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MGE UPS Systems 40-75KVA manual

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Table of contents for the manual

  • Page 1

    Gala x y 40 0 0 40 – 75KV A Uninterruptible Power Systems Installation and User Manual Standard Features ◗ Emergency Power Of f button with safety cover . ◗ Interactive Display Panel. www .mgeups.com[...]

  • Page 2

    [...]

  • Page 3

    Installation and User Manual i G a l axy 4000 40 – 75KV A Uninterruptible Power Systems Installation and User Manual Revision History Galaxy 4000 Installation and User Manual 86-173010-00 Revision: A00 ECN#: 004540 12/2005 Copyright © 2005 MGE UPS SYSTEMS, INC. All rights reserved. Printed in U.S.A. MGE UPS SYSTEMS, INC. 1660 Scenic A venue Cost[...]

  • Page 4

    Galaxy 4000 Important Safety Instructions ii 86-173010-00 A00 IMPORT ANT SAFETY INSTRUCTIONS SA VE THESE INSTRUCTIONS – This manual contains important instructions for Galaxy 4000 that must be followed during operation and maintenance of the equipment. W ARNING Opening enclosures expose hazardous voltages. Always refer service to qualified person[...]

  • Page 5

    Installation and User Manual iii 86-173010-00 A00 W ARNING HIGH LEAKAGE CURRENT . Earth connection essential before connecting supply . A TTENTION COURANT DE FUITE ELEVE. Raccordement a la terre indispensable avant le raccordement au reseau. W ARNUNG! Hoher Ableitstrom V or Inbetriebnahme Schutzleiterverbindung herstellen. Certification Standards ?[...]

  • Page 6

    Galaxy 4000 iv 86-173010-00 A00[...]

  • Page 7

    Contents Contents I 86-173010-00 A00 section description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i IMPORT ANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . ii Certification Stand[...]

  • Page 8

    Galaxy 4000 Contents II 86-173010-00 A00 Section 2 Setup and Installation (continued) section description page 2.4 Relay Communication Card Contacts . . . . . . . . . . . . . . . . . . . . .2 — 5 2.4.1 Relay Communication Card Connections . . . . . . . . . . . . . . . . . .2 — 6 2.4.2 Characteristics of the Output Contacts . . . . . . . . . . .[...]

  • Page 9

    Installation and User Manual III 86-173010-00 A00 Section 6 W arranty , Registration & Customer Support description page MGE W arranty & Proprietary Rights for Three Phase Products . . . . . . . . . . . . . .6 – 1 MGE Standard Three Phase W arranty Proprietary Rights Statement W arranty and Product Registration . . . . . . . . . . . . . .[...]

  • Page 10

    Galaxy 4000 IV 86-173010-00 A00 Figures figure description page 1-1 Galaxy 4000 UPS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 1 1-2 Galaxy 4000 UPS System - Single Line Diagram . . . . . . . . . . . . . . . . . .1 — 2 1-3 Cabinet Placement, Airflow and Recommended Clearances . . . . . . . . .1 — 4 1-4 C[...]

  • Page 11

    Installation and User Manual V 86-173010-00 A00 Symbol Usage This manual uses five icon symbols with text to convey important information and tips. W ARNING Indicates information provided to protect the user and service personnel against safety hazards and/or possible equipment damage. CAUTION Indicates information provided to protect the user and [...]

  • Page 12

    Galaxy 4000 VI 86-173010-00 A00[...]

  • Page 13

    Introduction 1.0 Scope Provides a general description of the Galaxy 4000 systems intended use, major components, mechanical and environmental specifications. 1.1 General Description The Galaxy 4000 is the world’s first data center grade Uninterruptible Power Supply system designed specifically for mid-range enterprise level applications. The Gala[...]

  • Page 14

    Galaxy 4000 1 — 2 86-173010-00 A00 1.2 Major Components Rectifier Converts AC input voltage to DC voltage. The rectifier uses IGBT (Insulated G a t e Bipolar T ransistor) power transistors and a Pulse Width Modulated (PWM) technique to provide input power factor correction and to minimize any harmonic reflected onto the input power lines. Inverte[...]

  • Page 15

    Installation and User Manual 1 — 3 86-173010-00 A00 1.4 Galaxy 4000 Standard Cabinets The Galaxy 4000 individual cabinet dimensions are: ◗ UPS cabinet: 72.1in (1831mm) H x 33.5in (851mm) W x 35.6in (904mm) D. ◗ External battery cabinet: 72.1in (1831mm) H x 26.5in (673mm) W x 33.5in (851mm) D OR – ◗ External battery cabinet: 72.1in (1831mm[...]

  • Page 16

    Galaxy 4000 1 — 4 86-173010-00 A00 Figure 1-3: Cabinet Placement, Airflow and Recommended Clearances. T able 1-1: Heat Rejection Data. NOTE: T o provide for adequate ventilation, a minimum of 36 inches clearance should be maintained above the top of the Galaxy 4000 cabinet. 1.8 Cabinet Clearances The Galaxy 4000 UPS cabinet top clearance of 36 in[...]

  • Page 17

    Installation and User Manual 1 — 5 86-173010-00 A00 Figure 1-4: Configuration for Bottom Entry . 1.10 Conduit Plate Locations for T op Entry The UPS cabinet for the Galaxy 4000 is capable of accepting power input and output cables through a top entry . The conduit plate on the top of the cabinet provides provisions for knockouts for conduit and i[...]

  • Page 18

    1.1 1 Preparation for Storage If the equipment is to be stored prior to installation, it should be stored in a cool, dry , well-ventilated location that is protected against rain, splashing water , chemical agents, etc. The equipment should be covered with a tarpaulin or plastic wrapper to protect it against dust, dirt, paint, or other foreign mate[...]

  • Page 19

    Setup and Installation 2.0 Scope Guides the user through tools and equipment required for unpacking and performing connections required for initial installation. Included are the electrical specifications, environmental recommendations and connection details. 2.1 Installation Steps MGE recommends correct installation verification and unit startup t[...]

  • Page 20

    2.2.2 Electrical Specifications T able 2-1: Electrical Specifications for the Galaxy 4000. NOTE: Interrupted T ransfer 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 vol[...]

  • Page 21

    Installation and User Manual 2.3.1 UPS Connections Electrical connections and cabinet interconnection will vary depending upon the configuration and options selected with your Galaxy 4000 UPS system. Refer to the installation drawings supplied with your equipment. Connecting Power Cable Connections: T o access the connection terminal blocks, open t[...]

  • Page 22

    Figure 2-1: T ypical Power Connections. 2.3.5 Battery Connections The connections to be made are the positive, negative, and ground cables from the battery cabinet to the UPS. The battery cables are terminated at the positive, negative, and ground busbars. See Figure 2-1. 2.3.6 Remote Emergency Power Off Connections The control connections are avai[...]

  • Page 23

    Installation and User Manual 2.3.8 External Maintenance Bypass Control Connections (optional) The external maintenance bypass (MBP) control connections are made with the MBP control cable from the external MBP to the UPS terminal block TB4-9 to TB4-10. See Figure 2-1. ELECTRICAL These wires carry HIGH VOL T AGE 120V AC. 2.3.9 Accessories Outlets Th[...]

  • Page 24

    CAUTION Isolate and lock-out all power sources for this card before making connections. Never connect ELSV (extra low safety voltage) and non-ELSV circuits to the different outputs of the same card. 2.4.1 Relay Communication Card Connections Refer to Figure 2-3 for relay communication card, cover and hardware details. See Figure 4-1 for communicati[...]

  • Page 25

    Installation and User Manual 2.4.2 Characteristics of the Output Contacts Relay T ype Normally Open. Max. voltage 250V AC, 30VDC. Max. current 2 A. Cable 4 x 0.93 mm, 6.6 ±0.3 mm. 2.4.3 Characteristics of the Input Contacts Switched voltage 5VDC. Consumption 10 mA. Cable 4 x 0.34 mm, 5 ±0.5 mm. Output alarms are always activated on the conditions[...]

  • Page 26

    (This page left blank intentionally) Galaxy 4000 2 — 8 86-173010-00 A00[...]

  • Page 27

    Display Panel 3.0 Scope Describes the operator display panel, interface screens, keys, and mimic diagram. 3.1 Operator Interface Keys and Indicators The operator interface screens contained on the Galaxy 4000 display panel provide an easy to use method to access and control the Galaxy 4000 features. The Soft Keys are programmed to allow you to scro[...]

  • Page 28

    3.1.1 LED Indicator Functions The three LED indicators (see Figure 3-1) provide the following information as shown in T able 3-1: T able 3-1: Three LED Indicators. IMPORT ANT When the Red LED is ON, the load is not protected. Green LED Orange LED Red LED ON Load on UPS ON Minor fault such as: ON Major fault such as: Flashing Load is on battery powe[...]

  • Page 29

    Installation and User Manual 3.2 Display Menu Structure This display menu structure is provided below for the Galaxy 4000 system in Figure 3-4. Figure 3-4: UPS Display Menu Structure. UPS MAIN MENU MEASUREMENTS MIMIC DIAGRAM S ST A TUS SETTINGS COMMANDS ST ARTUP PROCEDURE ST ARTUP PROCEDURE ST ARTUP UPS SHUTDOWN TRANSFER TO MANUAL BYP ASS COMMANDS [...]

  • Page 30

    3.3 Main Menu Screen The Main Menu screen allows the operator to access many displays to monitor the operating performance of Galaxy 4000, obtain alarm information, change operational settings as well as issue software based commands. The Main Menu conveniently displays groups of items according to function. By using one of the first two soft keys [...]

  • Page 31

    Installation and User Manual ◗ Battery temperature does not stay within ±10°C from the starting temperature point. ◗ Communication fault. ◗ Input current 0 amps or > 100% load current. ◗ Rectifier or inverter overload. ◗ Mains 1 or Mains 2 failure. In case the BPI cannot be done, a simplified autonometer will be used. This autonomete[...]

  • Page 32

    3.4.4 V oltage Measurements Screen The V oltage Measurements screen displays the voltage presently on any one of the input phases (AC N and AC BP) and each phase of the load, as well as the differential voltage as measured between any two phases of the inputs and the load. See Figure 3-9. 3.4.5 Frequency Measurements Screen The Frequency Measuremen[...]

  • Page 33

    Installation and User Manual 3.5 Mimic Diagrams The Mimic Diagrams screen is unlike any of the other screens we have examined. This screen is actually two screens in one. The top half of the screen contains a single line representation of the current operating condition of the Galaxy 4000 unit. Through the use of color changes in the screen, it wil[...]

  • Page 34

    3.7 Settings Screen The Settings screen provides a variety of options for the operation of the Galaxy 4000 system. See Figure 3-14. The Settings screen provides the following: Language With an opportunity for the Galaxy 4000 unit to be located in any country , it is possible to select the language of preference from several options. Date/Time Can b[...]

  • Page 35

    Installation and User Manual 3.8 Commands Screen The Commands screen presents options that impact the operation of the UPS system. Extreme care should be exercised when selecting ANY of these menu options. See Figure 3-15. The Commands screen provides the following: Fault reset Allows the user to reset a fault condition. Battery equalization T urns[...]

  • Page 36

    (This page left blank intentionally) Galaxy 4000 Display Panel 3 — 10 86-173010-00 A00[...]

  • Page 37

    Operation 4.0 Scope Provides startup, shutdown, and normal operation of the Galaxy 4000 UPS. Included are pre and post startup safety checklists. The Galaxy 4000 system is simple to operate and yet provides a wealth of continuous monitoring and diagnostic features to ensure the proper operation. Operators gain access to information in the Galaxy 40[...]

  • Page 38

    Figure 4-1: Galaxy 4000 Device Locations. Galaxy 4000 Operation 4 — 2 86-173010-00 A00 COMMUNICA TION CARD PORTS Q1 INPUT SWITCH Q3BP MAINTENANCE BYP ASS SWITCH (optional) EMERGENCY POWER OFF Q4S BYP ASS SWITCH Q5N OUTPUT CIRCUIT BREAKER CUSTOMER A C CESS QU ALIFIED TECHNICIAN AC CESS ONL Y ELECTRICAL INTERL OCK (optional) AC CESSORIES OUTLETS[...]

  • Page 39

    Installation and User Manual 4.2 Normal Startup Procedure With all of the initial safety check lists verified, the Galaxy 4000 UPS system can now be powered. The following startup procedure should be performed during the initial startup following installation and commis- sioning of the system (typically by a MGE Field Engineer), and this sequence s[...]

  • Page 40

    4.3 Post Startup Safety Check List After initial startup of the system, normal operation should be tested. At the minimum, the following tests should be performed as applicable to your installation. ◗ Emergency Power Off (EPO) test. ◗ Remote Emergency Power Off (REPO) test (if applicable). ◗ Inverter start and stop. ◗ Battery transfer test.[...]

  • Page 41

    Maintenance 5.0 Scope Describes maintenance and safety information on servicing batteries for the Galaxy 4000. 5.1 Servicing Batteries IMPORT ANT SAFETY INSTRUCTIONS FOR SER VICING BA TTERIES Servicing of batteries should be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel awa[...]

  • Page 42

    (This page left blank intentionally) Galaxy 4000 5 — 2 86-173010-00 A00[...]

  • Page 43

    Installation and User Manual W arranty , Registration, & Customer Support 6 — 1 86-173010-00 A00 MGE W arranty & Proprietary Rights Statement for Three Phase Products (Applicable within the United States, Canada and Mexico) MGE Standard Three Phase W arranty MGE UPS SYSTEMS, INC. (“MGE”) warrants three phase products it manufactures t[...]

  • Page 44

    Galaxy 4000 W arranty , Registration, & Customer Support 6 — 2 86-173010-00 A00 W arranty 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 [...]

  • Page 45

    Installation and User Manual W arranty , Registration, & Customer Support 6 — 3 86-173010-00 A00 MGE Customer Care Center – Three Phase Products T echnical Support and Product Services T echnical questions? If you encounter a problem while following the instructions in this manual, or have questions about the operation, repair , or servicin[...]

  • Page 46

    Galaxy 4000 Caution: Record All Serial Numbers! 6 — 4 86-173010-00 A00 CAUTION: Record All Serial Numbers! RECORD ALL SERIAL NUMBERS FOR THE GALAXY 4000 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 NUMB[...]

  • Page 47

    Glossary T erm 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. ® T rade Mark. 2nd Second. ABC Normal sequence of phases in three phase power . AC or ac Alternating current, also implies root-mean-square (rms).[...]

  • Page 48

    dB Decibels. dBA Decibel Adjusted. DC or dc Direct current, or voltage. Digital Meter The LCD display on the front panel of inverter system. Earth ground A ground circuit that has contact with the earth. Electrician Refers to an installation electrician qualified to install high-energy electrical components in accordance with national and local cod[...]

  • Page 49

    Glossary G — 3 86-173010-00 A00 Module Refers to individual power inverter module. N Neutral. NC Normally closed. NO Normally open. NEC National Electrical Code. NFP A National Fire Protection Association. PN Part number . On-line mode Inverter output power is the primary energy source to load. OSHA Occupational Safety and Health Agency . PCA Pri[...]

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    Galaxy 4000 G — 4 86-173010-00 A00 (This page left blank intentionally)[...]

  • Page 51

    Reorder Form 1660 Scenic A venue Costa Mesa, CA 92626 Use this form 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 MGE Rep Web site. Please contact your MGE UPS SYSTEMS, INC. Representative for assistance[...]

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    www .mgeups.com 1660 Scenic Avenue, Costa Mesa, California 92626 • (714) 557-1636 Contact MGE United States MGE UPS SYSTEMS 1660 Scenic Ave. Costa Mesa, CA 92626 T el: (714) 557-1636 Fax: (714) 557-9788 email: info@mgeups.com www: mgeups.com Canada MGE UPS SYSTEMS #9, 2789 Thamesgate Drive Mississauga, ON L4T 4E8 T el: (905) 672-0990 (877) 672-09[...]