MGE UPS Systems 40-75KVA Power Supply User Manual
Contents
1. AIR EXHAUST DO NOT BLOCK 16 x 1 125 KQ 34 857 26W BATTERY 33W BATTERY DISTRIBUITION UPS 86 173010 00 A00 Introduction 1 5 4000 1 11 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 materials See the section of this manual titled Environmental Recommendations for recommended storage environmental conditions NOTE Batteries should be stored no longer than three 3 months at 25 C 77 F or lower prior to recharging Exceeding the recommended ambient storage temperature will reduce battery back up time and may adversely affect battery life 1 6 Introduction 86 173010 00 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 to be performed by a qualified MGE Field Service Engineer A CAUTION Scheduling of2. 4000 VI 86 173010 00 A00 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 Galaxy 4000 family consists of units available in power ratings from 40 75KVA and are optimized for compatibility with nonlinear computer type loads By incorporating the Ultra High Availability Topology UHAT the Galaxy 4000 family of UPS systems are designed to provide the optimal level of reliability and to react to any power disturbance in an inherently safe way to protect the critical load The Galaxy 4000 all in one design incorporates every feature into one compact cabinet including a graphical user interface power factor corrected input and communication cards that support network based power management The Galaxy 4000 UPS and its auxiliary equipment are designed for installation in a room where humidity and temperature can be controlled The Galaxy 4000 UPS and auxiliary equipment is listed for safety by Underwriters Laboratories Inc UL under UL Standard 1778 Uninterruptible Power Systems and also listed by Underwriters Laboratories CUL under Canadian Standards Association CSA standard C22 107 Figure 1 1 Galaxy 4000 UPS System
3. 2 3 2 3 4 AC Output Connections 2 3 2 3 5 Battery Connections 2 4 2 3 6 Remote Emergency Power Off Connections 2 4 2 3 7 Battery Control Connections 2 4 2 3 8 External Maintenance Bypass Control Connections optional 2 5 2 3 9 Accessories Outlets 2 5 86 173010 00 Contents 4000 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 2 7 2 4 3 Characteristics of the Input Contacts 2 7 Section 3 Display Panel 3 0 CODO ann ee nn srta a bees a 3 1 3 1 Operator Interface Keys and Indicators 3 1 3 1 1 LED Indicator Functions 3 2 3 1 2 Screen Saver 3 2 3 1 3 Operational Summary Screen 2 3 2 Display Menu Structure 3 3 20 Main Menu Screen 3 4 3 4 Measurements 3 4 3 4 1 Battery Measurements Screen 3 4 3 4 2 Power Measurements S
4. 86 173010 00 00 Introduction 1 1 4000 1 2 1 3 Major Components Rectifier Converts AC input voltage to DC voltage The rectifier uses IGBT Insulated Gate Bipolar Transistor 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 Inverter Converts DC voltage from the rectifier or from the batteries into AC output voltage to maintain the attached load This module uses the IGBT technology to provide digital power quality Static Switch Automatically supplies the attached load from the bypass source when the inverter is off Battery System Stores energy for utilization by the inverter and attached load in the event that utility AC power is lost or is of unacceptable quality Single Line Diagram During normal operation the utility power Main input is supplied to the UPS rectifier The rectifier converts the AC power to DC that is supplied to the inverter The inverter converts the DC voltage to three phase regulated AC voltage which is supplied to the attached load During power failure conditions the inverter is supplied by the stored energy in the battery system and the load is powered continuously with no interruption The Galaxy 4000 UPS is designed for internal operation of 208VAC input and output External batteries and an output distribution panel may be contained in auxiliary cabinets sim
5. ADDITIONAL SERIAL NUMBERS NOTE 6 4 Caution Record All Serial Numbers 86 173010 00 A00 Term used lA C E Q 2nd ABC AC or ac Ambient Temp Ambient noise ANSI AWG Breaker BTU or Btu BYPASS mode Carrier CB CB1 Conduit Current rating 86 173010 00 A00 Glossary Definition Meaning At And or Plus or Minus Equal to or less than Number Degree Celsius Degree Fahrenheit Phase angle Ohm unit of resistance Trade Mark Second Normal sequence of phases in three phase power Alternating current also implies root mean square rms Temperature of surrounding air Acoustical noise of surrounding environment American National Standard Institute American Wire Gauge A standard unit for measuring wire cross sectional area Electrical circuit interrupter British thermal unit Defined as the amount of heat required to raise the temperature of one pound of water by 1 F Load is powered by the bypass input line through the static switch The company or individual responsible for delivering goods from one location to another Circuit breaker Battery disconnect circuit breaker A flexible or rigid tube enclosing electrical conductors The maximum current that a conductor or equipment can carry reliably without damage Glossary G 1 4000 dB dBA Digital Meter Earth ground Electrician Frequ
6. As standards specifications and designs are subject to change please ask for confirmation of the information given in this publication Comme les normes sp cifications et produits peuvent changer veuillez demander confirmation des informations contenues dans cette publication Normen Spezifizierungen und Pl ne unterliegen Anderungen Bitte verlangen Sie eine Best tigung ber alle Informationen die in dieser Ausgabe gemacht wurden 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 To reduce the risk of fire or electric shock install in a controlled indoor environ ment free of conductive contaminants This equipment is intended only for installations in a RESTRICTED ACCESS LOCATION Pour r duire le riske d inccendie ou d lectrocution installer dans une enciente int rieure contr l e en temp rature et humidit et sans c
7. 0990 877 672 0990 Fax 905 672 7667 email info mgeups com www mgeups com Latin America and Other International MGE UPS SYSTEMS 1660 Scenic Ave Costa Mesa CA 92626 Tel 714 513 7831 Fax 714 434 0199 email info mgeups com www mgeups com MGE UPS SYSTEMS 1
8. 30VDC Max current 2A 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 Installation and User Manual Output alarms are always activated on the conditions stated unless requested by customer to operate on other conditions Input contacts are designed for remote UPS operation Use extreme caution when using these contacts so as not to endanger persons or compromise the UPS load Installation 4000 This page left blank intentionally 86 173010 00 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 scroll up and down through the list of alarms soft keys 1 and 2 Soft key 3 allows you to delete a specific alarm message Soft key 4 allows you to examine in further detail a specific alarm message Although slightly different in operation the detail key soft key 4 must be held down to examine the message details See Figure 3 1 The four dedicated purpose keys are the main menu online help ON green and OFF gray buttons For inverter OFF a confirmation will always be requested Figure 3 1 Display P
9. CU t JACKS DISTRIBUTION UPS CABINET EXTERNAL BATTERY CABINET Galaxy 4000 CABINET Optional CASTERS Optional FRONT VIEW Table 1 1 Heat Rejection Data Heat Rejection Data 208 208VAC UPS cabinet 40KVA 50KVA 65KVA 75KVA BTU Hr 14 900 18 700 24 200 28 000 NOTE To 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 inches for fan exhaust is recommended Additionally adequate space must be included in the front and top of each cabinet approx 36 inches to allow the doors panels of the cabinet to be opened for service and maintenance procedures For an installation where seismic requirements must be met additional clearance at the side of the cabinet must be included to accommodate the seismic anchors Contact your local MGE Sales Representative to order See Figure 1 4 1 9 Conduit Plate Locations for Bottom Entry Cable entry through the bottom is the standard preferred design for the Galaxy 4000 UPS cabinet The bottom entry conduit plate provides space for up to five 5 separate conduit entries The plate is secured with screws which should be retained for the conduit plate after the power connections are made See Figure 1 4 for the location of the bottom entry conduit plates 1 4 Introduction 86 173010 00 Installation and User Manual Figure 1 4 Configuratio
10. alarm message 4 To further examine a specific alarm message The detail key 4 must be held down to examine the message details To exit this display it is necessary to press the Main Menu key Status Screen Selecting the Status option from the Main Menu provides the following screen selections Status and Alarms Event log Statistics and History See Figure 3 13 Status and Alarms Provides the user with the present list of alarms and warnings Event Log Provides the user with the history of events with date and time stamp Statistics Provides total time on battery power on AC Bypass AC BP on UPS AC N or battery with battery temperature TBatt gt 25 C History Provides history after 60 days for battery capacity backup time of load Installation and User Manual Figure 3 12 Mimic Diagrams screen NORM Load Protected Er 22 t 4 9 p 2 3 4 y Figure 3 13 Status screen Select type of list Status and Alarms Event log Statistics History 11 g Display Panel 3 7 4000 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 severa
11. amounts of toxic materials To avoid accidents the directives listed below must be observed 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 Batteries constitute a danger electrical shock burns The short circuit current may be very high Precautions must be taken for all handling remove watches rings bracelets and any other metal objects use tools with insulated handles Do not lay tools or metal parts on top of batteries Product Safety Upstream protection must be installed and be easily accessible The UPS can be disconnected from the AC power source by opening the input protective devices UPS must be connected to a nearby power source that is easily accessible Never block the ventilation openings of the UPS The UPS must be installed in a controlled environment Special Precautions P The UPS connection instructions and operation described in the manual must be followed in the indicated order Check that the indications on the rating nameplate correspond to your AC powered system and to the actual electrical consumption of all the equipment to be connected to the UPS Before and after the installation if the UPS remains de energized for a long period the UPS must be energized for a period of 24 hours at least once every 3 months for a normal storage te
12. cursor may be moved up and down until the desired display group is selected Then by pressing the fourth soft key the selected display or display group will be summoned See Figure 3 5 Measurements Selecting the Measurements option from the main menu provides the following screen selections battery power current voltage frequency measurements and ratios 3 4 1 Battery Measurements Screen The Battery Measurements screen provides a rapid assessment of the available battery voltage current battery charge temperature as well as expected service life See Figure 3 6 The backup time measurement will be calculated if the following battery parameter identification BPI require ments are met Required Conditions to Initiate BPI BPI set to automatic in personalization Battery charge level 100 UPS On line Inverter Coupled Mains 2 within tolerance Percent load is gt 15 Battery temperature 0 40 C 32 104 F No battery faults No rectifier or inverter overload condition Figure 3 5 Main Menu screen Main Menu Measurements vo lt Mimic Diagrams O IO IO IO IO 11 Status O IO IO VN Settings Commands tl a Figure 3 6 Battery Measurements screen Battery measurements Voltage 257V Current 0 0A Backup Time not avail Battery Charge 100 Temperature 2l c Service Life 60 Mth T th If the above conditions are met and maintained then the UPS will run a succ
13. fault on normal or bypass AC source Transfer to bypass AC source disabled Operation in ECO mode The output contacts numbers for a second relay board installed will be 2 1 to 2 6 Contacts are of the NO normally open type For dry contacts setting see section 3 7 86 173010 00 Installation 2 5 4000 Figure 2 3 CAUTION Isolate and lock out all power sources for this card before making connections 2 Never connect ELSV extra low safety voltage and non ELSV circuits to the different outputs of the same card 4 1 Relay Communication Card Connections Refer to Figure 2 3 for relay communication card cover and hardware details See Figure 4 1 for communication card port location in the unit 1 gt pe xu du sum Remove the cover 3 secured by the screws 1 Run the communication cables through the cable entry holes 4 Connect the conductors to the input 6 and output 5 terminal blocks refer to Figure 2 3 for a connection example Put the cover back in place and secure it with the screws 1 Tighten the screws 7 to clamp the cables Indicate the locations of the power sources on the labels Insert the card in its slot Secure the card with two screws 2 Relay Communication Card Revmove Cover Installation 86 173010 00 A00 86 173010 00 2 4 2 Characteristics of the Output Contacts Relay Type Normally Open Max voltage 250VAC
14. left blank intentionally 3 10 Display Panel 86 173010 00 A00 4 0 4 1 Operation 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 Galaxy 4000 system through the display panel See section 3 for operation of the display panel Preparing for Startup Before being able to use the display panel to monitor and control your Galaxy 4000 system a number of items should be verified to insure that all conditions will provide for safe operation The following check lists are provided to aid in the successful pre and post startup ofthe Galaxy 4000 They include items to verify prior to applying power and then tests that should be performed when appropriate after startup to verify the health and functionality of all critical modules within the system Before starting the Galaxy 4000 read this Installation and User Manual thoroughly Be certain that you fully under stand the operation of the indicators controls and operational sequences MGE UPS SYSTEMS offers professional startup services in most countries It is strongly suggested that before applying power to your Galaxy 4000 you contact Field Services to properly commission your system 4 1 1 Pre St
15. soft key with the double arrows to select the item of interest and then pressing the soft key with the magnifying glass 3 4 2 Power Measurements Screen Figure 3 7 Power Measurements screen The Power Measurements screen displays the load power on each phase in KVA and in KW Additionally the AC normal AC N source is shown with the KVA See Figure 3 7 Load Load AC N kW Power measurements Ph 0 6 0 5 Ph2 0 6 0 5 Ph3 0 6 0 5 gt 3 4 3 Current Measurements Screen Figure 3 8 Current Measurements screen The Current Measurements screen displays the current on the load AC normal AC N and AC Current measurements bypass AC BP on each of the three phases and neutral See Figure 3 8 Load ACN ACBP 5 A 5A OA 5 A 6A OA 5 A 5A OA 7A OA TU A 86 173010 00 A00 Display Panel 3 5 4000 3 4 4 Voltage Measurements Screen The Voltage 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 Measurements screen displays the frequency presently on any one of the input lines AC N and AC BP and the load See Figure 3 10 3 4 6 Ratios Screen The Ratios screen displays the crest factor for each phase the present percentage of load
16. 2 1 Typical Power Connections FRONT VIEW REAR AREA Output TB2 ut 0 3 2 9 Y gt Ground Q FRONT gt Neutral Battery Positive Q AR TB1 5 2 Battery Negative 1 AS i GROUND i NEUTRAL Jl NEGATIVE 22222222 POSITIVE BUSBARS 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 available for Remote Emergency Power Off REPO through a customer supplied normally closed pushbutton With REPO connected the jumper on the REPO terminal blocks must be removed See Figure 2 1 1 Remove the jumper from terminal block TB4 located across terminals 7 and 8 2 Connect the remote emergency power off NC contact to terminals 7 and 8 IMPORTANT The UPS is also equipped with a local Emergency Power Off EPO button on the front of the UPS cabinet This switches all UPS critical power off EPO or REPO should be used for emergency only 2 3 7 Battery Control Connections The battery control connections are made with the battery control cables from the external battery cabinet to the UPS terminal block TB
17. 3 4 UPS Display Menu Structure 3 3 3 5 Main Menu Screen 3 4 3 6 Battery Measurements screen 3 4 3 7 Power Measurements 5 3 8 Current Measurements screen 3 5 3 9 Voltage Measurements screen 3 6 3 10 Frequency Measurements screen 3 6 3 11 Ratios screen 3 6 3 12 Mimic Diagrams screen 3 7 3 13 Status screen 3 7 3 14 Settings screens 3 8 3 15 Commands screens 3 9 4 1 Galaxy 4000 Device 4 2 Tables table description page 1 1 Heat Rejection Data 1 4 2 1 Electrical Specifications for the Galaxy 4000 2 2 2 2 Relay Contacts communication card 2 5 3 1 Three LED lt 3 2 IV Contents 86 173010 00 Installation and User Manual Symbol Usage This manual uses five icon symbols with text to convey important information and tips WARNING Indicates info
18. 4 1 to TB4 4 See Figure 2 1 Installation 86 173010 00 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 h ELECTRICAL These wires carry HIGH VOLTAGE 120 2 3 9 Accessories Outlets The 120VAC outlets to be used on MGE authorized accessories only The outlets total current not to exceed 2 amps CAUTION Improper use of outlets may cause failure or damage to UPS 2 4 Relay Communication Card Contacts The relay communication card contains six programmable dry contact outputs and two programmable dry inputs and is standard on the Galaxy 4000 The inputs and outputs are factory programmed according to functions listed in Table 2 2 Table 2 2 Relay Contacts communication card INPUTS Factory Settings Options available on both contacts 1 A UPS ON Room temperature fault Transfer to bypass disabled Transfer to bypass disabled if bypass AC source out of tolerance 1 B UPS OFF Desynchronize UPS from bypass AC source SS OUTPUTS Factory Settings Options available on all contacts 1 1 Overload PFC Fault Inverter fault Automatic bypass fault Bypass AC source out of tolerance Emergency power off activated Battery circuit breaker s open Phase sequence
19. 95mm W x 33 5in 851mm D The UPS cabinet is designed to provide for top and bottom entry of the utility power feed An output voltage of 208VAC is standard with the Galaxy 4000 and does not require any additional cabinetry The complete list of additional cabinets that could be included with your Galaxy 4000 system are external maintenance bypass wall cabinet external battery cabinet and distribution cabinet The external battery cabinets are provided in two different cabinet sizes depending upon the battery type selected Up to four battery cabinets may be provided The cabinets may be installed adjacent to the UPS or remotely and are designed for top and bottom entry The distribution cabinet provides a 42 pole panelboard with an optional submain circuit breaker The cabinet is designed for top and bottom entry Preparation for Operation Several items must be considered when preparing the Galaxy 4000 UPS system for operation First The UPS cabinet and its auxiliary cabinets must be arranged in the required configuration to insure that the interconnection cables are located in the correct adjacent cabinets Second The cabinets must be in a location that provides for proper air flow and heat rejection Third The room in which the Galaxy 4000 UPS system is located must maintain environmental conditions within recommended tolerances Forth All electrical connections must utilize the top or bottom conduit entries provided The following se
20. TPUT CIRCUIT BREAKER 86 173010 00 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 Field Engineer and this sequence should be followed any time that the Galaxy 4000 UPS is being restarted from an off condition i e after the UPS has been powered down by removing the upstream AC input power and opening all the circuit breakers of the UPS For device locations refer to Figure 4 1 a Apply power to the UPS bypass by closing the upstream circuit breaker supplying Q4S mains 2 b Apply power to the UPS input by closing the upstream circuit breaker supplying the main AC input Q1 mains 1 c Close the maintenance bypass switch Q3BP in the UPS cabinet or in an external cabinet if present Power is now available at the UPS output the load is energized via maintenance bypass d Close the bypass switch Q4S The static switch will come on line the fans will start and the display will illuminate e Close the output isolation circuit breaker Q5N f Open the maintenance bypass switch Q3BP in the UPS cabinet or in an external cabinet if present The load is now supplied via the static bypass If your UPS configuration does not include the maintenance bypass opt
21. age MGE Warranty amp Proprietary Rights for Three Phase Products 6 1 Standard Three Phase Warranty Proprietary Rights Statement Warranty and Product Registration 6 2 User Information Product information Warranty Extension Warranty MGE Customer Care Center 6 3 Technical Support and Product Services Who To Contact Scheduling Field Service Engineer Support Return Policy for Repair of Three Phase Products RGA Caution Record All Serial Numbers 6 4 Glossary Reorder Form 86 173010 00 Contents 4000 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 Configuration for Bottom 1 5 1 5 Configuration for Top 1 5 2 1 Typical Power Connections 2 4 2 3 Relay Communication Card 2 6 3 1 Display Panel Keys and 3 1 3 2 Screen 3 2 3 3 Operational Summary 3 2
22. alaxy 4000 unit are A The main and bypass power connections B The load connection C Any cable connection to external or auxiliary modules D The communication card options The access method for connections made to the communication cards is clearly seen when the front right door to the Galaxy 4000 unit is opened However access to the main bypass and load connections is made through the removal of the safety panel located in the lower right of the Galaxy 4000 with the right door open This safety panel is removed by first removing the screws securing the panel It can then be removed by lifting the safety panel away from the unit CAUTION Before making any electrical connections verify that all battery disconnect circuit breakers CB1 are in the off position Customer supplied upstream protective devices and distribution circuits should be OFF 2 2 Installation 86 173010 00 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 To access the connection terminal blocks open the right door to the Galaxy 4000 UPS Remove the safety panel located in the lower right hand section of the unit See Figure 2 1 a The ground and neutral conductors must be connected to the
23. alization Turns the charger on to the maximum battery voltage Forced transfer to UPS Allows transfer to UPS when bypass is not available Use of this command will drop load Forced transfer to BP Bypass Allows transfer to bypass with 100ms break Use of this command will drop load Desynchronize AC BP To desynchronize the Inverter from the AC bypass Transfer inhibit will not allow transfer to and from inverter Resynchronize AC BP To resynchronize the Inverter to the AC bypass Lamp Test Allows the user to test the backlight Buzzer Off Allows the user to disable the buzzer Close AC Bypass SS static switch Closes the bypass static switch Normally closed Open AC Bypass SS Disconnects the bypass source Validate LCM Signalization Factory set Requires password Inhibit LCM Signalization Factory set Requires password Startup Procedure Screen The Startup Procedure screen provides the user general information for startup shutdown and transfer ring to manual bypass 86 173010 00 Display Panel Installation and User Manual Commands screens Commands Fault reset Batt equalization Forced transfer to UPS Forced transfer to BP Desynchronize AC BP 11 g Commands Resynchronize AC BP Lamp Test Buzzer Off Close AC Bypass SS Open AC Bypass SS 11 Commands Validate LCM Signalization Inhibit LCM Signalization 4000 This page
24. anel Keys and Indicators Galaxy 4000 COLOR DISPLAY Screen Saver shown SOFTKEYS 1 Scroll up 2 Scroll down 3 View Alarm messages 4 Detail of Alarm message MAIN MENU KEY ONLINE HELP KEY LOAD PROTECTED green LED INDICATOR INVERTER OFF BUTTON MINOR FAULT orange LED INDICATOR MAJOR FAULT red LED INDICATOR INVERTER ON BUTTON 86 173010 00 Display Panel 3 1 4000 3 1 1 LED Indicator Functions The three LED indicators see Figure 3 1 provide the following information as shown in Table 3 1 Table 3 1 Three LED Indicators Green LED Orange LED Red LED Load on UPS Minor fault such as Major fault such as Load is on battery power Loss of AC input power Internal fault Inverter not connected to load Battery problem Rectifier fault Bypass static switch fault Load on bypass Battery not connected IMPORTANT When the Red LED is the load is not protected 3 1 2 Screen Saver When the Galaxy 4000 system has been in continuous operation the operator interface will present a screen saver display See Figure 3 2 The product name Galaxy 4000 will be moving around the screen to provide an indication that the unit is functional 3 1 3 Operational Summary Screen Pressing any of the keys will cause the unit to provide an operational summary display with the following information This display will quickly show the operator the time date the KVA load on all three phases as wel
25. artup Safety Check List P Ensure all power and control wires have been properly connected and securely tightened P Check to see that the upstream and downstream protective devices are not tripped and have been sized properly for the UPS and load requirements Check that the input voltage is the same as indicated on the UPS nameplate located inside the door of the Galaxy 4000 UPS Make certain that nothing is blocking the air intake underneath and around the front bottom of the UPS and that the air exhaust on the top of the UPS is free of all obstructions P If present check to see that the external optional maintenance bypass circuit breakers CB1 CB2 and optional breaker are in the OFF open position P Check to see that the battery disconnect circuit breaker s CB1 in battery cabinet is in the OFF open position P Check to see that the cabinet is resting on its lifting leveler jacks and are not on the 4 casters Check that the load circuit breakers where applicable in the OFF position 86 173010 00 00 Operation 4000 Figure 4 1 Galaxy 4000 Device Locations QUALIFIED TECHNICIAN ACCESS ONLY CUSTOMER ACCESS 1 EMERGENCY POWER OFF Bla WLLL L Operation COMMUNICATION CARD PORTS ACCESSORIES OUTLETS Q1 INPUT SWITCH Q3BP MAINTENANCE BYPASS SWITCH optional 045 BYPASS SWITCH ELECTRICAL INTERLOCK optional Q5N OU
26. ber of the unit and include them in any discussions or correspondence Serial number Who To Contact Customer Care Center 1 800 438 7373 Hours 24 7 Customer FAQ or International calls 1 714 557 1636 Commitment MGE UPS SYSTEMS INC is committed to providing easy to access factory trained experts that will provide responses to any questions that you might have Scheduling Field Service Engineer Support Scheduling of the 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 MGE 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 MGE Customer Care Center and obtain a Return Goods Authorization RGA prior to shipping your unit Never ship equipment to MGE without first obtaining an RGA number Date RGA Number Contact Name Rev BOO 8 2005 86 173010 00 Warranty Registration amp Customer Support 6 3 4000 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 NUMBER BATTERY SERIAL NUMBER AUXILIARY SERIAL NUMBER
27. cess 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 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 BO2 8 2005 Warranty Registration amp Customer Support 86 173010 00 A00 Installation and User Manual MGE Customer Care Center 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 MGE UPS SYSTEMS INC Customer Care Center or visit our web site www mgeups com for complete service information To insure that your questions are correctly answered please obtain the serial num
28. circular mil standard wire sizes for multiple stranded conductors over 4 0 AWG in diameter M is from Roman numerical system indicating 1000 Glossary 86 173010 00 Module NC NO NEC NFPA PN On line mode OSHA PCA PCB PWM Q1 045 5 Remote Emergency Power Off REPO SCR Shipping damage SCR Shipping Pallet Static Transfer Technician Test connector UL V VA VAC Vdc 86 173010 00 A00 Installation and User Manual Refers to individual power inverter module Neutral Normally closed Normally open National Electrical Code National Fire Protection Association Part number Inverter output power is the primary energy source to load Occupational Safety and Health Agency Printed circuit assembly Printed circuit board Pulse Width Modulation UPS input isolation switch Optional maintenance bypass switch UPS bypass switch UPS isolation circuit breaker A switch used for shutting down electrical equipment from a location away from the equipment Remote Emergency Power Off Silicon controlled rectifier Any damage done to an article while it is in transit Silicon controlled rectifier A platform on which articles are fixed for shipping A solid state switching mechanism electronically controlled to pass AC power directly from the utility to an output load Refers to an electronic technician qualified to maintain and repair electronic equipment Not necessari
29. creen 3 5 3 4 3 Current Measurements Screen 3 5 3 4 4 Voltage Measurements Screen 3 6 3 4 5 Frequency Measurements Screen 3 6 3 4 6 Ratios Screen 3 6 38 Mimic Diagrams 3 7 3 6 Status Screen 3 7 3 7 Settings Screen 8 3 8 Commands Screen 3 9 3 9 Startup Procedure Screen 3 9 Section 4 Operation 4 0 acne be oe Daf bape ees ce er Ee 4 1 4 1 Preparing for Startup 4 1 4 1 1 Pre Startup Safety Check List 4 1 4 2 Normal Startup Procedure 4 3 4 3 Post Startup Safety Check List 4 4 4 4 Shutdown Procedure 4 4 4 5 Shutdown Using 4 4 4 6 Recovery from EPO 4 4 Section 5 Maintenance 5 0 CODE rered nee een Eee ene Ge esa 5 1 5 1 servicing Batteries 5 1 Contents 86 173010 00 Installation and User Manual section6 Warranty Registration amp Customer Support description p
30. ctions discuss these items in more detail Cabinet Placement The complete UPS system may consist of one to three cabinets depending on the options selected The UPS cabinet allows system options to be selected based on the application When facing the Galaxy 4000 UPS from the front the standard arrangement provides for any external batteries to be located on the right hand side and the distribution cabinet to be located on the left hand side of the UPS Refer to Figure 1 3 for cabinet placement Heat Rejection and Air Flow The Galaxy 4000 UPS cabinets generate heat and exhaust air through the top portion of its enclosures Air intake is through the bottom and front of the cabinet All other cabinets are convection cooled To assist you in planning for your HVAC needs heat rejection data is provided in Table 1 1 The cabinet airflow and recommended top clearance are provided in Figure 1 3 The Galaxy 4000 is intended for use in an environment where control of temperature and humidity is provided 86 173010 00 A00 Introduction 4000 Figure 1 3 Cabinet Placement Airflow and Recommended Clearances DISPLAY PANEL AIR EXHAUST ALLOW 36 TOP CLEARANCE FOR FAN EXHAUST AND SERVICE MAINTENANCE AIR INTAKE zn rm LEVELING 5 5 y 8 t
31. d 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 173010 00 A00 Warranty Registration amp Customer Support 6 1 4000 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 ac
32. ency slew rate GND Hz Inverter mode IEC IEEE Input branch circuit Inverter IGBT I T or IT KVA KW E LCD LED Mains or Mains 1 Mains 2 mA MAX MCM Decibels Decibel Adjusted Direct current or voltage The LCD display on the front panel of inverter system A ground circuit that has contact with the earth Refers to an installation electrician qualified to install high energy electrical components in accordance with national and local codes and regulations Not necessarily qualified to maintain or repair electrical or electronic equipment Compare to Technician Emergency Power Off Used to switch all UPS critical power OFF For emergency power shutdown only The change in frequency per unit of time Given in term of Hz per second Hz sec Electrical ground Hertz frequency measurement unit 1Hz is one cycle per second See on line mode Current International Electrotechnical Commission Institute of Electrical and Electronic Engineers The input circuit from the building power panel to the equipment An electrical circuit that generates an AC voltage source from a DC voltage source Insulated gate bipolar transistors Input Output Information Technology KiloVolt Ampere is equal to 1000 Volt Ampere True power Kilo Watt 1000 Watt Line Liquid Crystal Display Light Emitting Diode Main AC input source Bypass AC input source Milliampere Maximum Thousand
33. eplacement 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 an
34. essful A normal BPI will drain the batteries to a level of 80 capacity When the BPI is completed successfully the backup time will be displayed when the batteries are 100 charged If the load does not change by more than 20 then a BPI will be run again in one year Another BPI will run only if the load changes by 20 or the BPI is a year old If one of the conditions below occurs during the performance of the BPI the BPI will be aborted Factors Leading to Abort a BPI Inverter to mains 2 source transfer Load percent drops to 159 Battery temperature outside 0 40 32 104 F Display Panel Percent load changes more than 5 from starting power level 86 173010 00 A00 Installation and User Manual Battery temperature does not stay within 10 C from the starting temperature point Communication fault Input current 0 amps or gt 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 autonometer will start and display backup time when the batteries are 100 charged Because the calculation used is more simplified than the one used for calculating backup time using a BPI these will be less accurate Therefore it is preferable to use the whenever possible This provides an option for example when less than 15 load or cannot run a BPI NOTE Any of the displayed items be examined further by using the
35. fications Table 2 1 Electrical Specifications for the Galaxy 4000 Output Power Rating 0 8 PF 40KVA 50KVA 65KVA 75KVA UPS Voltage input output 208 208 208 208 208 208 208 208 Input Output Requirements amp Frequency Three phase Three wire N 60Hz Input Phase Rotation A B C Clockwise Input Power Factor gt 98 102A 127A Input Current 166A 191A Maximum Input Current at low line 15 120A 150A 195A 225A Bypass Current 111A 139A 180A 208A Output Current 111A 139A 180A 208A Battery Voltage 198 VDC End Voltage 240VDC Nominal 282VDC Max Maintenance Voltage Max Battery Current at Nominal Battery Voltage 240 VDC at 100 Load 157A 196A 255A 294A Max Battery Current at Nominal End Voltage 198 VDC at 100 Load 190A 238A 309A 357A Battery Disconnect Circuit Breaker Rating Input Bypass and Maintenance Bypass optional Switch Rating Input Fuse Rating Output Isolation Circuit Breaker Rating 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 2 3 Electrical Connections CAUTION Only an authorized electrical professional should access electrical connections A severe shock hazard exists The ONLY user serviceable items in the G
36. for each phase and for the total unit Additionally the load in KVA KW is provided See Figure 3 11 Display Panel Figure 3 9 Voltage Measurements screen Voltage measurements Load AC BP V1 120V 121V 120 V V2 120V 121V 120 V V3 121V 121V 120 V U12 207 209 209 U23 207 V 209 209 V U31 207 209 209 V Figure 3 10 Frequency Measurements screen Frequency measurements Load ACN AC BP 60 0 Hz 59 9Hz 59 9 Hz TU gt Figure 3 11 Ratios screen Ratios Crest Factor Load Ph1 1 5 13 Ph2 1 5 13 Ph3 1 5 13 Load KW kVA 0 8 kW percent load 12 FTU gt 86 173010 00 A00 3 5 3 6 86 173010 00 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 will indicate whether the unit is operating normally is on bypass or is currently running on batteries Segments are green when the function is active orange when not active and red when a fault has occurred See Figure 3 12 The lower half of the screen will show any existing alarm conditions Soft Keys 1 amp 2 Soft keys are now programmed to allow the user to scroll up and down through the list See Figure 3 12 3 To delete a specific
37. ground and neutral busbars respectively The input and output neutral are connected at the neutral busbar b Connect the three conductors of the main AC source to terminal block TB1 c If bypass source is present connect the conductors of the bypass AC source to terminal block TB3 If bypass source is not present verify jumpers in place between TB1 and TB3 d Connect the three conductors supplying the load to terminal block TB2 e Connect the battery conductors to the positive and negative busbars f Secure all cables with cable ties g Putall panels and covers back in place 2 3 2 Main AC Input Connections The connections to be made are the three phases neutral and ground cables from the utility AC power source to the UPS The main AC input cables are terminated at the main input terminal block TB1 See Figure 2 1 IMPORTANT For single input optional configuration jumper cables are provided from terminal blocks TB1 to TB3 2 3 3 Bypass AC Input Connections optional The bypass AC input cables are terminated at the bypass input terminal block TB3 This option provides a separate AC input source for bypass operation See Figure 2 1 2 3 4 AC Output Connections The connections to be made are the three phases neutral and ground cables from the load to the UPS The output cables are terminated at the output terminal block TB2 See Figure 2 1 86 173010 00 Installation 2 3 4000 Figure
38. ilar in design to the Galaxy 4000 cabinet Batteries or external maintenance bypass circuit breakers may also be contained in third party cabinets or wall mounted units Figure 1 2 Galaxy 4000 UPS System Single Line Diagram OPTIONAL BYPASS INPUT 208YVAC MAIN INPUT 208YVAC Q3BP OPTIONAL asm BYPASS BYPASS INPUT 4S SWITCH TB3 948 TT In ar ee INPUT PFC OUTPUT INPUT STATIC BOOST STATIC OUTPUT see Q1 FUSES SWITCH RECTIFIER INVERTER SWITCH OUTPUT CB nn DA E ID N TB2 N 42 POLE gt O E BA EA EN PANELBOARD OPTIONAL OPTIONAL BATTERY EY STATIC SWITCH DISTRIBUTION SUPPLIED BY MGE amp CONTROL CONNECTIONS CONNECTED BY CUSTOMER SEE UPS INSTALLATION DWG SUPPLIED BY MGE amp CON NECTED BY CUSTOMER ADJACENT VERSION SUPPLIED amp CONNECTED BY CUSTOMER STAND ALONE VERSION TB4 REPO ON MBS TO CRITICAL LOAD Introduction 86 173010 00 1 4 1 5 1 6 1 7 Installation and User Manual Galaxy 4000 Standard Cabinets The Galaxy 4000 individual cabinet dimensions are DB UPS cabinet 72 1in 1831mm H x 33 5in 851mm W x 35 6in 904mm D P External battery cabinet 72 1in 1831mm H x 26 5in 673mm W x 33 5in 851mm D OR P External battery cabinet 72 1in 1831mm H x 33 5in 851mm W x 33 5in 851mm D P Distribution cabinet 72 1in 1831mm H x 19 5in 4
39. ion startup requires only closing Q4S and Q5N to supply the bypass source to the attached load IMPORTANT If the UPS is programmed for automatic restart the inverter will automatically start g Close the input switch Q1 Verify that the following conditions exist The red load not protected LED is on The rectifier automatically starts If either condition is not present there is a fault Open Q1 and contact MGE Field Services h Close the battery disconnect circuit breakers CB1 The batteries are now connected to the battery charger and have begun charging i If the UPS is programmed for manual restart press the inverter on green pushbutton j The UPS will automatically transfer the load to the UPS inverter output The green load protected LED will turn on and remain on k Close the optional output distribution circuit breakers if present a NOTE If the transfer conditions are not satisfied bypass AC input source is out of tolerance or some other reason a forced transfer is required 86 173010 00 A00 Operation 4 3 4000 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 B Emergency Power Off EPO test B Remote Emergency Power Off REPO test if applicable Inverter start and stop P Battery transfer test B Maintenance by
40. l as the battery level See Figure 3 3 Display Panel Figure 3 2 Screen Saver Galaxy 4000 pe gt p Galaxy 4000 Figure 3 3 Operational Summary screen NORM Load Protected 03 30 2004 09 30 KVA 0 6 0 6 0 6 m Battery 86 173010 00 A00 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 STATUS SETTINGS COMMANDS STARTUP PROCEDURE MEASUREMENTS BATTERY POWER CURRENT VOLTAGE FREQUENCY RATIOS MEASUREMENTS MEASUREMENTS MEASUREMENTS MEASUREMENTS MEASUREMENTS MIMIC DIAGRAMS STATUS STATUS MIMIC DIAGRAMS EVENT LOG STATISTICS MEASUREMENTS MIMIC DIAGRAMS MEASUREMENTS STATUS AND ALARMS HISTORY SETTINGS COMMANDS BATTERY FORCED TRANSFER STARTUP PROCEDURE STARTUP PROCEDURE UPS SHUTDOWN FORCED TRANSFER DESYNCHRONIZE TO BYPASS AC BYPASS TRANSFER TO MANUAL BYPASS 86 173010 00 Display Panel 3 3 4000 3 3 3 4 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 the selection
41. l options Date Time Can be set to insure that the time stamps on the event and alarm logs reflect the current local time and date Contrast Allows the contrast of the operator interface unit to be adjusted to maximize its visibility in the current ambient lighting conditions Buzzer Allows the volume of the buzzer to be set Personalization Allows the operator to select any number of operating parameters for the UPS Output Voltage Factory set Requires a password Dry Contacts Factory set Requires a password Password Factory set Requires a password factory default 000 Figure 3 14 Settings screens Settings Language Date Time Contrast Buzzer Personalization tJ Settings Output Voltage Dry Contacts Password c Do NOT adjust any parameters in the personalization section without a clear under standing of the implications to your operation Should there be any questions about a factory or present setting please do not hesitate to contact the Customer Support Center at MGE UPS Systems Inc CAUTION 3 8 Display Panel 86 173010 00 3 8 3 9 Commands Screen Figure 3 15 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 equ
42. ly qualified to install electrical wiring 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 Underwriter s Laboratories Inc Volts Volt amperes unit for apparent power measurement equal V x I Voltage of AC type Voltage of DC type Glossary G 3 4000 This page left blank intentionally G 4 86 173010 00 Reorder Form MGE UPS SYSTEMS 1660 Scenic Avenue SS 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 NAME COMPANY STREET ADDRESS CITY STATE ZIP would like to order quantity 75 00 each additional copies of the Galaxy 4000 40 75KVA Installation and User Manual 86 173010 00 would like to report the following problems with this document 1660 Scenic Avenue Costa Mesa California 92626 714 557 1636 www mgeups com Contact MGE United States MGE UPS SYSTEMS 1660 Scenic Ave Costa Mesa CA 92626 Tel 714 557 1636 Fax 714 557 9788 email info mgeups com www mgeups com Canada MGE UPS SYSTEMS 9 2789 Thamesgate Drive Mississauga ON LAT 4E8 Tel 905 672
43. mperature less than 25 This charges the battery thus avoiding possible irreversible damage 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 MGE UPS SYSTEMS INC 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 MGE UPS SYSTEMS INC branch office Packing UPS packing materials must be recycled in compliance with all applicable regulations WARNING This product contains lead acid batteries Lead is a dangerous substance for the environment if it is not properly recycled by specialized companies 86 173010 00 A00 Certification Standards Safety of Persons iii 4000 iv 86 173010 00 Contents section oo ansehe Pep Revision 5 amp IMPORTANT SAFETY 5 5 i Certification Standards Three Phase UPS iii Safety Of PersonS iii Product Safety iii Special Precautions iii ENVILONMENE PERITI t TT LR OTROS TIT iii Symbol V Sectio
44. n Descriptions V Section 1 Introduction 1 0 1 1 1 1 General Description 1 1 1 2 Major Components 1 2 1 3 Single Line Diagram 1 2 1 4 Galaxy 4000 Standard Cabinets 1 3 1 5 Preparation for Operation 1 3 1 6 Cabinet Placement 1 3 1 7 Heat Rejection and Air 1 3 1 8 Cabinet Clearances 1 4 1 9 Conduit Plate Locations for Bottom Entry 1 4 1 10 Conduit Plate Locations for Top Entry 1 5 1 11 Preparation for Storage 1 6 Section 2 Setup and Installation 2 0 OCODE TTC 2 1 2 1 Installation Steps ven na de co E ge 2 1 2 2 Environmental and Electrical Specifications 2 1 2 2 1 Environmental Recommendations 2 1 2 2 2 Electrical Specifications 2 2 2 3 Electrical Connections 2 2 2 9 4 UPS COMMCCUONS erraten 2 3 2 3 2 Main AC Input Connections 2 3 2 2 3 Bypass AC Input Connections optional
45. n for Bottom Entry AIR INTAKE DO NOT BLOCK 25 0 24 18 0 28 8 32 0 3 2 15 7 SEISMIC BRACKET optional 4 PLCS 38 1 CABLE ENTRY PLATE 46 6 53 6 1 10 Conduit Plate Locations for Top 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 is secured to the cabinet with screws See Figure 1 5 Figure 1 5 Configuration for Top Entry 76 5 25 0 32 0 10 x 20 5 9 x 20 5 CONDUIT CONDUIT 18 8 32 0 290000000090 16 5
46. ontaminants conducteurs Ce mat riel est destin seulement pour des installations dans un EMPLACEMENT RESTREINT D ACCES Um die Gefahr von Feuer und elektrischem Schock zu reduzieren muss das Ger t in einem temperatur und feuchtigkeitskontrollierten Raum frei von leitungsf higen Verunreinigungen installiert werden Dieses Ger t ist nur f r die Installation an einem Ort mit geingeschr nkter Zugangserlaubnis vorgesehen Diese Ausr stung ist nur f r Anlagen in einem EINGESCHRaNKTEN ZUGRIFF STANDORT bestimmti Important Safety Instructions 86 173010 00 A00 Installation and User Manual WARNING un LEAKAGE CURRENT Earth 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 Safety of Persons The UPS has its own internal power source the battery Consequently the power terminals may be energized even if the UPS is disconnected from the AC power source P The UPS must be properly grounded The battery supplied with the UPS contains small
47. pass procedure ved As soon as AC input power is supplied to the Galaxy 4000 customer supplied upstream circuit breaker is in the ON position the load is initially supplied via the Static Switch Verify that no error indications are present on the operator interface display panel 4 4 Shutdown Procedure Proceed as follows 1 Press the gray Inverter OFF button 2 Confirm by pressing the function key The load is no longer protected by the UPS It is supplied via the bypass 3 Set the battery circuit breakers CB1 in battery cabinet to the OFF position 4 Close Q3BP open input switch Q1 bypass switch Q4S and output breaker Q5N 5 To completely remove power from the UPS open Q3BP and open the upstream circuit breakers supplying AC power to switches Q1 and Q4S Attention There is no power to the load 4 5 Shutdown Using EPO During an emergency situation the UPS and all downstream devices can be instantly shutdown by pressing the red emergency power off EPO pushbutton on the front door of the UPS cabinet or pressing the remote emergency power off REPO pushbutton if applicable located within the room IMPORTANT Pressing the EPO button disconnects the attached load The emergency power off EPO is to be used during emergency situations only where a hazard to personnel or equipment exists 4 6 Recovery from EPO To recover from an emergency power off press the EPO pushbutton again Follow the normal startup proced
48. rmation 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 service personnel against possible equipment damage ELECTRICAL Indicates information provided to protect the user and service personnel against possible electrical hazard and equipment damage IMPORTANT Indicates information provided as an operating instruction or as an operating tip NOTE Indicates information provided as an operating tip or an equipment feature Section Descriptions 1 Introduction Provides a general description of the Galaxy 4000 systems intended use major components mechanical and environmental specifications 2 Setup and Installation 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 3 Display Panel Describes the operator interface screens keys and mimic diagram 4 Operation Provides startup shutdown and normal operation of the Galaxy 4000 UPS Included are pre and post startup safety checklists 5 Maintenance Describes maintenance and safety information on servicing batteries for the Galaxy 4000 A Glossary provides definitions of abbreviations and terms used in this manual 86 173010 00 A00 Symbol Usage and Section Descriptions V
49. tems 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 misappli cation 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 r
50. the MGE Field Service Engineers typically should be done 7 to 10 days before they are required on site If the startup of the UPS is critical to maintaining your schedule please call the MGE toll free telephone number at 1 800 438 7373 for assistance To insure a successful installation each of these 5 steps should be followed in their correct sequence Note that any unauthorized installation may cause damage to the UPS s First steps by an on site qualified Technical Engineer Step 1 Unpack and position the unit Step 2 Connect the main utility power Step 3 Connect the output to the load Final steps by MGE Field Service Engineer Step 4 Call MGE and wait for the MGE Field Service Engineer to approve the installation Step 5 The MGE Field Service Engineer finalizes installation and the startup process 2 2 Environmental and Electrical Specifications 2 2 1 Environmental Recommendations Recommended environment 20 to 25 C 68 to 77 F 50 relative humidity computer room or other temperature and humidity controlled environment Operating temperature 0 to 30 32 to 86 except battery Storage 20 to 40 C 4 to 113 F except battery Humidity up to 90 non condensing operating Altitude sea level to 3 000 feet without derating Acoustic noise 69 dBA at rated load as measured 5 feet from the front of the UPS cabinet 86 173010 00 A00 Installation 2 1 4000 2 2 2 Electrical Speci
51. ure in Section 4 2 NOTE The EPO pushbutton is a latching device The EPO condition will remain until the EPO button is depressed a second time 4 4 Operation 86 173010 00 Maintenance 5 0 Scope Describes maintenance and safety information on servicing batteries for the Galaxy 4000 5 1 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 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 likelinood of such shock
52. will be reduced if such grounds are removed during installation and maintenance 86 173010 00 Maintenance 5 1 4000 This page left blank intentionally 86 173010 00 Installation and User Manual MGE Warranty amp Proprietary Rights Statement for Three Phase Products Applicable within the United States Canada and Mexico MGE Standard Three Phase Warranty MGE UPS SYSTEMS INC 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 prior to returning i
53. www mgeups com Standard Features Emergency Power Off button with safety cover Interactive Display Panel Galaxy 4000 40 75KVA Uninterruptible Power Systems Installation and User Manual MGE UPS SYSTEMS 7 Installation and User Manual Galaxy 4000 40 75KVA 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 UPS SYSTEMS INC All rights reserved Printed in U S A e E UPS SYSTEMS INC 1660 Scenic Avenue Costa Mesa CA 92626 UPS SYSTEMS 714 557 1636 Customer Care Center 1 800 438 7373 Hours 24 7 www mgeups com 86 173010 00 A00 4000 IMPORTANT SAFETY INSTRUCTIONS SAVE TH ESE INSTRU CTIONS This manual contains important instructions for Galaxy 4000 that must be followed during operation and maintenance of the equipment WARNING ATTENTION WARNUNG WARNING ATTENTION WARNUNG NOTE WARNING ATTENTION WARNUNG Opening enclosures expose hazardous voltages Always refer service to qualified personnel only L ouverture des cabinets expose des tensions dangereuses Assurez vous toujours que le service ne soit fait que par des personnes qualifiees Das offnen der Gehause legen gefahrliche Spannungen bloss Service sollte immer nur von qualifizierten Personal durchgefuhrt werden
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