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Galaxy PW ™ 100 to 225kV A Uninterruptible Power Systems Installation and User Manual 86-133060-00 A00 www .mgeups.com Features ◗ Single and Parallel UPSs ◗ Battery Cabinet ◗ Maintenance Bypas.
IMPORT ANT SAFETY INSTRUCTIONS SA VE THESE INSTRUCTIONS – This manual contains important instructions for the Galaxy PW™ that must be followed during operation of the equipment. W ARNING Opening enclosures e xpose hazardous volta ges. Alwa ys refer service to qualified personnel onl y .
How T o Use This Manual and Symbol Usage iii 86-133060-00 A00 W ARNING T o reduce the risk of fire or electric shock, install in a temperature and humidity controlled indoor area free of conductive contaminants. This equipment is intended only f or installations in a RESTRICTED ACCESS LOCA TION.
iv 86-133060-00 A00 Galaxy PW ™ UPS 100 to 225kV A CAUTION: Record All Serial Numbers! RECORD ALL SERIAL NUMBERS FOR THE GALAXY PW ™ AND COMPONENTS.
Installation and User Manual Galaxy PW ™ 100 to 225kV A Installation and User Manual Revision History Galaxy PW™ 100 to 225kV A Installation and User Manual 86-133060-00 A00 Revision: X1 Initial Release 06/2003 A00 ECN#: 003469 02/2006 Copyright © 2006 MGE UPS SYSTEMS, INC.
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Contents Contents c i 86-133060-00 A00 description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page IMPORT ANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Galaxy PW ™ UPS 100 to 225kV A Contents c ii 86-133060-00 A00 Section 2 System Setup (continued) section description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2.3 Galaxy PW™ Cabinet Major Components .
Installation and User Manual Section 4 Operation (continued) section description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 4.4 Operation with Engine Generator Set . . . . . . . . . . . . . . . . . . . . .
Appendices description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page Appendix A Front Control Panel Display Definitions . . . . . . . . . . . . . . . . . . . . . . . . . .A — 1 Display of Primary and Secondary Messages .
Installation and User Manual Figures figure description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-1: Galaxy PW™ System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figures (continued) figure description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 5-5: Start-up Procedure After Isolation Diagram. . . . . . . . . . . . . . . . . . . . . . .5 — 5 5-6: Redundancy for Increased Output Diagram.
Introduction 1.0 Scope Introduction is a general description and overview of Galaxy PW™ 100 to 225kV A components, its intended use, environment, and applicable specifications, power input/output requirements, and system characteristics for different system configurations.
1.2 General Description The cabinets are cooled by forced ventilation. The air enters via the doors and grids at the bottom and is discharged through the roof, which means the cabinets can be positioned against the back wall. Connections are made through the bottom.
Installation and User Manual 1.3 System Major Power Components Rectifier/charger module (A) Converts 3-phase AC power from the normal AC source supply (1) into DC power for the normal inverter input and float charges or recharges the battery .
1.4 Different T ypes of Galaxy PW™ Systems 1.4.1 Single UPS System Figure 1-2: Galaxy PW™ Single UPS System. Note: *The Fuse is to protect against catastrophic rectifier/inverter semiconductor failure.
1.5 System Specifications 1.5.1 Electrical Characteristics Installation and User Manual Introduction 1 — 5 86-133060-00 A00 UPS power rating in kV A 100 130 150 180 200 225 Normal AC input number of.
1.6 Electrical Parameters for Selecting Protective Devices 1.6.1 Normal AC Source The parameters given in T able 1-1 can be used to determine the required rating of the upstream protective circuit breaker on the normal AC input for one single-UPS or parallel-UPS unit.
Installation and User Manual 1.6.2 Bypass AC Source The parameters given in T able 1-2 and 1-2A can be used to determine the required rating of the upstream protec- tive circuit breaker on bypass AC input.
1.7 Recommended Protection 1.7.1 Protection Upstream of Galaxy PW™ The information provided here is purely indicative, for a single UPS unit. Check that all the criteria mentioned in the previous section are taken into account (short-circuit current and protection of the static switch semiconductors on the bypass AC input).
Installation and User Manual 1.8 Parallel Connected UPS Units For installations with redundant units, take into account only the units required to supply the load power (e.
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System Setup 2.0 Scope System Setup describes receiving and handling of the Galaxy PW™ 100 to 225kV A, a description of major compo- nents, the battery cabinet, and definition of the control panel indicators, which includes electrical, mechanical and environmental specifications.
2.1 Receiving On delivery , check that the equipment has not been damaged in transport (declare any damage to the carrier in accordance with customary claim procedures). Also check that the characteristics noted in the test report for the equipment correspond to those specified on the order form.
Installation and User Manual Figure 2-1: Handling Cabinet From the Bottom or Rolling on Bars. 2.1.2 Storage The equipment must be stored in a dry and well-aired location, sheltered from rain, water sprays or splashes and all chemical agents.
2.2 Unpacking 1. Remove the packing box and the document holder on the top of the cabinet; raise the cabinet. 2. Dismantle the blocks fixed beneath the cabinet by M12 screws, see Figure 2-2 (A or B), according to the width of the cabinet); 3. Dismantle the 4 M12 screws screwed on the 4 leg supports (C).
Installation and User Manual 2.3 Galaxy PW™ Cabinet Major Components Legend: AA : cross-sectional view of the cabinet, B : front view of the cabinet, C : front panel, D : rear panel, 1 : normal AC i.
2.4 Battery Cabinet Legend: AA : cross-sectional view of the cabinet, B : front view of the cabinet, C : front panel, D : rear panel, E : cable ties to duckboard shelf, F : cable exit through the bott.
Installation and User Manual 2 — 7 86-133060-00 A00 2.5 Remote External Maintenance Bypass Cabinet 350A and 1200A (See Figure 2-5) Refer to “Installation Instructions” 90-133056-01 for detailed information about 350A cabinet. Refer to Installation drawing 90-133077-00 for detailed information about 1200A cabinet.
2.6 General Instructions for Screens T o display the desired information and enter commands using the ▲ , ▼ and ø keys: 1. Press the key to exit the time-stamping consultation mode and return to the main menu. If no commands are entered for five minutes, the system automatically returns to the normal display mode.
Installation and User Manual Control Panel Alphanumeric Legend: 1 "Rectifier/charger" light Indicates on/off and charging activity . 2 "Battery light" Indicates battery status. 3 "Static-bypass" light Indicates static bypass tolerance status.
2.7 System Start-up 2.7.1 Single UPS unit or Redundant Parallel UPS Proceed in the following order: See Figure 2-7. 1. Close the upstream switches supplying normal and bypass AC source power (on the L V switchboard). 2. Close normal AC input switch Q1.
Installation and User Manual 2.8 Parallel UPS Unit for Increased Output Proceed in the following order: See Figure 2-8. 1. Check that all load devices are off or that the load is disconnected. 2. Close the upstream switch supplying normal AC source power (on the L V switchboard).
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3 — 1 86-133060-00 A00 Installation 3.0 Scope Installation guides the User through single and parallel UPS unit power cable connections, hot swap options, connections between cabinets, communication card connections, battery ‘temperature monitoring’ installation.
3.3 Power-Circuit Wiring Diagrams The single UPS wire diagram is for typical UPS installations shown in Figure 3-1. The heavy lines represent the cables that must be connected (F), refer to section 3.5 ‘Connections Between Cabinets’ for more detail on cables.
Installation and User Manual Figure 3-3: Parallel UPS Unit Power Circuit Diagram. Legend: 1 : Normal AC source, 2 : Bypass AC source, A : Rectifier/charger module, B : Inverter module, C : Static-bypa.
3.5 Connections Between Cabinets These connections are made on the UPOZ board (marked T) and MUSI board (marked U). See Figure 2-3, page 2—5. 3.5.1 Connections Between UPOZ Boards These connections are made using the cables (A) supplied, see Figure 3-4.
Installation and User Manual 3.5.3 Connections Between MUSI Boards These connections are made using the special cables (A) supplied, see Figures 3-5. 1. Connectors XM5, XM6 and XM7 on the MUSI board are used to transmit signals. 2. Connectors XM10, XM1 1 and XM12 on the MUSI board are used to receive signals.
Figure 3-6: Three Parallel UPS Units Connections. Figure 3-7: Four Parallel UPS Units Connections. 'MUSI' Galaxy PW TM 1 'MUSI' Galaxy PW TM 2 A XM5 XM6 XM7 XM5 XM6 XM7 'MUSI&.
Installation and User Manual 3.6 Environmental Signal of the Media Contacts 1 1 Board T erminals XR2, XR3, XR4 and XR5 on the "Media Contacts 1 1" board of each type of unit can be used to r.
"load on battery power" signa l: (V olt-free changeover contact) indicating that the inverter is supplied by the battery in the following cases: - normal AC source outage or voltage drop. - rectifier/charger shutdown. - rectifier/charger current limiting.
Installation and User Manual 3.7 "Media Contacts 1 1" Standard Auxiliary Circuits Connection Connecting the auxiliary circuits to the three connectors on the "Media Contacts 1 1" board in the Galaxy PW™ UPS cabinet, see the position of this board, marked "O", see Figure 2-3, page 2—5.
3.7.1 Battery Circuit Breaker "QF1" Connection Connect the cable from connector XR3 (pins 2 to 8) on the "Media Contacts 1 1" board in the UPS cabinet to connector XR1 in the battery cabinet containing battery circuit breaker QF1.
Installation and User Manual 3.8.1 "T emperature Monitor" installation in a Battery Room The "T emperature Monitor" should be secured against a wall or any vertical support. See Figure 3-10. 1. Choose a location near the batteries and away from draughts which adversely affect the accuracy of temperature measurements.
3.8.2 Connection of the Battery "T emperature Monitor" This unit must be connected to the XR2 connector on the remote indications "Media Contacts 1 1" board of the UPS cabinets. For the location of the "Media Contacts 1 1" board, marked "O" see Figure 2-3, page 2—5.
Installation and User Manual Figure 3-12: Connection of the Battery "T emperature Monitor." (In Parallel UPS Units with Batteries in Same Room.
Figure 3-13: Connection to the "Media Contacts 1 1" Board. 3.9 About Final Installation Steps After making the connections, install the front and rear base plates of the cabinets, clipping t.
Operation 4.0 Scope Operation describes the start-up for single and parallel units, modes of operation, normal specifications for operating the Galaxy PW™ 100 to 225kV A, including display messages, measurement systems, alarms, batteries, and log time stamping operations.
4.1.3 Single UPS Unit The inverter starts, then, if the bypass AC source transfer conditions are satisfied, the load is transferred to the inverter , if the on-line mode is selected. For on-line mode: ◗ The green "inverter" light 4 remains on.
Installation and User Manual 4.2 Operation in On-line Mode 4.2.1 Normal Operation Normal AC source power is available, see Figure 4-5. ◗ Lights 1 , 4 and 5 shine green on the control panel. -The power necessary for the load is provided by the normal AC source (1) through the rectifier/charger (A) and the inverter (B) .
4.2.2 Operation with the Normal AC Source Down In the event of a normal AC source failure or voltage outside specified tolerances of ± 10% in amplitude (± 15% optionally), the rectifier/charger (A) stops and the battery (D) supplies the necessary backup power to the load via the inverter (B) .
Installation and User Manual 4.3 Operation with the Normal AC Source Restored When normal AC source power (1) is restored or its voltage returns to within specified tolerances, the system automatically returns to its normal operating mode described above (on the condition it did not reach the end of battery power).
Figure 4-8: Battery Charge Cycle Chart. 4.4 Operation with Engine Generator Set If a stand-by generator is included in the installation, it is generally started automatically in the event of a normal AC source failure and connected to the main low voltage switchboard.
Installation and User Manual 4.5 Battery Time The available battery time during a normal AC source outage depends on the: ◗ Rated capacity of the battery . ◗ Power consumed by the load. ◗ T emperature of the battery . ◗ Age of the battery . The specified battery time corresponds to a minimum duration at full rated load.
4.6.1 Single UPS Unit (On-line mode) In the event of a UPS shutdown (initiated by the user or by an internal protective device), the load is automatically transferred to the bypass AC source. If transfer conditions are satisfied, transfer takes place instantly , without inter- ruption to the load.
Installation and User Manual The shutdown of one inverter results in overload on the other inverters in operation. T wo cases may then arise: A) if the overload on each remaining inverter is > than 1.65 in, the load is immediately transferred to the bypass AC source.
4.7.1 Steady State V oltage Regulation For stable or slowly varying load conditions, the inverter output voltage is regulated to within ±0.5% in amplitude.
Installation and User Manual Operation 4 — 11 86-133060-00 A00 4.8 Measurement System The display may be used to read a number of input and output measurements made at different points in the system.
4.8.1 V oltage Measurements These measurements may be accessed by pressing the "V" key 13 . The following data is displayed. Note: M1: normal AC source M2: bypass AC source 4.8.2 Current Measurements These measurements may be accessed by pressing the "A" key 14 .
Installation and User Manual Operation 4 — 13 86-133060-00 A00 4.9 Selections and Settings These selections and settings may be accessed by pressing the "contrast" key 12 .
◗ Lamp test: When this function is selected, all the lights shine orange for three seconds. ◗ Set Date and Time: Use the " ▲▼ " keys to enter the data and confirm using the " ø " key .
Installation and User Manual - this screen is displayed following a positive, manual battery test: - this screen is displayed following a negative, manual battery test: - this screen is displayed following a positive, automatic battery test.
4.10 Alarms The auto diagnostic system considers any system status other than normal as a problem. Before taking any action , note down the messages displayed on the control panel.
Installation and User Manual 4.12 Logging and Time-Stamping 4.12.1 Event Time-Stamping T ime-stamping of events by Galaxy PW™ makes it possible to: ◗ Log the events. ◗ Consult the last 500 events that occurred on the Galaxy PW™ UPS. ◗ Consult general statistical data on UPS operation.
4.13 Setting the Date and Time for the UPS - Utilization Via the Galaxy PW™ Display The time and date can be set for the UPS via the main menu on the display (see below), using the DA TE AND TIME command. The time-stamping information, statistics and measurement records are also available via the same menu, using the P AST EVENTS command.
Installation and User Manual 4.14 Consulting Statistics Legend: total backup time (h): This is the total time of operation on battery power since initial startup of the UPS. It is expressed in hours. total time on static This is the total time of operation on the static switch since initial startup of the UPS.
Legend: nb of backups: This is the number of times the load was supplied by the UPS from battery power since the last reset. nb of backups < 1 min: This is the number of times the load was supplied by the UPS from battery power for less than one minute, since the last reset.
Installation and User Manual 4.14.1 Consulting Recorded Measurements Recorded measurements are presented in the same manner (see below): ◗ the lists indicate the last 30 measurements recorded for the given parameter . The chronological order of the measurements is indicated in the Figure opposite.
The battery capacity is the value measured by the UPS microprocessor . It is expressed in Ampere-hours. This value changes over time depending on the parameters of the battery itself and its environment. This measurement is used to check that the battery is capable of supplying the rated power in the event of a mains outage.
Maintenance 5.0 Scope Maintenance procedures include preventive maintenance, isolation procedures for maintenance, startup for single and parallel units after isolation, functional and visual checks, software options and configurations, and testing scenarios.
5.2 Replacement Parts There are no user replaceable parts inside the Galaxy PW™. Three levels of replacement parts are available for the Galaxy PW™ UPS.
Installation and User Manual Start-up Following servicing, proceed in the following order: (See Figure 5-3) 1. Close switch Q1, then after approximately ten seconds, switches QF1, Q5N and Q4S, 2. 0pen bypass switch Q3BP , 3. Start the inverter (press the "inverter ON" button 7 ).
CAUTION W ork should be carried out in accordance with applicable safety regulations. to av oid interrupting the load, the v arious switching operations must be carried out in the correct order . Operations are explained in diagrams placed ne xt to the switches.
Installation and User Manual Start-up Following servicing, proceed in the following order: (see Figure 5-5) 1. Close switches Q5N on the UPS units. 2. Close switch Q5N in the external bypass unit. 3. Open switch Q3BP in the parallel-connection unit. 4.
5.4 Battery Maintenance Consult the instructions supplied by the battery manufacturer . Below are a few general indications: ◗ Sealed lead-acid Batteries: - these batteries require no maintenance, but check the terminals of each cell from time to time and clean if necessary .
Installation and User Manual 5.7 T esting Parallel Systems 5.7.1 Galvanic Isolation and V oltage Matching T ransformers The UPS can be equipped with an isolation or auto transformer on both the input and output to provide galvanic isolation or voltage step-up or step-down as required.
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Appendices Appendix A Front Control Panel Display Definitions 1 "Rectifier/charger" light ◗ light off: rectifier/charger OFF . ◗ light shines green: rectifier/charger ON.
4 "Inverter" light ◗ light off: inverter OFF . ◗ light flashing green: inverter starting, inverter ON but not connected to the load. ◗ light shines green: normal inverter operation.
Installation and User Manual 13 "V" Key This key is used to access voltage measurements: ◗ normal AC source phase-to-phase voltages. ◗ bypass AC source phase-to-phase and phase-to-neutral voltages. ◗ load phase-to-phase and phase-to-neutral voltages.
Display of Primary and Secondary Messages The display is structured around primary and secondary messages, measuring tables and setting screens. As a rule, the message displayed on the screen is always a primary one. The secondary messages, if any , are accessed by pressing keys 9 ▲ and 10 ▼ .
Installation and User Manual Primary Messages LOAD PROTECTED ON-LINE MODE This is the normal display when there are no alarms or problems and the load is correctly supplied by the inverter , in on-line mode.
LOAD PROTECTED ECO MODE This is the normal display when there are no problems: the load is supplied by the inverter or the bypass AC source, and battery backup is available. LOAD NOT PROTECTED ECO MODE Ø This display indicates that the load is supplied but has no battery backup.
Installation and User Manual INTERNAL UPS FAULT LOAD TRANSFER FAULT, CALL MAINTENANCE A fault has occurred in the static switch that transfers the load between the inverter and the bypass AC source (M2). Servicing by the after-sales support department is required.
BATTERY CHARGING I BAT.=XXX A U BAT. = XXX V The battery is currently be recharged. BATTERY AT END OF SERVICE LIFE CALL MAINTENANCE The battery is nearing the end of its estimated service life. This information is based on average service-life calcu- lations since its initial installation.
Installation and User Manual THE NUMBER OF UPS READY IS INSUFFICIENT, LOAD TRANSFER IN STANDBY This message may be displayed in non-redundant, parallel UPS systems, when the number of ready inverters in not sufficient to supply the load.
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Installation and User Manual Appendix B Monitoring - Electrical Supervision Options "T eleservice" "T eleservice" is a contract offering continuous remote supervision and maintenance of UPS systems via a modem.
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Installation and User Manual Appendix C Link to an IBM AS/400 ® Computer The Galaxy PW™ can dialogue with an IBM AS/400 ® computer via a link in compliance with IBM communications recommendations, thus enhancing the protection provided by your Galaxy PW™.
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MGE W arranty & Proprietary Rights for Three Phase Products MGE W arranty The liability of MGE UPS SYSTEMS, INC. hereunder is limited to replacing or repairing at MGE UPS SYSTEMS, INC.
Galaxy PW TM UPS 100 to 225 kV A 86-133060-00 A00.
MGE Customer Care Center 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 servicing of your equipment, please direct calls to MGE UPS SYSTEMS, INC.
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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. ® Trade Mark. 2nd Second. AC or ac Alternating current, also implies root-mean-square (rms).
DC Direct current. Conduit A flexible or rigid tube enclosing electrical conductors. C.S.S. Customer Support Service. Current rating The maximum current that a conductor or equipment can carry reliably without damage. dBA Decibel Adjusted. dBrnC Decibel above reference noise.
Glossary G — 3 86-133060-00 A00 MCM Thousand circular mil. standard wire sizes for multiple stranded conductors over 4/0 A WG in diameter . M is from Roman numerical system indicating 1000. Module Refers to individual power inverter module. N Neutral.
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Reorder Form 1660 Scenic A venue Costa Mesa, CA 92626 Use this form to report any err ors, omissions, or other problems you have experienced, or to or der additional hardcopies of this document. A fr ee copy of this document may be downloaded from the proprietary MGE Rep W eb site.
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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 T el: (714) 557-1636 (800) 523-0142 Fax: (714) 557-9788 email: info@mgeups.com www: mgeups.
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