.1 "Return to the Normal Operation, Single UPS". Figure 3-2: Restarting a Single UPS 1 - Set the Normal AC source input switch Q1 (8) to the ON position. 2 - Wait until the end of the start sequence. 3 - Set the battery circuit breaker of the auxiliary cabinets to the ON position. The UPS starts automatically. LED (31) is ON. The load is protected by the UPS. If LED (31) remains OFF, press the ON button (37) (the UPS is in manual start mode) and confirm if necessary by pressing the function key (35) marked . If LED (31) still remains OFF and either of LEDs (32) or (33) is ON, a fault has occurred (see Section 4.1). 35 3.3 Shutting Down a Parallel Configuration Figure 3-3: Shutting Down a Parallel Configuration 1 - Press a button on each unit to exit sleep mode. 2 - Press the OFF button (38) on each unit for 3 seconds. The load is no longer protected by the UPSs. It is supplied via the bypass. 3 - Set the battery circuit breakers of the auxillary cabinets to the OFF position. 4 - Set the input switch Q1 (8) in each UPS to the OFF position. The charger no longer operates to keep the batteries fully charged. 5 - Open the upstream circuit breakers of Normal AC source and Bypass AC source to completely power off the installation. 3—2 Operation 86-174010-00 B00 Installation and User Manual 3.4 Restarting a Parallel Configuration Check that switches Q4S (9) and Q5N (11) are closed. If this is the case, continue with this procedure, otherwise refer to Section 4.4.2 or Section 4.4.3 "Return to the Normal Operation, Parallel UPS". Figure 3-4: Restarting a Parallel Configuration 1 - Check that the output switch CB2 in the external system bypass cabinet is closed. 2 - Check that the bypass switch CB1 in the external system bypass cabinet is open. Then carry out steps 3 to 5 below on each of the UPSs. 3 - Set the Normal AC source input switch Q1 (8) to the ON position. 4 - Wait until the end of the start sequence. 5 - Set the battery circuit breaker of the auxiliary cabinets to the ON position. The UPSs start automatically. On each unit, LEDs (32) and (33) go OFF and LED (31) goes ON. The load is protected by the UPSs. If LED (31) remains OFF, press the ON button (37) on each UPS (the UPS is in manual start mode) and confirm if necessary by pressing the function key (35) marked . If LED (31) still remains OFF and either of LEDs (32) or (33) is ON, a fault has occurred (see Section 4.1). 86-174010-00 B00 Operation 3—3 MGE Galaxy 5000 3.5 Operation of Mimic-Panel LEDs The MGE Galaxy 5000 system is simple to operate and yet provides a wealth of continuous monitoring and diagnostic features to ensure proper operation. Operators gain access to information in the MGE Galaxy 5000 system through the display and its integrated LED mimic panel. Figure 3-5: Operation of Mimic-Panel LEDs 37 Single UPS Start Sequence on Normal AC Input Steps Action LED (39) LED (40) LED (41) LED (42) LED (43) 1 Q1 open Off Off Off Off Off 2 Close Q1 green Off red Off red 3 Close Battery CB green Off Off Off red 4 Close Q4S green Off Off Off green 5 Close Q5N green Off Off green green 6 Open Q3BP green Off Off green green 7 Press ON button (37) green green Off green Off Single UPS Start Sequence on Bypass AC Input 3—4 Steps Action LED (39) LED (40) LED (41) LED (42) LED (43) 1 Q4S open Off Off Off Off Off 2 Close Q4S Off Off red Off green 3 Close Q5N Off Off red green green 4 Open Q3BP Off Off red green green 5 Close Q1 green Off red green green 6 Close Battery CB green Off Off green green 7 Press ON button (37) green green Off green Off Operation 86-174010-00 B00 Installation and User Manual 3.6 Operating Modes Normal (Double Conversion) Mode This is the standard operating mode, set by default in the factory. Two possible cases: Figure 3-6: Normal (Double Conversion) Operating Mode 1 - Normal AC source available: LED (31) is ON. The load is protected by the UPS. 2 - Normal AC source not available: LED (32) is ON. The buzzer sounds intermittently. LED (41) on the mimic-panel is green. The load is supplied by the UPS from battery power. The display indicates any anomalies related to the AC source or the UPS as well as remedial action if applicable. Press the function key (35) indicated by the display to turn the buzzer OFF. 3.7 Load on Battery Power The load continues to be protected by the UPS when the normal AC source is not available. Power is supplied by the battery. Figure 3-7: Load on Battery Power Transfer to Battery Power LED (32) is ON. The buzzer sounds intermittently. The load is supplied by the battery. End of Battery Power LED (33) is ON. The buzzer sounds intermittently. The load is transferred on the bypass AC input if it is present. 86-174010-00 B00 Operation 3—5 MGE Galaxy 5000 3.8 UPS Personalization Access to the Personalization Functions CAUTION Personalization must be carried out with switches Q1 (8) and Q5N (11) open (OFF) and switch Q4S (9) closed (ON). Figure 3-8: UPS Personalization 1 - Press the menu key (36). 2 - Select "Settings", then "Personalization" using the function keys (35) or . 3 - Confirm by pressing the function key (35) . 4 - Enter the password by successively selecting each icon using the corresponding function key. 5 - Confirm by pressing the function key (35) . 6 - To save the personalization settings, confirm by pressing the function key (35) . The password is factory set. To change the password, see the Settings menu. Personalization Settings Operating Mode Function Factory setting Options UPS operating mode NORMAL UPS automatic start Disabled Enabled Authorized number of starts 4 1 to 255 Delay before reset of number of executed automatic starts 4 seconds 1 to 60 seconds UPS output frequency 60 Hz 60Hz Tolerance for bypass AC source 8% 0.5 - 1 - 2 - 4 % Synchronization speed with bypass AC source 2 Hz / s 1 Hz / s Transfer to bypass AC source Enabled Disabled – disabled when limiting Transfer to bypass with bypass AC source out of tolerances Enabled Disabled Frequency Automatic Bypass 3—6 Operation 86-174010-00 B00 Installation and User Manual Battery 3.9 Low battery warning threshold if battery monitor inactive 40% remaining backup time 20 - 60 - 80 % remaining backup time Low battery warning threshold if battery monitor active 4 minutes of battery backup time 1 to X minutes of battery backup time Interval between two battery tests 30 days 1 to 180 days Display Messages List Fault of downgraded mode Internal CAN communication fault External CAN communication fault CAN communication relay fault UPSs not connected by CAN cable Resynchronizing CAN communication resynchronization fault Loss of communication with UPS 1 Loss of communication with UPS 2 Loss of communication with UPS 3 Loss of communication with UPS 4 Loss of communication with UPS X Fault, filtering of customer communication Customer communication disabled Generic fault on equipment Emergency Power Off (EPO) UPS personalization fault Personalization does not match UPS Transfer to bypass disabled Major Fault on subassembly Charger fault Bypass static switch fault PFC fault Inverter fault Power supply board fuse blown Fan fault TVSS fault Internal and external switches Q3BP switch closed Q5N switch open Q4S switch open External Q3BP switch closed (MBC or SBC CB1) External Q5N switch open (MBC or SBC CB2) External Q4S switch open (MBC CB3) Abnormal bypass operation Abnormal external bypass operation Fault or state of installation Installation overload Non-redundant installation Inverter starting Not enough inverters for load connection Not enough bypass static switches Inverter ready for load connection Fault or state on Normal AC Q1 switch open Normal AC source downgraded Normal AC input phase rotation fault Normal AC fuse blown Normal AC source static switch failure Normal AC source outside tolerances Normal AC backfeed (KA1) is open Normal AC backfeed (KA1) fault Fault or state on Bypass AC or Bypass Static Switch Bypass source present Bypass static switch overload AC Bypass static switch thermal overload Bypass input phase rotation fault Bypass source outside tolerances Bypass AC backfeed (KA2) is open Bypass AC backfeed (KA2) fault Fault or state for PFC PFC overload PFC thermal overload Starting Fault or state standard charger Low battery warning Low battery shutdown Battery circuit breaker open (QF1) (Battery Cabinet #1 or #3) Battery circuit breaker 2 open (QF2) (Battery Cabinet #2 or #4) End of theoretical battery service life Battery temperature fault Battery deep discharge Battery room temperature fault Battery test result not OK Battery test in progress Charger shutdown by PFC overload Fault or state inverter Inverter current limiting Inverter overload Inverter thermal overload Inverter fuse blown Inverter and bypass desynchronized Fault or state load Abnormal presence of output voltage Load short circuit Fault or state external synchronization External sync frequency outside tolerances UPS on external synchronization 86-174010-00 B00 Operation 3—7 MGE Galaxy 5000 3.10 Operation of the Relay Communication Card (Dry Contacts) All systems are equipped with this remote transmissions card (also known as SECI). A complete specification exists for the card used in MGE Galaxy 5000. This card is used for the transmission of information between the system and the environment. Two inputs and six outputs are available for the user (see the table below for the default programming). 3.10.1 Standard Mode It is compatible with all MGE systems that are I2 C compatible. All the SA1 microswitches must be set to OFF (if two SECI cards are installed in the unit, the second card must be identified differently. On the second card, microswitch 1 on SA1 must be set to ON). In this mode, the relays switch when the UPS changes status. The information listed below is transmitted if the parameters were enabled in UPS Tuner. Inputs Factory configuration Other possible signals for each contact 1A UPS ON 1.B UPS OFF - Temperature fault in room - Transfer to bypass AC input disabled - Transfer to bypass AC input disabled if it is out of tolerances - UPS not synchronized with the bypass AC input Outputs Factory configuration 1.1 General alarm 1.2 1.3 1.4 1.5 1.6 Other possible signals for each contact - Overload - PFC fault - Inverter fault Battery fault - Charger fault - Automatic-bypass fault - Bypass AC source out of tolerances Load on UPS - Battery-temperature fault - Ventilation fault Load on automatic bypass - Emergency power OFF activated - Battery circuit breaker(s) open - Phase inversion on normal or bypass AC input Load on battery power - Fuses blown - Transfer to AC bypass disabled Low battery warning - Operation in ECO mode - Load on maintenance bypass The indications 1.X become 2.X for a second identical card in the UPS. Contacts are of the NO (normally open) type. (1) The general alarm can be tested by opening the battery circuit breaker. 3.10.2 Programmable Mode This operating mode is specific to the MGE Galaxy 5000. The description in this document concerns only the MGE Galaxy 5000. Microswitch 3 on SA1 must be set to ON (if two SECI cards are installed in the unit, the second card must be identified differently. On the second card, microswitch 1 on SA1 must be set to ON). In this mode, it is possible to assign predefined operating status conditions (see the complete list) to the various SECI output relays and predefined UPS commands to the SELV inputs. Assignments are made using the MGE Galaxy 5000 user-machine interface. 3—8 Operation 86-174010-00 B00 Installation and User Manual 3.10.3 List of Operating Status Conditions That May be Assigned to an SECI Output Operating status conditions Description GENERAL ALARM PFC fault OR Inverter fault OR Bypass static switch fault OR Charger fault OR Thermal overload on AC bypass OR Normal AC input fuse blown OR ALIN board input fuse blown OR Q3BP and Q5N are closed simultaneously OR External Q3BP and external Q5N are closed simultaneously OR EPO activated OR Battery backup time ended, shift to wait mode OR Battery temperature fault > 45°C , charger shutdown OR Battery deep discharge OR Charger shutdown due to battery room temperature outside tolerances OR Abnormal presence of voltage on the output before closing the bypass static switch. (frequency converter) OR UPS in downgraded mode OR External CAN communication fault OR Internal CAN communication fault (GDEN, MIZNUS and CHAN) OR CAN cable physically cut OR CAN communication relay fault OR UPS personalization fault. BATTERY FAULT The battery will soon reach the end of its theoretical service life OR Battery must be checked (following a faulty battery test) LOAD ON UPS Inverter connected to the load and operating on normal AC input. Battery operations due to a BPI or battery test are signalled as operation on the normal AC input. LOAD ON AUTOMATIC BYPASS The static switch on the AC bypass is closed. LOAD ON BATTERY POWER Inverter connected to the load and operating on battery power. Battery operations due to a battery test are not signalled. LOW BATTERY WARNING Battery has reached the low-battery warning level (voltage or time). The two thresholds may be user set. OVERLOAD 86-174010-00 B00 One of the unit modules (rectifier, inverter or AC bypass) is overloaded (thermal or instantaneous). Operation 3—9 MGE Galaxy 5000 PFC FAULT Neutral leg fault OR Neutral leg IGBT temperature outside tolerances OR Voltage difference between 2 DC half-buses outside tolerances OR Top DC half-bus voltage outside tolerances OR Bottom DC half-bus voltage outside tolerances PFC fault OR DC-bus voltage at end of CSR1 walk-in is lower than a threshold OR DC-bus voltage at end of DC walk-in is lower than a threshold OR DC-bus voltage is higher than the high threshold OR DC-bus voltage is lower than the minimum threshold Mean DC-bus voltage is higher than the maximum setpoint OR Mean DC-bus voltage is lower than the minimum setpoint OR DC-bus voltage is higher than the fast hardware threshold OR Temperature of the static switch on the AC normal outside tolerances OR Temperature of the battery static switch outside tolerances OR Rectifier is current limiting OR Rectifier thermal overload OR PFC IGBT base-plate temperature outside tolerances OR IGBT inductor temperature outside tolerances. INVERTER FAULT Inverter short-circuit detected OR Inverter current limiting OR Inverter static switch failure OR Temperature fault on inverter static switch OR Inverter base-plate temperature outside tolerances OR Inverter thermal overload OR Inverter phase-1 fuse has blown OR Inverter phase-2 fuse has blown OR Inverter phase-3 fuse has blown OR Inverter phase-1 voltage amplitude outside tolerances OR Inverter phase-2 voltage amplitude outside tolerances OR Inverter phase-3 voltage amplitude outside tolerances OR Instantaneous inverter voltage outside tolerances OR Inverter relay for parallel connection is faulty. CHARGER FAULT Fault of non-isolated supply on charger board OR Fault of isolated supply on charger board OR Opening fault on battery circuit breaker no. 1 OR Opening fault on battery circuit breaker no. 2 OR Charger IGBT temperature outside tolerances OR Difference in charge-current measurements between safety and measurement systems OR Charge current on measurement system close to zero OR Charge current on safety system close to zero OR Charge current is higher than safety level OR Difference in voltage measurements between safety and measurement systems OR Voltage on measurement system close to zero OR Voltage on safety system close to zero OR Battery voltage higher than safety level OR Charger fuse blown. AUTOMATIC-BYPASS FAULT Supply fault for the static switch on the AC bypass OR Fault on static switch on AC bypass OR Temperature of the static switch on the AC bypass outside tolerances. BYPASS AC SOURCE OUT Bypass AC source outside of tolerances (voltage and/or frequency). OF TOLERANCE 3 — 10 Operation 86-174010-00 B00 Installation and User Manual BATTERY TEMPERATURE FAULT Battery ambient temperature outside tolerances. VENTILATION FAULT Excessive temperature on one or more inductors OR Inverter or AC bypass static switch fan fault. EMERGENCY POWER OFF ACTIVATED EPO set on control-monitoring board OR EPO set on charger board. BATTERY CIRCUIT BREAKER(S) OPEN One or two Battery circuit breaker is open. PHASE ROTATION FAULT Phase inversion on normal AC input OR Phase inversion on AC bypass. FUSES BLOWN Fuse blown at normal AC input OR Charger fuse has blown OR Power supply board fuse has blown OR Inverter phase-1 fuse has blown OR Inverter phase-2 fuse has blown OR Inverter phase-3 fuse has blown. TRANSFER TO BYPASS DISABLED Transfer to AC bypass disabled (control and monitoring board checks for disabling by the personalization and/or an SECI input). ECO MODE ACTIVATED The unit is operating in ECO mode. It is configured for ECO mode and the static switch on the AC bypass is closed. MAINTENANCE POSITION Switch Q5N is open. CHECK THE UPS A Life Cycle Monitoring alarm has been activated: ◗ End of warranty. ◗ End of AC capacitor service life ◗ End of DC capacitor service life ◗ End of fan service lives. ◗ End of power supply board service life. ◗ End of battery service life. Galaxy 5000 can be equipped with up to two SECI cards maximum. In this case, the second card must be identified differently. On the second card, microswitch 1 on SA1 must be set to ON. 86-174010-00 B00 Operation 3 — 11 MGE Galaxy 5000 (This page left blank intentionally) 3 — 12 86-174010-00 B00 Maintenance 4.0 Scope Identifies alarm conditions, UPS isolation operation, and maintenance and safety information on servicing batteries for the MGE Galaxy 5000. 4.1 Identification of Alarms Alarm conditions are identified by LEDs (31), (32), (33) and the buzzer. Table 4-1: Identification of Alarms LED (31) LED (32) – LED (33) Buzzer Significance – Intermittent Normal AC source not available – – Intermittent UPS shut down following end of battery power – – Intermittent UPS shut down on fault requiring servicing by after-sales support Detailed information on all alarms is supplied on the display. 1 - On the screen, select the alarm for which information is required. 2 - Hold down the corresponding function key to display the possible causes of the fault and the required action. 4.2 Life Cycle Monitoring (LCM) Figure 4-1: Life Cycle Monitoring (LCM) ◗ The "Life Cycle Monitoring" (LCM) function provides UPS maintenance advice to guarantee installation availability for the user. ◗ The display gives 3 messages enabling the following to be identified: - The end of the contractual legal warranty: "End of warranty check recommended". - Regular maintenance requirements and the end of service life for consumable components: "Technical check recommended". - The end of the battery service life: "Battery check required". In addition to these messages, the minor fault LED (32) lights up and the buzzer sounds. These messages can be deleted by pressing the function key (35). This also causes LED (32), to go out, the buzzer to stop and the removal of the "Global Alarm" remote signaling. To completely disable LCM indications, use the display to enter the password required to disable the function. 86-174010-00 B00 Maintenance 4—1 MGE Galaxy 5000 4.3 UPS Isolation 4.3.1 UPS Isolation Single UPS To isolate the UPS from the electrical power source and supply the load directly by the normal or bypass AC source, follow the instructions below. Figure 4-2: UPS Isolation 1 - Press a button to exit sleep mode. 2 - Shut down the UPS by pressing the OFF button (38) for 3 seconds. The load is no longer protected by the UPS. 3 - Set bypass switch Q3BP (10) to ON. 4 - Set output switch Q5N (11) to OFF. 5 - Set the battery circuit breaker of the auxiliary cabinets to OFF. 6 - Set the input switch Q1 (8) to OFF. 7 - Set the switch Q4S (9) to OFF. 8 - Wait until the display and LEDs go off. The load is no longer protected by the UPS, but continues to be supplied with AC power. UPS maintenance or servicing can now be carried out. ATTENTION 4—2 Power is present on the power connection terminals. Maintenance 86-174010-00 B00 Installation and User Manual 4.3.2 UPS Isolation Parallel UPS Without External Bypass Cabinet Shutdown and isolation of the first UPS: Figure 4-3: Parallel UPS Configuration Without External Bypass Cabinet 1 - Check that the two UPSs are operating. 2 - Press a button to exit sleep mode. 3 - Shut down the UPS by pressing the OFF button (38) for 3 seconds. 4 - Set output switch Q5N (11) to OFF. 5 - Set the battery circuit breakers of the auxiliary cabinets to OFF. 6 - Set the input switch Q1 (8) to OFF. 7 - Set the switch Q4S (9) to OFF. 8 - Wait until the display and LEDs go off. The load is still protected by the other UPS. Maintenance or servicing can now be carried out on the UPS that has been shut down. ATTENTION Power is present on the power connection terminals. Shutdown and isolation of the second UPS: 1 2 3 4 5 6 7 8 - Press a button to exit sleep mode. Shut down the UPS by pressing the OFF button (38) for 3 seconds. Set bypass switch Q3BP (10) to ON. Set output switch Q5N (11) to OFF. Set the battery circuit breaker of the auxiliary cabinets to OFF. Set the input switch Q1 (8) to OFF. Set the switch Q4S (9) to OFF. Wait until the display and LEDs go off. The load is no longer protected by the UPS, but continues to be supplied with AC power. UPS maintenance or servicing can now be carried out. ATTENTION 86-174010-00 B00 Power is present on the power connection terminals. Maintenance 4—3 MGE Galaxy 5000 4.3.3 UPS Isolation Parallel UPS With External Bypass Cabinet Shutdown and isolation of one UPS: Figure 4-4: Parallel UPS Configuration With External Bypass Cabinet 1 - First check that the total capacity of the remaining UPSs is sufficient to supply the connected load. 2 - Press a button to exit sleep mode. 3 - Shut down the UPS by pressing the OFF button (38) for 3 seconds. 4 - Set output switch Q5N (11) to OFF. 5 - Set the battery circuit breaker of the auxiliary cabinets to OFF. 6 - Set the input switch Q1 (8) to OFF. 7 - Set the switch Q4S (9) to OFF. 8 - Wait until the display and LEDs go off. Shutdown and isolation of all the UPSs: Figure 4-5: Shutdown and Isolation of all the UPSs CB11 CB12 KS CB2 CB13 KB CB14 CB15 CB16 CB1 KA 1 - On each UPS, press a button to exit sleep mode. 2 - Shutdown each UPS by pressing their OFF buttons (38) for 3 seconds. 3 - Depress the “transfer initiate” switch on the SBC. Unlock “KS” and remove key “A”. 4 - Insert key “A” into CB1. Unlock and close CB1. 5 - Open CB2 and lock open, and remove key “B”. 6 - Insert key “B” into key interlock “KS” and turn to lock. 7 - Open output isolation CB11-16, as applicable, and open all Q5N (11) switches of each UPS. 8 - Open battery CB of each UPS. 9 - Open Q1 (8) and Q4S (9) switches of each UPS. 10 - Turn off all inputs to the UPSs. 11 - Wait until the control electronics of all UPS units have fully shutdown. The load is no longer protected by the UPSs, but continues to be supplied with AC power. UPS maintenance or servicing can now be carried out. 4—4 Maintenance 86-174010-00 B00 Installation and User Manual 4.4 Return to the Normal Operation 4.4.1 Return to Normal Single UPS Figure 4-6: Return to the Normal Operation for Single UPS 1 - Check that bypass switch Q3BP (10) is ON and that all other switches are OFF. 2 - Set switch Q4S (9) to ON. 3 - Set output switch Q5N (11) to ON. 4 - Wait until the display goes on and check that there are no faults on the static switch on the bypass line. 5 - Set bypass switch Q3BP (10) to OFF. 6 - Set the input switch Q1 (8) to ON. 7 - Set the battery circuit breaker of auxiliary cabinets to ON. The UPS starts automatically. LED (31) is ON. If LED (31) remains OFF, press the ON button (37) (the UPS is in manual start mode) and confirm if necessary by pressing the function key (35) marked . If LED (31) still remains OFF and either of LEDs (32) or (33) is ON, a fault has occurred (see Section 4.1). 86-174010-00 B00 Maintenance 4—5 MGE Galaxy 5000 4.4.2 Return to Normal Parallel UPS Without External Bypass Cabinet Restart the UPS unit for which switch Q3BP (10) is ON and the other switches are OFF. CAUTION It is imperative to restart this UPS. Otherwise, load power is lost if the other UPS is shut down. Figure 4-7: Parallel UPS Configuration Without External Bypass Cabinet 1 - Set the input switch Q4S (9) to ON. 2 - Set output switch Q5N (11) to ON. 3 - Check that the UPS is listed by the display, then confirm by pressing the function keys (35). 4 - Set bypass switch Q3BP (10) to OFF. 5 - Set the input switch Q1 (8) to ON. 6 - Set the battery circuit breaker of the auxiliary cabinets to ON. The UPS starts automatically. LED (31) is ON. The load is protected by the UPS. If LED (31) remains OFF, press the ON button (37) on each UPS (the UPS is in manual start mode) and confirm, if necessary, by pressing the function key (35) marked . If LED (31) still remains OFF and either of LEDs (32) or (33) is ON, a fault has occurred (See Section 4.1). 4—6 Maintenance 86-174010-00 B00 Installation and User Manual Restart the UPS for which all switches are set to OFF. 1 - Set the input switch Q4S (9) to ON. 2 - Set output switch Q5N (11) to ON. 3 - Check that all the UPS units present in the installation are included in the list on the display and confirm by pressing the function buttons (35). 4 - Set the input switch Q1 (8) to ON. 5 - Set the battery circuit breaker of the auxiliary cabinets to ON. The UPS restarts and LED (31) is ON. If LED (31) remains OFF, press the ON button (37) on each UPS (the UPS is in manual start mode) and confirm, if necessary, by pressing the function key (35) marked . If LED (31) still remains OFF and either of LEDs (32) or (33) is ON, a fault has occurred (see Section 4.1). 86-174010-00 B00 Maintenance 4—7 MGE Galaxy 5000 4.4.3 Return to Normal Parallel UPS With External Bypass Cabinet Figure 4-8: Parallel UPS Configuration With External Bypass Cabinet 1 2 3 4 - Check that all switches on the UPSs are set to OFF. - Apply bypass and input power to UPSs. - Set switch Q4S (9) on each UPS to ON. - Set output switch Q5N (11) on each UPS and CB11-CB16, as applicable, to ON. 5 - Check that all the UPSs present in the installation are included in the list on the display and confirm by pressing the function button (35) on each UPS. 6 - Set CB2 in the external system bypass cabinet to ON. 7 - Set CB1 in the external system bypass cabinet to OFF. 8 - Set the input switch Q1 (8) on each UPS unit to ON. 9 - Set the battery circuit breakers of the auxiliary cabinets to ON. The UPS units start automatically. LED (31) is ON. The load is protected by the UPS. If LED (31) remains OFF, press the ON button (37) on each UPS unit (the UPS is in manual start mode) and confirm, if necessary, by pressing the function key (35) marked . If LED (31) still remains OFF and either of LEDs (32) or (33) is ON, a fault has occurred (see Section 4.1). 4—8 Maintenance 86-174010-00 B00 Installation and User Manual 4.5 Servicing Batteries IMPORTANT SAFETY INSTRUCTIONS FOR SERVICING BATTERIES Servicing of batteries should be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries. When replacing batteries, use the same model and manufacturer of batteries. CAUTION Do not dispose of battery or batteries in a fire. The battery may explode. Do not open or mutilate the battery or batteries. Released electrolyte is harmful to the skin and eyes. It may be toxic. A battery can present a risk of electrical shock and high short-circuit current. The following precautions should be observed when working with batteries: 4.6 ◗ Remove watches, rings, or other metal objects. ◗ Use tools with insulated handles. ◗ Wear rubber gloves and boots. ◗ Do not lay tools or metal parts on top of batteries. ◗ Disconnect charging source prior to connecting or disconnecting battery terminals. ◗ Determine if the battery is inadvertently grounded. If inadvertently grounded, remove the source of ground. Contact with any part of a grounded battery can result in electrical shock. The likelihood of such shock will be reduced if such grounds are removed during installation and maintenance. Training Center To allow you to use Schneider Electric products effectively and carry out basic maintenance, we offer a complete range of technical training courses in English and French. 60 Hz Training Center 50 Hz Training Center Schneider Electric 1660 Scenic Avenue Costa Mesa CA 92626 USA Schneider Electric 140 avenue Jean-Kuntzmann Zirst - Montbonnot St-Martin 38334 St-Ismier Cedex FRANCE Tel. +1 714 557 1637 Fax +1 714 437 9072 technical.training@mgeups.com www.mgepowerlearning.com On-line catalog and registration. Tel. +33 (0)4 76 18 34 14 Fax +33 (0)4 76 18 45 21 training@mgeups.com www.mgepowerlearning.com On-line catalogue and registration. 86-174010-00 B00 Maintenance 4—9 MGE Galaxy 5000 (This page left blank intentionally) 4 — 10 86-174010-00 B00 Appendices A1 Electrical Characteristics Selection of Protection Devices UPS with common normal and bypass AC inputs Q3BP Q4S Upstream circuit breaker (not supplied) Main Input Q1 Normal AC Bypass AC Bypass Static Switch PFC Boost Rectifier Inverter Downstream circuit breaker (not supplied) Q5N Output Load Battery CB UPS unit with separate normal and bypass AC inputs Q3BP Upstream circuit breaker (not supplied) Upstream circuit breaker (not supplied) Bypass Input Main Input Q4S Q1 Bypass Static Switch PFC Boost Rectifier Inverter Q5N Downstream circuit breaker (not supplied) Output Load Battery CB NOTE: Interrupted Transfer to Bypass Source: If the bypass source is beyond the conditions stated below, the UPS will make an interrupted transfer (not more than 100 msec. in duration). 1. Bypass voltage greater than +15%, -15% from the UPS rated output voltage. 2. Bypass frequency greater than ±2 Hz from the UPS rated output frequency. 86-174010-00 B00 Appendices A—1 MGE Galaxy 5000 When sizing the upstream circuit breakers, the parameters presented below must be taken into account: Time/current curves for UPS input and output fuses: t (s) 104 103 102 10 40-80 kVA: 160A 1 100-130 kVA: 315A 10-1 10-2 10-3 10-4 I (A) 10 102 103 104 UPS short-circuit current with inverter coupled and By-pass AC source out of tolerances Sn 40KVA 50KVA 60KVA 80KVA 100KVA 130KVA In 48 A 60 A 72 A 96 A 120 A 156 A Limitation 230 A 230 A 230 A 260 A 435 A 435 A Line Current Values Rated power of each UPS unit A—2 Continuous input current at V=480V Input current at V=480V overload = 1.25 In limited to 10 min. 40KVA 48 A 60 A 72 A 160 A 50KVA 60 A 75 A 90 A 160 A 60KVA 72 A 90 A 108 A 160 A 80KVA 96 A 120 A 144 A 160 A 100KVA 120 A 150 A 180 A 315 A 130KVA 156 A 195 A 234 A 315 A Appendices Input current at V=480V overload = 1.5 In limited to 1 min. Input/output fuse ratings 86-174010-00 B00 Installation and User Manual Input/Output Characteristics Normal AC source/Bypass AC source UPS Uin 432 to 528 V Input voltage range permitted by the standard according to the curve below 310 to 528 V Fin 45 to 65 Hz Power supplied as a function of input voltage 310V 432V 528V 86-174010-00 B00 Permissible UPS overloads as a function of time V Appendices A—3 MGE Galaxy 5000 General characteristics of Galaxy 5000 UPSs UPS power in KVA 40 50 60 80 100 130 Normal AC input Number of conductors 3 phases + ground Reference voltage at Pn 432 V to 528 V Reference frequency 45 Hz to 65 Hz THDI Typically 3% at Pn Power factor >0.99 Bypass AC input Number of conductors 3 phases + ground Reference voltage at Pn 432 V to 528 V Reference frequency 45 Hz to 65 Hz Load output Number of conductors 3 phases Set phase-to-phase voltages 480 V Voltage variation ± 1% Adjustable frequencies and tolerance (on battery power) 60 Hz ± 0.1 Hz Voltage variation for 0 to 100% load step change ± 1% Permissible overloads 150% for 1 minute, 125% for 10 minutes THDU Ph-to-Ph and Ph-to-N for nonlinear load < 2% Ph-to-Ph Battery Standard battery technology Sealed lead-acid battery (gas-recombination) Inverter Active power (kW) 36 45 54 72 90 117 Heat losses in kW Heat Heat losses in BTUs 2.71 9250 3.39 11560 4.06 13870 5.42 18500 5.74 19610 7.47 25490 Storage temperature range -13°F to 103°F (-25°C to +45°C) Relative humidity 20% to 95% Maximum operating altitude without derating 3281 ft (< 1000 m) Operating temperature range 32°F to 104°F (0°C to 40°C) at Pn INFORMATION The operating temperature range is 32°F to 104°F (0°C to +40°C); for overload conditions is 32°F to 86°F (0°C to +30°C). Optimum operating range is within 68°F to 77°F (20°C to +25°C). Battery backup time is adversely affected by high and low temperatures. It is significantly reduced at temperatures under 50°F (10°C). Above 77°F (25°C), battery service life is cut in half every 18°F (10°C). Above 104°F (40°C), battery manufacturers no longer guarantee operation due to the risk of thermal runaway. A—4 Appendices 86-174010-00 B00 Installation and User Manual A2 Maximum Allowable Power for Parallel UPS Units Without external system bypass cabinet: = 1 x Pn + = 1 x Pn With external system bypass cabinet: + = 2 x Pn + + = 3 x Pn + + + + + + + + + + + = 4 x Pn = 5 x Pn + = 5 x Pn INFORMATION The maximum allowable power for 6 parallel UPSs is limited to 5 x Pn for 40-80kVA UPSs. For 100-130kVA UPSs, the maximum is up to 4 x Pn. 86-174010-00 B00 Appendices A—5 MGE -Galaxy 5000 A3 UPS Cabinet Major Internal Components IGBT charger + neutral leg IGBT PFC IGBT inverter EXTN PCA DC capacitors Normal AC and battery SS PCA Output fuse Bypass AC and inverter SS PCA DALIN PCA Output capacitors ALIN PCA Input fuse Input capacitors Inductor and SS fans Output-filter PCA ETONUS PCA Input-filter PCA A—6 Appendices 86-174010-00 B00 Installation and User Manual A4 Available Options NMC (Network Management Card) option This option is a communications card for supervision and protection of a three-phase device. Each UPS can be equipped with a maximum of four NMC communications cards. Optional communications card with additional power relay The UPS is already equipped with a relay communications card. But it is possible, with this option, to add another card with programmable power-relay functions. Optional serial communications card This option is an RS232 or RS485 serial communications card operating under the JBUS protocol. AS4I option This option consists of a low-power relay card for shut-off and scheduling functions. Multislot option This option consists of communications cards to concentrate the communication of two parallel-connected UPSs. External synchronization module option With this option, a SYNIN communications card and two circuit breakers are added to each UPS unit. The external synchronization module issues a reference frequency used to synchronize the UPS units. CAUTION 86-174010-00 B00 Check the different input/output signal levels (LV, ELV, SELV) on the optional communication cards (4) and use appropriate wiring. Appendices A—7 MGE Galaxy 5000 A5 Environment Schneider Electric has implemented an environmental-protection policy. Products are developed according to an eco-design approach. Substances This product does not contain CFCs, HCFCs or asbestos. Packing To improve waste treatment and facilitate recycling, separate the various packing components. The cardboard we use includes over 50% of recycled cardboard. Sacks and bags are made of polyethylene. 01 Packing materials are recyclable and bear the appropriate identification symbol . PET Material Abbreviation Symbol Number 01 PET Polyethylene terephthalate PET 01 High-density polyethylene HDPE 02 Polyvinyl chloride PVC 03 Low-density polyethylene LDPE 04 Polypropylene PP 05 Polystyrene PS 06 Follow all local regulations for the disposal of packing materials. End of life Schneider Electric will process products at the end of their service life in compliance with local regulations. Schneider Electric works with companies in charge of collecting and eliminating our products at the end of their service life. Product The product is made up of recyclable materials. Dismantling and destruction must take place in compliance with all local regulations concerning waste. At the end of its service life, the product must be transported to a processing center for electrical and electronic waste. Make the product unusable by cutting the internal supply cables. Battery The product contains lead-acid batteries that must be processed according to applicable local regulations concerning batteries. The battery may be removed to comply with regulations and in view of correct disposal. The "Material Safety Data Sheets" (MSDS) for the batteries are available on our web site*. (*) For more information or to contact the Product Environmental manager, use the "Environmental Form" on the site: www.mgeups.com -> About us -> Environment. A—8 Appendices 86-174010-00 B00 Installation and User Manual MGE Warranty & Proprietary Rights Statement for Three Phase Products (Applicable within the United States, Canada and Mexico) MGE Standard Three Phase Warranty MGE UPS SYSTEMS, INC. (“MGE”) warrants three phase products it manufactures to be free from defects in materials and workmanship for a period of three hundred sixty five (365) days counting from the date of purchase by or for the first end user (“Purchaser”), or, if applicable, the date of MGE’s completion of initial startup of the subject product, provided however said warranty shall not exceed eighteen (18) months from the date of delivery of the subject product to Purchaser (the “Warranty Period”). MGE’s liability hereunder is limited to replacing or repairing at MGE’s factory or on the job site, at MGE’s option, any part or parts that are defective and reported to MGE during the Warranty Period. MGE shall have the sole right to determine if the parts are to be repaired at the job site or whether they are to be returned to the factory for repair or replacement. All items returned to MGE for repair or replacement must be sent freight prepaid to its factory. Purchaser must obtain MGE’s Return Goods Authorization (“RGA”) prior to returning items. The conditions stated herein must be met for MGE’s warranty to be valid. MGE will not be liable for any damage done by unauthorized repair work, unauthorized replacement parts, from any misapplication of the subject product, for damage due to accident, abuse, or act of God (such as earthquake, flood, inclement weather, rain or fire), or relating to Purchaser’s failure to follow proper environmental conditions for the product. In no event shall MGE be liable for loss, damage, or expense directly or indirectly arising from the use of or any defects in the subject product, or from any other cause, except as expressly stated in this warranty. EXCEPT AS EXPRESSLY STATED IN THIS WARRANTY, MGE UPS SYSTEMS, INC. MAKES NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY AS TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE OR NON-INFRINGEMENT. MGE is not liable for and Purchaser waives any right of action it has or may have against MGE for any consequential or special damages arising out of any breach of warranty, and for any damages Purchaser may claim for damage to any property or injury or death to any person arising out of its purchase or the use, operation or maintenance of the subject product. The warranty stated herein includes parts and labor; however, MGE will not be liable for any labor subcontracted or performed by Purchaser for preparation of the warranted item for return to MGE’s factory or for preparation work for field repair or replacement, and MGE will not be responsible to pay any invoice therefore. This warranty shall be exclusive of any and all other warranties express or implied and may be modified only by a writing signed by an authorized officer of MGE UPS SYSTEMS, INC. This warranty shall extend to the Purchaser but to no one else. Accessories supplied by MGE, but manufactured by others, carry any warranty the manufacturers have made to MGE, and which can be passed on to Purchaser. MGE UPS SYSTEMS, INC. makes no warranty with respect to whether the products sold hereunder infringe any patent, U.S. or foreign, and Purchaser represents that any specially ordered products do not infringe any patent. Purchaser agrees to indemnify and hold MGE UPS SYSTEMS, INC. harmless from any liability by virtue of any patent claims where Purchaser has ordered a product conforming to Purchaser’s specifications, or conforming to Purchaser’s specific design. Purchaser has not relied and shall not rely on any oral representation regarding any products sold hereunder and any oral representation shall not bind MGE UPS SYSTEMS, INC. and shall not be part of any warranty. There are no warranties which extend beyond the description on the face hereof. In no event shall MGE UPS SYSTEMS, INC. be responsible for consequential damages or for any other damages except as expressly stated herein. Proprietary Rights Statement The information in this manual is the property of MGE UPS SYSTEMS, INC., and represents a proprietary article in which MGE UPS SYSTEMS, INC. retains any and all intellectual property rights, including exclusive rights of use and/or manufacture and/or sale. Possession of this information does not convey any permission to reproduce, print, manufacture or have made the article or articles shown herein. Such permission may be granted only by specific written authorization signed by an authorized officer of MGE UPS SYSTEMS, INC. IBM, PC-AT, ES/9000, and AS/400 are trademarks of International Business Machines Corporation. MGE and MGE UPS SYSTEMS are trademarks of MGE UPS SYSTEMS, INC. Other trademarks that may be used herein are owned by their respective companies and are referred to in an editorial fashion only. For Three Phase Warranty outside of the United States, Canada and Mexico, refer to Three Phase International Warranty. January 2005 Rev C00 86-174010-00 B00 Warranty, Registration, & Customer Support W—1 MGE Galaxy 5000 Warranty and Product Registration Thank you for choosing MGE UPS SYSTEMS, INC. for your power protection, distribution, and quality requirements. We are pleased to have you join our increasing family of users. In order to maximize the value you receive from this product, and to ensure that you are kept informed of product or software updates, we recommend that you take a few minutes to register your new purchase. You may register online at the URL noted below. Should you not have Internet access, you may mail or fax this form back (attn: Warranty Registration) as indicated at the bottom of the page. Register your product at: http://www.mgeups.com/email/warranty/menu.htm Please be prepared with the following information to register and validate your product’s warranty, keep informed on software and product updates, and register your extension "Warranty+" if purchased with the product. User Information Last name ____________________________________________________________________ First name ____________________________________________________________________ Company name ____________________________________________________________________ Address ____________________________________________________________________ Zip code ____________________________________________________________________ City ____________________________________________________________________ State/Province ____________________________________________________________________ Country ____________________________________________________________________ Tel ____________________________________________________________________ Fax ____________________________________________________________________ Email ____________________________________________________________________ Product Information Model ____________________________________________________________________ Serial Number ____________________________________________________________________ Date of purchase ____________________________________________________________________ Warranty Extension (Warranty+) I have purchased a warranty extension (Warranty+) Reference: ________________________Contract Number: __________________________________ Thank you from all of us at MGE. MGE UPS SYSTEMS, INC., 1660 Scenic Avenue, Costa Mesa, CA 92626, USA Tel: 714-557-1636 Fax: 714-557-9788 41-000154-53 Rev B02 8/2005 W—2 Warranty, Registration, & Customer Support 86-174010-00 B00 Installation and User Manual Service Solutions Team — Three Phase Products Technical Support and Product Services ? Technical questions? If you encounter a problem while following the instructions in this manual, or have questions about the operation, repair, or servicing of your equipment, please direct calls to the Service Solutions Team or visit our web site www.mgeups.com for complete service information. To insure that your questions are correctly answered, please obtain the serial number of the unit and include them in any discussions or correspondence. Serial number: ________________________________________________________________________________ Who To Contact Service Solutions Team: 1-800-438-7373 (Hours: 24/7) Customer FAQ or International calls: 1-714-557-1636 Commitment: We are committed to providing easy access to factory trained experts that will provide responses to any questions that you might have. Scheduling Field Service Engineer Support Scheduling of the Schneider Electric Field Service Engineers typically should be done 7 to 10 days before they are required on-site. If the startup of the product is critical to maintaining your schedule, please call the Schneider Electric toll free telephone number at 1-800-438-7373 for assistance. Return Policy for Repair of Three Phase Products (RGA) Should you require factory service for your equipment, contact Schneider Electric Service Solutions Team and obtain a Return Goods Authorization (RGA) prior to shipping your unit. Never ship equipment to Schneider Electric without first obtaining an RGA number. Date: ________________________________________________________________________________ RGA Number: ________________________________________________________________________________ Contact Name: ________________________________________________________________________________ Website service address http://www.mgeups.com/products/pdt120/service/ccc.htm 86-174010-00 B00 Warranty, Registration, & Customer Support S—1 MGE Galaxy 5000 (This page left blank intentionally) S—2 86-174010-00 B00 Glossary Term used Definition/Meaning @ At. / And/or. +/- Plus or Minus. ≤ Equal to or less than. # Number. °C Degree Celsius. °F Degree Fahrenheit. Ø Phase angle. Ω Ohm; unit of resistance. ® Trade Mark. AC or ac Alternating current, also implies root-mean-square (rms). Ambient Temp. Temperature of surrounding air. Ambient noise Acoustical noise of surrounding environment. ANSI American National Standard Institute. AWG American Wire Gauge. A standard unit for measuring wire cross-sectional area. BTU or Btu British thermal unit. Defined as the amount of heat required to raise the temperature of one pound of water by 1°F. BYPASS mode Load is powered by the bypass input line through the static switch. CB Circuit breaker. DC or dc Direct current, or voltage. Earth ground A ground circuit that has contact with the earth. GND Electrical ground. Hz Hertz, frequency measurement unit, 1Hz is one cycle per second. I Current. In Nominal current. IEC International Electrotechnical Commission. 86-174010-00 B00 Glossary G—1 MGE Galaxy 5000 G—2 IEEE Institute of Electrical and Electronic Engineers. Inverter An electrical circuit that generates an AC voltage source from a DC voltage source. IGBT Insulated gate bipolar transistors. I/O Input/Output. KVA KiloVolt-Ampere; is equal to 1000 Volt-Ampere. KW True power. Kilo-Watt = 1000 Watt. L Line. LCD Liquid-Crystal Display. LED Light Emitting Diode. Mains or Mains 1 Main AC input source. Mains 2 Bypass AC input source. mA Milliampere. MAX. Maximum. N Neutral. NC Normally closed. NO Normally open. NEC National Electrical Code. NFPA National Fire Protection Association. PN Part number. Pn Nominal power. On-line mode Inverter output power is the primary energy source to load. OSHA Occupational Safety and Health Agency. PCA Printed circuit assembly. PCB Printed circuit board. PWM Pulse Width Modulation. Q1 UPS input isolation switch. Q3BP UPS maintenance bypass switch. Q4S UPS bypass switch. Q5N UPS output switch. Remote Emergency Power Off A switch used for shutting down electrical equipment from a location away from the equipment. REPO Remote Emergency Power Off. Glossary 86-174010-00 B00 SCR Silicon controlled rectifier. Static Transfer A solid state switching mechanism electronically controlled to pass AC power directly from the utility to an output load. Test connector DB-9 type connector on the LCD panel allowing MGE UPS SYSTEMS Customer Support Service technician to access programmable and diagnostic features of the system. UL Underwriter’s Laboratories, Inc. V Volts VA Volt-amperes, unit for apparent power measurement, equal V x I. VAC Voltage of AC type. Vdc Voltage of DC type. 86-174010-00 B00 Glossary G—3 MGE Galaxy 5000 G—4 86-174010-00 B00 Reorder Form 1660 Scenic Avenue Costa Mesa, CA 92626 Use this form NAME to report any errors, omissions, or other problems you have experienced, or to order additional hardcopies of this document. A free copy of this document may be downloaded from the proprietary Web site. Please contact your APC by Schneider Electric Sales Representative for assistance. _____________________________________________________________________________________ COMPANY ___________________________________________________________________________________ STREET ADDRESS ____________________________________________________________________________ CITY ________________________________________ STATE __________________ ZIP ___________________ I would like to order______ (quantity @ $75.00 each) additional copies of the: MGE Galaxy 5000 40 – 130KVA Installation and User Manual 86-174010-00 B00 I would like to report the following problems with this document: 86-174010-00 B00 Reorder R—1 Contact Information Schneider Electric 1660 Scenic Avenue, Costa Mesa, California 92626 Tel: (714) 557-1636 (800) 523-0142 Fax: (714) 557-9788 email: info@mgeups.com w w w. m g e u p s . c o m
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