Ups
Ups
c o m
Features
◗ Battery Cabinet
◗ Maintenance Bypass
◗ Optional Up-link to an
IBM AS4000
Galaxy PW™
100 to 225kVA
Uninterruptible Power Systems
86-133060-00 A00
Galaxy PW™ UPS 100 to 225kVA
ATTENTION L'ouverture des cabinets expose des tensions dangereuses. Assurez-vous tou-
jours que le service ne soit fait que par des personnes qualifiees.
WARNUNG! Das öffnen der Gehäuse legen gefährliche Spannungen bloss. Service sollte
immer nur von qualifizierten Personal durchgeführt werden.
WARNING As standards, specifications, and designs are subject to change, please ask for
confirmation of the information given in this publication.
NOTE This equipment has been tested and found to comply with the limits for a Class
A digital device, pursuant to part 15 of the FCC rules. These limits are designed
to provide reasonable protection against harmful interference when the equip-
ment 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.
Certification Standards
◗ IEEE 587-1980/ANSI C62.41 1980 Standards for Surge Withstand Ability
◗ ISO 9001
WARNING To reduce the risk of fire or electric shock, install in a temperature and humidity
controlled indoor area free of conductive contaminants.
ATTENTION Pour réduire le riske d'inccendie ou d'électrocution, installer dans une enciente
intérieure contrôlée en température et humidité et sans contaminants conducteurs.
WARNUNG! Um die Gefahr von Feuer und elektrischem Schock zu reduzieren, muss das
Gerät in einem temperatur - und feuchtigkeitskontrollierten Raum, frei von
leitungsfähigen Verunreinigungen, installiert werden. Dieses Gerät ist nur für
die Installation an einem Ort mit eingeschränkter Zugangserlaubnis vorgesehen.
Typographical conventions use single quote marks in procedures to denote a prompt for User action:
For example: 1. After the selections are complete, click on the “Save” button.
This manual uses four icon symbols with text to convey important information and tips.
WARNING 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 service personnel against
possible equipment damage.
86-133060-00 A00 How To Use This Manual and Symbol Usage iii
Galaxy PW™ UPS 100 to 225kVA
RECORD ALL SERIAL NUMBERS FOR THE GALAXY PW™ AND COMPONENTS.
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!
____________________________ ______________________________
____________________________ ______________________________
____________________________ ______________________________
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Galaxy PW™
100 to 225kVA
Installation and User Manual
Revision History
G a l a x y P W ™ 1 0 0 t o 2 2 5 k VA I n s t a l l a t i o n a n d U s e r M a n u a l 86-133060-00 A00
Revision: X1 Initial Release 06/2003
A00 ECN#: 003469 02/2006
Technical Support:
1-800-523-0142 (during business hours)
86-133060-00 A00 v
Galaxy PW™ UPS 100 to 225kVA
vi 86-133060-00 A00
Contents
description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page
Section 1 Introduction
section description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page
1.0 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 1
1.1 Section Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 1
1.2 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 2
1.3 System Major Power Components . . . . . . . . . . . . . . . . . . . . . . . .1 — 3
1.4 Different Types of Galaxy PW™ Systems . . . . . . . . . . . . . . . . . .1 — 4
1.4.1 Single UPS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 4
1.4.2 Parallel UPS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 4
1.5 System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 5
1.5.1 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 5
1.6 Electrical Parameters for Selecting Protective Devices . . . . . . . .1 — 6
1.6.1 Normal AC Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 6
1.6.2 Bypass AC Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 7
1.7 Recommended Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 8
1.7.1 Protection Upstream of Galaxy PW™ . . . . . . . . . . . . . . . . . . . . .1 — 8
1.7.2 Protection Downstream of Galaxy PW™ . . . . . . . . . . . . . . . . . . .1 — 8
1.8 Parallel Connected UPS Units . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 9
Section 3 Installation
3.0 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 1
3.1 Optional Communications Card Installation . . . . . . . . . . . . . . . . .3 — 1
3.2 Notes on Connection of Power Circuits . . . . . . . . . . . . . . . . . . . .3 — 1
3.3 Power-Circuit Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 2
3.4 Hot Swap Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 2
3.5 Connections Between Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 4
3.5.1 Connections Between UPOZ Boards . . . . . . . . . . . . . . . . . . . . . .3 — 4
3.5.2 Connections Between UPS Cabinets and the
Remote External Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 4
3.5.3 Connections Between MUSI Boards . . . . . . . . . . . . . . . . . . . . . .3 — 5
3.6 Environmental Signal of the Media Contacts 11 Board . . . . . . . .3 — 7
3.6.1 Signal Reception . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 7
3.6.2 Signal Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 7
3.7 "Media Contacts 11" Standard Auxiliary Circuits Connection . . . .3 — 9
3.7.1 Battery Circuit Breaker "QF1" Connection . . . . . . . . . . . . . . . . .3 — 10
3.8 Installation of the "Temperature Monitor" in the
Battery Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 10
3.8.1 "Temperature Monitor" installation in a Battery Room . . . . . . . .3 — 11
3.8.2 Connection of the Battery "Temperature Monitor" . . . . . . . . . . .3 — 12
3.9 About Final Installation Steps . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 14
Section 4 Operation
4.0 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 1
4.1 Start-up of a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 1
4.1.1 Start-up of an Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 1
4.1.2 Emergency Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 1
4.1.3 Single UPS Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 2
4.1.4 Parallel UPS Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 2
4.2 Operation in On-line Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 3
4.2.1 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 3
4.2.2 Operation with the Normal AC Source Down . . . . . . . . . . . . . . . .4 — 4
4.3 Operation with the Normal AC Source Restored . . . . . . . . . . . . .4 — 5
Section 5 Maintenance
5.0 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 — 1
5.1 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 — 1
5.2 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 — 2
5.2 Maintenance Isolation Procedures . . . . . . . . . . . . . . . . . . . . . . . .5 — 2
5.2.1 Single UPS Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 — 2
5.3 Steps for Parallel UPS Redundancy to Increase Output . . . . . . .5 — 4
5.4 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 — 6
5.5 Visual Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 — 6
5.6 Functional System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 — 6
5.7 Testing Parallel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 — 7
5.7.1 Galvanic Isolation and Voltage Matching Transformers . . . . . . . .5 — 7
5.8 Management of Computer Networks . . . . . . . . . . . . . . . . . . . . . .5 — 7
5.8.1 Integrated SNMP Agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 — 7
5.8.2 Two-channel Network Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 — 7
Appendices
description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page
Appendix A
Front Control Panel Display Definitions . . . . . . . . . . . . . . . . . . . . . . . . . .A — 1
Display of Primary and Secondary Messages . . . . . . . . . . . . . . . . . . . . .A — 4
Primary Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A — 5
Secondary Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A — 6
Appendix B
Monitoring - Electrical Supervision Options . . . . . . . . . . . . . . . . . . . . . .A — 11
"Teleservice" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A — 11
Utilization Via Teleservice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A — 11
GTC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A — 11
GTC + Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A — 11
Appendix C
Link to an IBM AS/400® Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . .A — 13
Connect and Configure the AS400 Link . . . . . . . . . . . . . . . . . . . . . . . . .A — 13
Glossary
Term and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G — 1
Figures
figure description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page
Figures (continued)
figure description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page
Tables
1.0 Scope
Introduction is a general description and overview of Galaxy PW™ 100 to 225kVA components, its intended use,
environment, and applicable specifications, power input/output requirements, and system characteristics for
different system configurations.
Introduction is a general description and overview of the Galaxy PW™ 100 to 225kVA components, its intended use,
environment, and applicable specifications, power input/output requirements, and system characteristics for
different system configurations.
2 System Setup
System Setup describes receiving and handling of the Galaxy PW™ 100 to 225kVA, a description of major compo-
nents, the battery cabinet, and definition of the control panel indicators. Includes electrical, mechanical and
environmental specifications.
3 Installation
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. Wire diagrams
are included for configuring the unit to specifications.
4 Operation
Operation describes the theory of operation, start-up for single and parallel units, modes of operation, normal speci-
fications for operating the Galaxy PW™ 100 to 225kVA. The User procedures include display messages,
measurement systems, alarms, battery cabinet, and log time-stamping procedures.
5 Maintenance
Maintenance procedures for isolation for maintenance, startup for single and parallel units, functional and visual
checks, software configurations, and testing scenarios.
Appendices
Connections are made through the bottom. (Connections through the top are an available option.)
◗ On the floor under the cabinets, in the free space equal to the height of the feet; in this case the cables
should be run side by side to avoid blocking the flow of air for ventilation.
◗ The bypass AC-source transformer in an auxiliary cabinet and the UPS cabinet.
Only the wires for the inter cabinet control connections between parallel-connected UPS units are supplied.
The other power cables for connections between cabinets are not supplied.
Battery unit (D) Provides backup power for the inverter in the event of a voltage drop or a normal AC
source failure.
Inverter module (B) Converts the DC power supplied by the rectifier/charger module or the battery unit
into 3-phase AC power for the load.
Static bypass module (C) Ensures the instantaneous transfer of the load to the bypass AC source input in the
event of an inverter shutdown (initiated by the user or by a protective device) or a
sudden overload.
Maintenance Bypass Isolates the UPS for maintenance and transfers the load to bypass AC source input
without interrupting the supply of power. The maintenance bypass is made up of
three manual switches (Q3BP, Q4S and Q5N).
Q5N: Isolation of the inverters of all the parallel UPS systems from the load.
The normal AC input and the bypass AC input have different functions and, depending on the installation, may be
protected differently upstream and/or come from different sources.
When increased power is required, several Galaxy PW™ units may be connected in parallel (up to four, refer to
section 4.0). In this configuration, an "isolation" function is added for the UPS system as a whole for maintenance
purposes, without interrupting the supply of power to the load.
UPS power rating in kVA 100 130 150 180 200 225
Normal AC input
number of conductors 3 phases
rated voltage and tolerances 480 V ± 10% (adjustable to ± 15%)
rated frequency and tolerances 60 Hz / ± 10%
THDI < 14% < 11% < 10% < 8% < 7.6% < 7.5%
power factor up to 0.9
Bypass AC input
number of conductors 3 phases 3 phases + neutral
rated voltage and tolerances 480 V / ± 10%
rated frequency and tolerances 60 Hz / ± 10%
Load
number of conductors 3 phases 3 phases + neutral
Ph/Ph voltages 480 V
Ph/N voltages 277 V
voltage fluctuations (Ph/Ph,Ph/N) ± 1%
adjustable frequency and tolerances
(on battery power) 60 Hz ± 0.05 Hz
synchronization with bypass ± 0.5 Hz (adjustable from ± 0.25 Hz to ± 2 Hz)
transient voltage variation for 0 to 100% load step change ± 2% (with battery), +2%/-6% (without battery)
permissible overloads 150% for 1 minute, 125% for 10 minutes
Isc Ph/Ph (% of I rated) 4.7 3.6 3.2 2.6 2.4 2.1
Isc Ph/N (% of I rated) 7.4 5.7 5 4.1 3.7 3.3
THDU Ph/Ph and Ph/N for linear load < 1.5% Ph/Ph, < 2% Ph/N
THDU Ph/Ph and Ph/N for non-linear load < 2% Ph/Ph, < 3% Ph/N
(at 80% of Pn)
Battery
voltage floating 512V to 561V
standard battery type gas-recombination sealed lead-acid battery
UPS characteristics
active power (kW) 100 130 150 180 200 202.5*
efficiency at 50% load (%) 90.5 91 92 92.5 92.5 93
(values ± 1%)
efficiency at 100% load (%) 92.5 93 93 93 93.5 93.5
(values ± 1%)
heat losses (1) in KW 8.1 9.8 11.3 13.5 13.9 14.1
in cal./s 1940 2350 2700 3240 3340 3380
storage temperature range ºF (ºC) -13 to 158 (-25 to 70) dry heat — unit without battery
-4 to 113 (-20 to 45) — unit with battery
operating temperature range ºF (ºC) 32 to 95, 104 for 8 hours (0 to 35, 40 for 8 hours)
relative humidity 95% maximum non condensing at ambient temperature
maximum operating altitude without derating, FT(m) < 3280 (< 1000)
noise level (dBA) 62 63 64 65 67 68
dimensions, in. (mm) width 47.8 (1215)
depth 33 (840)
height 74.8 ± .39 (1900 ± 10)
weight lbs (kg) 3050 (1388)
standards design NFPA / NEC / NEMA / OSMA
product and safety UL 1778 - ULC
electromagnetic compatibility FCC Part 15, Subport J, Class A - IEEE587 / ANSI 62.41
(1): The losses indicated are those produced at full rated load with the battery float charging. They must be taken into account when sizing the ventilation system.
* pf of 225kVA unit has 0.9 and remaining units have 1.0.
IMPORTANT It is essential to choose the type of circuit breaker according to its breaking
capacity and the prospective short-circuit current at its place of installation.
This choice must also be made so as to protect the static-switch semicon-
ductors with respect to the maximum permissible currents and ensure
discrimination between the UPS output fuses and the downstream
protection devices.
(1) The rated normal AC source currents (In) have been determined for a rated phase-to-phase voltage of 480 V,
a battery with a 10 minute backup time at the beginning of its charge (412 x 1, 2 = 494 Volts) and full rated load
with a power factor of 0.9.
(2) The rated normal AC source currents (In) have been determined for float charging voltage and full rated load
with a power factor of 0.9
(3) The normal AC source currents given for an overload of 25% or 50% are maximum values. They have been
determined for a battery with float charging voltage and a load power factor of 0.9. When choosing the circuit
breaker rating, use the "rated current" column and check that the circuit breaker tripping curves are compatible
with the values in the overload columns.
NOTE If the installation includes a transformer on the bypass AC input, allow for the
inrush current caused by magnetization of the transformer windings.
(1) The bypass AC source currents have been determined for a rated phase-to-phase voltage of 480 V, a load
power factor of 0.9 and for full rated load as well as overloads of 25% or 50%. When choosing the circuit breaker
rating, use the "rated current" column and check that the circuit breaker tripping curves are compatible with the
data in the overload columns. See table and chart below.
Table 1-2A:
10 1
1
10- 1
10- 2
10- 3
10- 4
102 10 3 10 4 I(A)
Ratings
Table 1-5 serves as an example for a parallel connected installation comprising up to four UPS units.
Table 1-5: Parameters for Bypass AC Source and Load Cables for a Parallel UPS.
Parameters
rated unit number of total UPS bypass AC
output parallel- rated output source or load
in kVA connected in kVA line current
units in Amps
2.0 Scope
System Setup describes receiving and handling of the Galaxy PW™ 100 to 225kVA, a description of major compo-
nents, the battery cabinet, and definition of the control panel indicators, which includes electrical, mechanical and
environmental specifications.
MGE also recommends obtaining an MGE field service engineer for final installation and basic startup for single and
parallel units.
CAUTION Scheduling of 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. The MGE Field Service Engineers will insure a
quick installation for the initial safe startup and configuration of your Galaxy PW™.
Final installation and start-up should be completed by a qualified MGE Field Service Engineer.
Step 5. The MGE Field Service Engineer finalizes installation and the startup process.
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. In the event of a non-conforming item, quote the delivery note reference number when making your
claim.
2.1.1 Handling
The cabinets are delivered on pallets, equipped with a shock absorbing system. Ideally, the equipment should be
unpacked just before installation (see "unpacking" section below). Cabinet weights and dimensions are specified on
the packaging. Cabinets may be handled in one of the following ways (see Figure 2-1):
Do not mount the foot pads, but place the cabinet on the rollers (at least three). The cabinet may be pulled on rollers
using a sling positioned horizontally. This technique should only be used when absolutely necessary (narrow
doorway or corridor, preventing the use of a fork-lift or pallet-mover).
The cabinets can be moved from the front or the rear (715 mm wide cabinets) using a pallet truck or fork-lift truck,
or on the 4 surfaces (1015 mm and 1215 mm wide cabinets) using a fork-lift truck.
The 715 mm wide cabinets are designed to pass through 715 mm wide openings, and the other cabinets are
designed to pass through 825 mm wide openings. For narrow openings, (follow the instructions below) cabinets are
normally 825 mm deep.
unpack the cabinet, refer to section 2.2 ‘Unpacking’, page 4. The cabinet can then be handled by lifting machines
on all surfaces after the pallets have been dismantled by removing the rear panels, and remove the fixing screws
using a "torx" screwdriver.
3. For cabinets fitted with a control panel, carefully disconnect the ribbon cables from the panel circuit boards
located on the inside of the door.
A B
From Bottom On Rollers
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. Storage in original packing is recommended, since this packaging is designed to provide
maximum protection during storage and handling. If the unit must be unpacked prior to final installation, cover the
equipment with a shroud providing protection against dust, debris, or paint.
IMPORTANT Transport: the temperatures must remain within the -30° to +50°C range and the
duration should not exceed 30 days.
Storage: the battery is of the sealed lead-acid or vented lead-acid type and should not be stored for more than six
months at 20°C without recharging for batteries that are initially fully charged (for partially charged batteries, the
storage time should be reduced). After the recommended maximum storage time, the battery must be charged,
requiring partial start-up of the equipment (rectifier-charger).
The battery cells can be stored at a temperature between -20°C and +45°C if delivered in their initial packing.
The ideal battery storage temperature is between 15° and 25°C (higher temperatures result in reduced storage life
or downgraded technical characteristics). If higher temperatures cannot be avoided during transport or storage,
please consult us.
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).
4. Withdraw the "hexagonal spacer + leg" assemblies delivered inside the document holder.
5. Screw the spacers onto the cabinet frame (C).
6. Lock these spacers in position using a 24 mm flat wrench, and fit the cabinet on its legs.
7. Adjust cabinet height and verticality by screwing or unscrewing the legs using a 13 mm flat wrench.
A B C
AA B
A
H H K M N 3 O P
C D L
T
V
S
U
M
G R
Q
Z
Q1
W
Q4S Q3BP Q5N
1, 2, E,F
GND N
L1L2 L3 L1L2 L3 L1L2 L3
G G
1 F X 2 E Y
I
A
J
AA B
A
C D
XR1
QF1
+ +
E
H
I J
F A
K L
G
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.
If your installation is custom designed, a separate installation drawing may apply to your system.
Transfer instructions can be found in front of the cabinet including the proper operation of the kick key interlock.
350A 1200A
NEURTRAL
(NOT SHOWN)
SEISMIC
MOUNTING REMOVABLE PANEL
CUTOUTS FOR CONTROL AND
POWER
CONDUIT ENTRY
SEISMIC HOLE
LOCATION
FORKLIFT OPENINGS
(LEFT & RIGHT
SIDE TYPICAL)
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.
1. Press the ▲ and ▼ keys to scroll up and down through the screens.
For time-stamped events, the display begins with the last event logged. To access older events, press the ▼ key.
If during consultation, you wish to review more recent events, press the ▲ key.
Located in the upper right part of the cabinet front, the control panel is designed to provide an easy and rapid
overview of system status. See Figure 2-6.
Interpretation of symbols is very simple and requires no particular training. The information concerns only the
cabinet on which the panel is located. Refer to Appendix A for a complete List of Primary and Secondary display
messages.
1 2 3 4 5 6
2
7
22 8
9 10 11 12 13 14
15 15
V A W.Hz
17
16 18
fault
19 20 21
7 "Inverter ON" button This button is used to start the inverter locally.
8 "Inverter OFF" button This button turns the inverter off locally.
9 -10 Keys These keys are used to select commands in the main menu and access the secondary
messages.
12 ø Key This key is used to access the main menu: display language, display-contrast setting,
sound level of the buzzer, lamp test, date and time settings, inverse-video and event log.
19 "Forced-transfer" This key is used to voluntarily transfer the load to the inverter or from the inverter to the
static bypass (return transfer).
20 "Alarm reset" This key is used to reset stored alarms. The system accepts resetting only when alarms
have been cleared.
21 "Buzzer reset" This key is used to stop the buzzer. However, new alarms set the buzzer off again.
1. Close the upstream switches supplying normal and bypass AC source power (on the LV switchboard).
- 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.
QF1 22 8
4
0 I
1
1 1 1
5 0 0 0 0
7 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 LV switchboard).
3. Close the normal AC input circuit breakers Q1 on the UPS units. The system powers up:
- lights 2 go off.
6. Close output switches Q5N for the inverters and in the external bypass unit.
9. When a sufficient number of inverters are ready, the inverter-output contactors close:
Q1
4 1 0
1
0
1
0
5 6 7
external bypass
1 1
Q5N 0 0
Q3BP 0 1 1
0
7 8
7
2 — 12 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. Wire
diagrams are included for configuring the unit to specifications.
MGE recommends obtaining an MGE field service engineer for final installation and basic startup for single and
parallel units. Final installation and start-up should be completed and performed by a qualified MGE Field
Service Engineer.
◗ Boards may be installed with the UPS on, without removing the protective covers.
◗ Boards must be pushed to the end of the slots to ensure correct installation.
◗ Board front plates must be screwed to the protective "Media Contacts 11" board cover.
◗ Wire routing holes are provided in the support for the "Media Contacts 11" board for tying down the wires;
◗ The control wires must then be routed through the cableway marked "W" in figure 2-3, page 2—5.
◗ All the cabinets must be interconnected for equipotential bonding, forming a mesh which is itself connect-
ed to the building structure and earthing electrode.
The connection drawings hereafter show the cabinets with doors open and terminal shields removed.
CAUTION Before making connections, check that switches Q1, Q4S, Q3BP, Q5N and QF1 are
in the "open" position.
IMPORTANT For parallel UPS with an external bypass unit, the power connections between
each UPS cabinet and the external bypass unit must imperatively be of the same
length. Outside the cabinets, separate the auxiliary wiring from the power cables.
Legend:
QF1 + – + –
D E 1: Normal AC source,
F 2: Bypass AC source,
F
A: Rectifier/charger module,
1 Q1 Q5N
A B ( ) B: Inverter module,
F: The equipotential-bonding
connection between cabinets.
The option may be used for single UPS units and redundant parallel UPS. For the power-circuit connections of a
single UPS unit see Figure 3-2, for the power-circuit connections of parallel UPS see Figure 3-3.
Legend:
Q3BP
1: Normal AC source.
F: The equipotential-bonding
connection between cabinets.
Legend:
2 Q3BP
1: Normal AC source,
2: Bypass AC source,
QF1 + – + –
D E A: Rectifier/charger module,
F
F B: Inverter module,
1 Q1 Q5N
A B ( )
2 Q4S
( ) C
Galaxy PW
The purpose of the connection is to make a loop. Connector XM137 on the UPOZ board of one UPS unit must be
connected to connector XM136 on the UPOZ board of the next UPS unit and so on until the first board is returned
to origin.
'UPOZ'
Galaxy PW 1 TM
XM137
XM138
'UPOZ'
Galaxy PW 2 TM
XM137 A
XM138
'UPOZ'
Galaxy PW 3 TM
XM137
XM138
3.5.2 Connections Between UPS Cabinets and the Remote External Bypass
Refer to the installation drawing included with the Maintenance Bypass Cabinet for control and power connections.
These connections are provided and installed by the user.
1. Connectors XM5, XM6 and XM7 on the MUSI board are used to transmit signals.
2. Connectors XM10, XM11 and XM12 on the MUSI board are used to receive signals.
3. Connector XM5 is associated with connector XM10 for communication with one UPS unit; similarly, XM6 is
associated with connector XM11 for communication with a second UPS unit and XM7 is associated with
connector XM12 for communication with a third UPS unit.
◗ For connection with two parallel UPS units, see Figure 3-5.
◗ For connection with three parallel UPS units, see Figure 3-6, page 3—6.
◗ For connection with four parallel UPS units, see Figure 3-7, page 3—6.
IMPORTANT Outside the cabinets, group the "UPOZ" inter-board and "MUSI" inter-board
connections with the inter-cabinet auxiliary connections, and separate this
assembly using power cables.
'MUSI'
Galaxy PW 1 TM
XM5
XM10
XM6
XM11
XM7
XM12
A
'MUSI'
XM5
Galaxy PW 2 TM
XM10
XM6
XM11
XM7
XM12
'MUSI'
XM5
Galaxy PW 2 TM
XM10
XM6 A
XM11
XM7
XM12
'MUSI'
XM5
Galaxy PW 3 TM
XM10
XM6
XM11
XM7
XM12
'MUSI'
XM5
Galaxy PWTM 2
XM10
XM6
XM11
XM7
XM12
A
'MUSI'
XM5
Galaxy PWTM 3
XM10
XM6
XM11
XM7
XM12
'MUSI'
XM5
Galaxy PWTM 4
XM10
XM6
XM11
XM7
XM12
Emergency off: An NC contact causes shutdown of the inverter and the rectifier/charger, opening of
the battery circuit breaker, blocking of the static bypass and activation of a relay
contact on the "Media Contacts 11" board.
Battery room
ventilation fault: A ‘NO’ contact causes shutdown of the rectifier/charger.
Battery circuit
breaker QF1 closed: A ‘NO’ contact prevents inverter start-up if the circuit breaker is open.
Battery temperature: A PC-board, placed near the battery, supplies information on the battery tempera-
ture, thus enabling the rectifier/charger to regulate the battery voltage.
"Auxiliary" signals: Depending on the selected settings, these signals may be used to provoke:
- forced shutdown of the inverter (whatever the status of the bypass AC source),
- limiting of the battery charge current (programmable value) if the normal AC source
is replaced by an engine generator set with an insufficient power rating.
"low battery"
warning signal: (Volt-free changeover contact) indicating that battery time is about to run out.
The warning threshold may be personalized.
"load on UPS" signal: (Volt-free changeover contact) indicating that the load is supplied by the
inverter. For a single-UPS unit, one volt-free changeover contact may be used
to indicate that the load is supplied by the bypass AC source.
"load on battery power" signal: (Volt-free changeover contact) indicating that the inverter is supplied
by the battery in the following cases:
- rectifier/charger shutdown.
This signal, which may be used to initiate process saving and shutdown
procedures, is time-delayed 30 seconds to avoid unnecessary operations
following micro-breaks.
circuit breaker(s) QF1: In the event the "emergency off" button is pressed or to avoid an excessive
battery discharge (lasting more than three times the rated backup time plus two
hours).
Repo Contact: (Volt-free changeover contact) used to trip switching devices in the event of an
emergency shutdown.
- internal faults.
Recommended cable cross-section: 1 mm2. The male connectors that fit the female connectors on the board (XR2
to XR5) are supplied. The contacts are volt-free and are shown in the diagram under the following conditions: UPS
on, contact at rest. Contact breaking capacity: 250 V, 5 A.
XR4
XR5
IMPORTANT In the case of a complex installation with parallel units, there should be only one
emergency shutdown pushbutton and this pushbutton must interrupt all the units.
This pushbutton must therefore have as many contacts as there are units in the
installation. The emergency shutdown pushbutton turns off the rectifier/ chargers
and inverters, opens the battery circuit breakers (QF1), the input circuit breaker (Q1)
on the normal source, the backfeed protection contactor (K4S) on the bypass AC
source, blocks the static switches and activates a contact on the "Media Contacts 11"
board (terminals 1 to 3 on connector XR4).
1. Open the unit cover, and before fixing, break the self-cleaving seal on the base of the unit for insertion of the
connecting cable.
2. Fix the unit on the plate using the self-adhesive sticker and a screw (nut and washer combination, diameter 4
mm, length 16 mm, not supplied).
3. Connect and put back the cover. The temperature sensor MUST be placed at the top of the cabinet to work
properly.
4. Tie the connecting cable to the cabinet upright so that it does not pull on the unit.
Battery Cabinet
Temperature
Monitor unit
to UPS Cabinet
1. Choose a location near the batteries and away from draughts which adversely affect the accuracy of
temperature measurements. Dimensions: 75 x 75 x 21 mm.
2. Use the holes provided in the base plate to screw the unit to the vertical support, unless the connecting cable
runs on the surface, break the knock-out in the unit base plate provided for cable entry. Secure the cable by
suitable means so that it does not pull on the unit.
Mounting Hole
Mounting Hole
Dimensions: 75 x 75 x 21 mm
Use a shielded cable made up of 2 twisted telephone pairs with a conductor cross-section of at least 0.1 mm2, not
longer than 100 m in length. Do not forget to connect the cable shield to ground pin 12 on connector XR2;
In the case of a parallel UPS configuration, the connections between cabinets may be made by means of a shielded
cable made up of 1 or 2 twisted telephone pairs. In this case, the total length of all the connecting cables must not
exceed 100 m;
A "Temperature Monitor" unit can be connected to several UPS cabinets only when the batteries of these cabinets
are located in the same room at the same ambient temperature.
Figure 3-11: Single UPS Unit Connection of the Battery "Temperature Monitor".
12 each
11
XR2 10
9
8
7
6 -12V power supply
5 +12V
4 DC + temperature
3 DC - signal
2
XR1
1
-12 +12
(unit shown open)
Refer to Appendix C for link-up options using an IBM AS400 computer for additional monitoring capability.
Figure 3-12: Connection of the Battery "Temperature Monitor." (In Parallel UPS Units with Batteries in Same Room.)
12 each
11
XR2 10
9
8
7
6 -12V power supply
5 +12V
4 DC + temperature
3 DC -
2
signal
XR1
1
XR2 connector on
-12 +12 'Media Contacts 11' Board
(unit shown open) in Galaxy PW unit 2:
12 each
11
10
9
8
7
6
5
Shielded cable 4 DC +
(1 or 2 twisted temperature
3 DC -
telephone pairs) 2
signal
1
XR2 connector on
'Media Contacts 11' Board
in Galaxy PW unit n:
12 each
11
10
9
8
7
6
5
4 DC + temperature
3 DC -
2
signal
1
XR4
XR1
XR's connector
output signals:
10
9 load or inverter (ON)
8
7
6 load or battery (utility failure)
5
4
3 low-battery shutdown warning
2 (low battery)
1
1
6 1
2 9
7 2
3 10
8 3
4 11
9 4
5 12
5
13
load on bypass (bypass active)
6
14
7
15
8
commond W (system ground)
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 225kVA, including display messages, measurement systems, alarms, batteries, and log
time stamping operations.
1 2 3 4 5 6
rectifier/ inverter (B):
charger (A): DC to AC
1 AC to DC power
power isolation and
protection:
2 normal Q5N
*FUSE *FUSE
7 AC
input (1) Q1
22 8 isolation
and
protection harmonic QF1: isolation
9 10 11 12 13 14
15 15 fliter and protection
maintenance bypass:
Q3BP
IMPORTANT After EPO/REPO, unit has to be reset by opening M2 feed (switch Q4S). Open
switch Q5N also, and then follow the procedure of single UPS for single unit or
parallel UPS for parallel units to start-up the system.
D
C
2
◗ The green "inverter" light 4 on the control panels of the running inverters goes on.
Q3BP
Q5N
1
S
2
2
Galaxy 1
1
2 Galaxy 2
Q3BP
Q5N
1
2
2
Galaxy 1
1
2 Galaxy 2
1
2 Galaxy 3
1
2 Galaxy 4
-The power necessary for the load is provided by the normal AC source (1) through the rectifier/charger (A)
and the inverter (B). The rectifier/charger (A) also supplies the power to float charge and recharge the
battery if any.
◗ The float-charging or the recharging voltage for vented lead-acid or Ni/Cd batteries.
The voltages depend on the number of battery cells and the battery manufacturer. Factory set, they may also be
adjusted by support technicians.
An electronic board continuously measures the battery temperature and automatically adjusts the voltages.
NOTE In parallel Galaxy PW™ systems, the power drawn by the load is equally shared
between the different units.
1 4 5
A B
1
D
C
2
The battery, float-connected between the rectifier/charger and the inverter, discharges during this operating mode:
The user is warned of battery operation by the slow beeping of the buzzer 6 , see Figure 4-6, and the message
"LOAD PROTECTED, BATTERY DISCHARGING", followed by the remaining backup time and the percent load.
This information is also available via volt-free changeover contacts for remote control devices.
2 4 5
A B
1
D
C
2
The rectifier/charger recharges the battery (D) which was discharged during the mains outage. During battery
charging, light 2 flashes green.
The message "BATTERY CHARGING" is displayed, together with the value of the recharging current and battery voltage.
1 2 4 5
A B
1
D
C
2
The battery charge cycle takes place in two steps: See Figure 4-8.
step 1: the battery is recharged at a constant current limited to 0.1C10 (i.e. 1/10th of the battery capacity specified
for a 10 hour discharge). The DC voltage increases with the battery charge until the charge level is reached.
step 2: the battery is recharged at constant voltage equal to the charge level. The charging current gradually
decreases until reaching a specified low value (floating current).
For vented lead-acid batteries, the rectifier/charger supplies the charging voltage for 0 to 255 hours (parameter
defined by the after-sales support department) and then the floating voltage. For sealed lead-acid batteries, the
charging and floating voltages are the same.
NOTE If the normal AC source failure is shorter than 0 to 255 seconds (default value = 30
seconds) (parameter defined by after-sales support department), the charger
automatically supplies the floating voltage given the low battery discharge.
U/I U charge/floating
voltage (sealed batteries)
U "floating"
(vented batteries)
0,1 C10
current
With such a system, the required battery time may be reduced to the time necessary for starting and bringing on
line the stand-by generator. The battery (D) supplies power to the inverter (B) during the transfers:
The transfer sequences described above (normal AC source ➜ battery, battery ➜ generator, generator ➜ battery,
and battery ➜ normal AC source) are fully automatic. They in no way affect the load and require no manual
operation by the user.
NOTE To avoid load surges on the generator, the rectifier/charger is started with a 10
second maximum current consumption walk-in (lasting 3 to 10 seconds,
depending on the percent load).
The specified battery time corresponds to a minimum duration at full rated load.
The actual backup time can therefore be greater if the system operates below its full rated load during the normal
AC source outage. Operation on battery power can be extended beyond the specified time by reducing the load
power consumption (by disconnecting non-critical loads).
A "low battery" warning signal is sent via volt-free changeover contacts for remote control devices when the battery
voltage reaches a level slightly above the minimum level. This signal warns the user of the imminent end of battery
power. On the device itself, the buzzer beeps rapidly.
The message "LOW-BATTERY SHUTDOWN WARNING" is displayed, followed by the remaining backup time and
the percent load. Light 2 turns red and flashes.
Battery power stops when the voltage supplied by the battery reaches the minimum threshold. This results in
inverter shutdown and transfer of the load without interruption to the bypass AC source. Light 2 shines red (not
flashing). The message "LOAD NOT PROTECTED, ON-LINE MODE" is displayed and the buzzer sounds continuously.
If the bypass AC source also fails, the load is no longer supplied. The inverter automatically shuts down when the
time on battery power exceeds three times the specified backup time.
NOTE The "low battery shutdown" warning signal can be sent with an adjustable time
delay prior to the effective end of battery power.
3 5
A B
1
D
C
2
NOTE Transfer conditions are not satisfied when bypass AC source characteristics are
outside tolerances (voltage: ±10%. frequency as per personalization. phase sync
with inverter ±3°).
In the event of a major transient overload (greater than 1.65 In), immediate transfer takes place as above, without
interruption to the load.
The return to the inverter is automatic when the overload disappears if the number of possible returns has not been
reached (0 to 255, programmable by personalization). If this number has been reached, the load continues to be
supplied by the bypass AC source. This operating mode allows start-up of load devices causing high inrush currents.
This system requires satisfied transfer conditions. If the conditions are not satisfied, the inverter will current limit to
165% of its rated current for 1 second before stopping.
In the event of a small but extended overload (i.e. a continuous level of power exceeding the full rated load), the
inverter will continue to supply power for a period depending on the magnitude of the overload (10 minutes for a
125% overload, 1 minute for a 150% overload). See the overload curve in Figure 4-11.
◗ In all the above cases, inverter shutdown and supply of the load via the bypass AC source results in the
following on the control panel:
WARNING During maintenance operation, when CB1 (MBP) is closed and CB2 (UPS
ISOLATION) is open, each UPS control panel display will show a message
“LOAD PROTECTED” when the UPS is placed in ON-LINE MODE. In this
mode the critical load is not protected because it is supplied by the mainte-
nance bypass power.
The shutdown of one inverter results in overload on the other inverters in operation. Two 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.
B) if the overload is less than 1.65 in, the remaining inverters support the overload (see curve in Figure 4-11), and
the load is transferred to the bypass AC source.
1,5 In
1,35 In
1,25 In
1,15 In
1,10 In
1,05 In
In
1 2 3 4 5 6 7 8 9 10 30 120 t (min)
- In the event of an overload, the system only loses its redundancy as long as the overload is less than the
total rated power of the functioning units. If the overload is greater, the operating mode is that previously
described for systems without redundancy.
The frequency of the output voltage can theoretically be regulated to within 0.1% of the rated value, however the
output frequency range may be intentionally extended to a maximum of ±2 Hz so that the inverter can remain
synchronized with the bypass AC source and its inherent frequency fluctuations, thus enabling transfer of the load
to the bypass line at any time.
When the bypass AC source frequency returns to within the specified tolerances, the inverter is gradually re-
synchronized to the bypass line at a rate of 0.5 Hz to 2 Hz/s (as per the value personalized by the after-sales
support department), thus avoiding exposing the load to sudden frequency variations.
This is made possible by the PWM (Pulse Width Modulation) chopping technique and the microprocessor-based
regulation system that instantly compensates for any variation. In particular, the inverter output voltage remains
within +/- 2% of the rated voltage for load step changes of 0 to 100% or of 100 to 0%.
step 1: The battery is recharged at a constant current limited to 0.1C10 (i.e. 1/10th of the battery capacity specified
for a 10 hour discharge). The DC voltage increases with the battery charge until the charge level is reached.
step 2: The battery is recharged at constant voltage equal to the charge level. The charging current gradually
decreases until reaching a specified low value (floating current).
For vented lead-acid batteries, the rectifier/charger supplies the charging voltage for 0 to 255 hours (parameter
defined by the after-sales support department) and then the floating voltage. For sealed lead-acid batteries, the
charging and floating voltages are the same.
◗ Battery 3
- voltage.
- battery temperature.
1 3 4 6
U -I-F U-I F U-V-I-F-P
A B
Q1 Q5N
1
QF1
D
2
U-V-I-F C
Q4S
2
Note:
Note:
Note:
FRENCH SPANISH
ENGLISH DUTCH
GERMAN SWEDISH
ITALIAN PORTUGUESE
◗ Lamp test:
When this function is selected, all the lights shine orange for three seconds.
Use the "▲▼" keys to enter the data and confirm using the "ø " key.
◗ Inverse Video:
When this function is selected, the text and background colors are reversed (white text on black or black
text on white).
◗ Past Events:
CHARGE LEVEL = -- %
REMAINING SERVICE LIFE = -- MONTH
■ MANUAL TEST press key ø
■ AUTO TEST press key ø
◗ Battery test:
the screen opposite is displayed when a battery test is requested. It indicates the battery charge status and
the remaining service life. A manual or automatic test may be requested.
TESTING BATTERY
U BATTERY = --- V
- this screen is displayed following a positive, automatic battery test. It indicates the time since the last test and
provides access to test settings:
- this screen is displayed following a negative, automatic battery test. It indicates the time since the last test
and provides access to test settings,
- this screen is displayed when the user requests access to the automatic test settings. It is possible to modify
the interval between two automatic tests,
TEST INTERRUPTED
CHECK PRESENCE OF THE BATTERY
CHECK ALARMS
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.
In this case, it is strongly recommended to call the MGE UPS SYSTEMS Customer Support Service at:
1-800-438-7373.
A) If the load is still correctly supplied with power, it has probably been transferred to the bypass AC source (static
bypass) and is therefore no longer protected (if the system is in on-line mode).
B) If the load is no longer supplied with power, transfer it manually to the maintenance bypass.
primary message
(ALARM MESSAGE N° 1)
(ALARM MESSAGE N° 2)
main screen
This operation is possible only if the system includes a bypass AC source. It results in the load being directly
supplied by the Bypass AC source via Maintenance Bypass switch Q3BP, thus ensuring a higher level of security in
the event of a malfunction.
Switching procedures are explained on drawings next to each switch in the UPS cabinet and the External Bypass unit.
◗ Consult the last 500 events that occurred on the Galaxy PW™ UPS.
◗ Consult measurement records for a number of physical values concerning system operation.
The time-stamping information may be accessed via the Galaxy PW™ keypad and display (standard equipment).
This information may also be forwarded for the Teleservice function using the JBUS RS232/485 communications
board. When the optional JBUS RS232/485 communications board is installed, the time-stamped information can
be sent to the Teleservice center. Refer to Utilization of Teleservice Card options Appendix B.
The complete log may comprise up to 500 events. If over 500 events have occurred, only the last 500 may be
consulted:
1. Press the ▼ key to display the event that occurred just before the displayed event. If the displayed event is the
oldest in the list, the display is not modified.
2. Press the ▲ key to display the event that occurred just after the displayed event. If the displayed event is the
most recent in the list, the display is not modified.
Example:
Note: numerical values are never indicated in screens for time-stamped events.
Example:
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 DATE AND TIME
command. The time-stamping information, statistics and measurement records are also available via the same
menu, using the PAST EVENTS command.
Simply select the desired command with the ">" sign that can be moved using the ▲ and ▼ keys. The selected
command can be confirmed by pressing the key.
When the DATE AND TIME command is selected, the date and time is displayed in the order of year, month, day,
hours, minutes, and seconds. When you leave this command, the date and time is displayed in the reverse order.
1. Position the ">" sign opposite the value to be modified. Then press the ø key.
5. Press the key at any time to exit the DATE AND TIME function.
That is the only means to leave the function. If no modifications to values are confirmed, exiting the function
corresponds to cancelling the request.
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.
switch (h): It is expressed in hours.
total time on UPS (d): This is the total time that the load has been supplied by the UPS since initial startup.
It is expressed in days.
total time with This is the total time of operation with the battery temperature greater than 25°C
Tbatt > 25°C (h): since initial startup of the UPS. It is expressed in hours.
last reset: This is the date that the information was last set to zero by the Teleservice function.
elapsed backup This is the total time of operation on battery power since the last reset. It is expressed
time (min): in minutes.
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.
1 min < nb of This is the number of times the load was supplied by the UPS from battery power
backups < 3 min: for more than one minute and less than three minutes, since the last reset.
nb of backups > 3 min: This is the number of times the load was supplied by the UPS from battery power for
more than three minutes, since the last reset.
nb of overloads < 5’s: This is the number of times the UPS was overloaded (output current greater than In)
for less than five seconds, since the last reset.
nb of overloads > 5’s: This is the number of times the UPS was overloaded (output current greater than In)
for more than five seconds, since the last reset.
nb of times This is the number of times the battery temperature was measured at over 25°C,
◗ 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 most recent measurement is presented first, in the upper left-hand corner of the list. The following
measurement is listed just below, and so on until the 30th value listed in the bottom right-hand corner of
the list.
◗ the period T between two successive measurements is 30 days. The displayed measurements are instan-
taneous values.
NOTE when this screen is selected, approximately ten seconds are required to call up
and display the information. If the number of measurements is greater than 30,
only the last 30 (the most recent) are displayed.
The backup time is the value calculated by the UPS microprocessor on the basis of measurements carried out on
the battery. It is expressed in minutes. The calculation uses the percent load and the battery charge status at the
time of the measurement.
The load level is the ratio between the power supplied by the UPS to the load at the time of the measurement and
the rated output of the UPS. It is expressed as a percentage.
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.
The technician or electrician performing preventive maintenance on the UPS must read thoroughly this manual
Galaxy PW™ Installation and Users Manual (MGE PN 86-133060-00) and be familiar with the indicators, controls,
and operation of the UPS prior to maintenance.
a. Isolate and de-energize all Galaxy PW™ equipment for all maintenance operations.
b. Ensure that all equipment is clean and free of loose dust, dirt, and debris. The exterior of the enclosures may
be cleaned with a mild solution of soap and water, lightly applied with a lint-free cloth.
c. Inspect the air intake and exhaust plates and clean as required. Verify that air flows freely through the
equipment. Clean the air intake and exhaust plates, and the enclosure interior, with a vacuum cleaner.
d. The Galaxy PW™ module is equipped with air filters that should be changed at regular intervals. Inspect the
filters regularly to determine how long the filters will last in your installation.
e. Initiate the start-up procedure, as described in the Installation and Users Manual section 2.7 System Start-up,
page 2—10.
f. Test the main operating sequences as applicable to your equipment configuration and installation.
Three levels of replacement parts are available for the Galaxy PW™ UPS. The three levels are designated A, B,
and C. The level that you should keep on hand for your installation will vary depending on the type of maintenance
planned on site, and the configuration of your UPS system. Having the replacement parts on hand will prevent any
unacceptable delays (due to time involved obtaining spare parts) during critical periods, such as system start-up.
Any items used during start-up will be replaced by MGE at no charge. Contact MGE Customer Support Services for
specific recommendations.
Level Description
A This level of replacement parts consists of consumable items, specifically fuses and air filters. It is
recommended to have these items on hand during installation of the UPS systems, including initial
start-up.
B This level of replacement parts is recommended when the user can tolerate short-duration UPS down-
time to obtain replacement parts in the event of a major UPS failure. This level of replacement parts
consists of consumable items, specifically fuses, air filters, an inverter leg, and the most critical circuit
board assemblies.
C This level of replacement parts is recommended when the user can tolerate only a minimum of down-
time in the event of a major UPS failure. This level of replacement parts consists of consumable items,
specifically fuses, air filters, an inverter leg, and a complete set of circuit board assemblies.
UPS Isolation
1. Shut down the inverter (press the "inverter OFF" button 8 for three seconds),
The UPS is powered down once the capacitors have discharged (a few minutes).
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,
D
C
Q4S
2
Q3BP
1
1 1 1
3 0 0 0 0
1
1 1 1
4 0 0 0 0
QF1
5
0 I
1
1 1 1
6 0
0 0 0
QF1
2
0 I
1
1 1 1
3 0 0 0 0
1
1 1 1
4 0 0 0 0
1
1 1 1
5 0 0 0 0
CAUTION Work should be carried out in accordance with applicable safety regulations. to
avoid interrupting the load, the various switching operations must be carried out
in the correct order. Operations are explained in diagrams placed next to the
switches. the system cabinet is only partially powered down. The load is still
supplied via the bypass AC source and switch Q3BP.
1. Shut down the inverters (press the "inverter OFF" buttons 8 for three seconds).
2. Close switch Q3BP and open switch Q5N in the external bypass unit.
7 8
Galaxy PW
1 2 3 4
external bypass
Q3BP 0 1 1
Q1 Q4S Q5N 0
1
1 1 1 1 1
4 00 0 0 Q5N 0 0
QF1
5
0 I
1
1 1
6 0 0 0
Start-up
Following servicing, proceed in the following order: (see Figure 5-5)
Q1
1 Q4S Q5N
1 1
1 0 0 0 2 3 4
external bypass
Q1 Q4S Q5N
1 1 1
Q5N 0 0
4 00
1
0
1
0
1
Q3BP 0 1 1
0
QF1
5
0 1
6 8
Q3BP
Q1 Q5N Q5N
1
QF1
Q4S
2
2
Galaxy 1
1
2 Galaxy 2
1
2 Galaxy 3
1
2 Galaxy 4
- these batteries require no maintenance, but check the terminals of each cell from time to time and clean
if necessary.
- check the voltage of each cell to determine if it is necessary to equalize the battery,
NOTE In redundant parallel UPS systems the check may be carried out successively on
each UPS unit without interrupting the load. In other configurations, the load
must be supplied via the maintenance bypass (see "maintenance bypass" in the
"Alarm" section).
1. Clean the system regularly, particularly the air filter inlet and outlet grills. Check that the air circulates freely in
the cabinets. Use a vacuum cleaner if necessary.
2. Check that nothing hinders the ventilation at the top and at the back of the system.
2. Press the "inverter OFF" button and check that the buzzer and control panel lights function correctly (see the
section on operating modes in the introduction).
3. Press the "inverter ON" button and check again that the control panel lights function correctly.
4. Run a transfer to battery test. With the inverter on, open input circuit breaker Q1. The orange "battery" light on
the control panel should light. After two minutes on battery power, close input circuit breaker Q1. The
rectifier/charger should automatically restart and the orange "battery" light on the control panel should go off.
The UPSs may then be supervised via the computer network. Furthermore, they can be used to close system files
without having to add an external SNMP agent.
The RJ45 connector of the communications option delivers information using the SNMP protocol. The sticker
located on the board indicates the UPS MAC address.
0080C8ABAA01
◗ The default IP address is 168.8.xx.yy (xx and yy are decimal values of XX and YY).
Please refer to the "userman.doc" user manual contained in the directory "emb/galaxy/snmp/release3.xx" of the
Solution-Pac CD-ROM in order to discover the management capabilities of your SNMP Galaxy PW™ UPS.
A) U-Talk is the protocol required to establish contact with the communications software.
B) Relay contacts may be used for specific network applications (IBM AS400, Novell, etc.).
Appendix A
◗ light shines red: rectifier/charger fault, the stored alarm indicates one or several of the following faults:
- fault, non-calibration or non-personalization of the electronic control board for the rectifier/charger,
2 "Battery light"
◗ light shines red: battery at end of backup time and circuit breaker QF1 open, or battery fault.
3 "Static-bypass" light
◗ light off: bypass AC source within specified tolerances and static bypass open.
◗ light shines red: the stored alarm indicates one or several of the following faults:
- static-bypass fault,
- fault on monitoring the "inverter ready" response channels (parallel UPS system).
4 "Inverter" light
◗ light flashing green: inverter starting, inverter ON but not connected to the load.
◗ light shines red: inverter fault, the stored alarm indicates one or several of the following faults:
- fault, non-calibration or non-personalization of the electronic control board for the inverter,
5 "Load" light
◗ light shines green: load supplied via the inverter or the bypass AC source (via the static bypass).
6 Buzzer
◗ load on battery.
◗ operating problems.
It sounds slowly and discontinuously for a minor problem or when the inverter is on battery power.
When the alarm "LOW BATTERY SHUTDOWN" is activated, the buzzer sounds more rapidly. Finally, if the inverter
shuts down, the beep is loud and continuous. The buzzer may be reset by pressing a button. If the buzzer is reset,
a higher level alarm will set it off again.
7 "Inverter ON" button This button is used to start the inverter locally.
8 "Inverter OFF" button This button turns the inverter off locally.
9 -10 Keys These keys are used to select commands in the main menu and access the secondary
messages.
12 Key ø This key is used to access the main menu: display language, display-contrast setting,
sound level of the buzzer, lamp test, date and time settings, inverse-video and event log.
13 "V" Key
14 "A" Key
◗ percent load.
15 "W.Hz" Key
16 "Anomaly" indicator light This indicator light indicates the presence of anomalies.
18 "Battery" Key ı
This key is used to access battery measurements:
◗ battery temperature.
This key is used to voluntarily transfer the load to the inverter or from the inverter to the static bypass
(return transfer). Transfer and return transfer are carried out only following confirmation requested by the
display and a warning as to the risk of an interruption in the supply of power to the load.
20 "Alarm reset" This key is used to reset stored alarms. The system accepts resetting only when alarms
have been cleared.
21 "Buzzer reset" This key is used to stop the buzzer. However, new alarms set the buzzer off again.
The presence of secondary messages is indicated by the arrow Ø at the end of the primary message. Return to
the primary messages is automatic if the keypad is not used for 2 minutes, or direct by pressing key 17 The display
screen lights up when a key is pressed, and goes off if no key is pressed for 5 minutes.
NOTE Most functions may be directly accessed. For example, when voltagemeasure-
ments are currently displayed, it is possible to directly access current
measurements by pressing the "A" button.
In addition to keypad operations, the graphical display brings up a window giving the overall device status. The
message displayed is then said to be primary (see list in the paragraph below). A primary message can be used to
access the measuring tables using keys 13 , 14 , 15 and 18 on the keypad The configuration screens can be
accessed by pressing key 12 .
A flashing arrow appears at the end of a primary message if there is a problem or an alarm. secondary messages
can be accessed by pressing key 9 on the keypad (see the list of secondary messages). The presence of another
message is indicated by the arrows Ø and ≠ at the end of the secondary message. They can be accessed by
pressing keys 9 and 10 on the keypad.
The return to the primary message is automatic after a 2 minute time delay or by pressing key 17 on the keypad.
IMPORTANT Select English U. S. as the display language to match the displays as presented
in this 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
PARALLEL 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 a parallel UPS system, in on-line mode.
LOAD PROTECTED
BATTERY DISCHARGING
Remaining battery time (min) = XX
% kW used = XXX
The load is supplied by the inverter, but the normal AC source is down or outside tolerances and power is supplied
by the battery.
This message indicates the remaining battery time in minutes prior to inverter shutdown and the percent load. The
battery time calculation takes into account:
◗ Battery temperature.
◗ Battery age.
LOAD PROTECTED
LOW-BATTERY SHUTDOWN WARNING
Remaining battery time (min) = XX
% kW used = XXX
This message replaces the preceding if the power outage persists and the warning level has been reached.
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.
Secondary Messages
LOAD ON MAINS 2
The load has been transferred to the bypass AC source (M2) and is no longer protected (only in on-line mode). The
buzzer sounds continuously.
Transfer of the load from the inverter to the bypass AC source (M2) or vice-versa will result in an interruption of the
supply of power to the load. The buzzer sounds slowly and discontinuously.
The user must take steps to re-establish correct operation of the ventilation system.
This message also signals an abnormally high temperature in the filter inductor.
OVERLOAD
RATED CURRENT PER PHASE = XXXA
CHECK LOAD LEVEL
This display informs the user that load current is greater than rated current, and gives the value. The buzzer sounds
continuously.
For parallel UPSs, this message should be interpreted as meaning the phase difference between the inverter for
which the message is displayed and the other inverters is outside tolerances.
UPS SHUTDOWN
BY AN EXTERNAL COMMAND
The inverter has received a command to shut down. The command is in the form of a signal from received the
remote-indications relay board which has been set for this function.
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. The buzzer sounds slowly and discontinuously.
EMERGENCY OFF
This message is displayed when the external emergency-off pushbutton is pressed. The result is:
PARALLEL UPS,
FORCED TRANSFER INHIBITED
This message is displayed when forced connection is requested on a parallel UPS system for a power extension.
VENTILATION FAULT
This message is displayed when a fault occurs on a fan.
Appendix B
"Teleservice"
"Teleservice" is a contract offering continuous remote supervision and maintenance of UPS systems via a modem.
Real-time communication is established with our "Teleservice" centre for communication of all alarms and events
occurring in the installation.
The center can remotely consult the same information and carry out the same modifications as the user locally on
the display. Note that only the Teleservice centre can reset the counters for the statistical data.
GTC Board
This electronic board provides user access to the J-Bus communications protocol. Using the data and address
tables provided, the user can customize his installation.
GTC + Software
The user has access to the J-Bus protocol and, in addition, the associated software acquires system parameters
(measurements, status conditions) and transforms them into diagrams, alarm messages and tables. With the click
of a mouse, the user can locally or remotely supervise the UPS system (comprising one or many UPS units).
Appendix C
The IBM AS/400® computer must be configured for the link. This section describes the physical connections
required as well as the system values that must be modified on the AS/400®. For further information, consult the
following IBM documents:
◗ "Back-up and Recovery Guide", chapter 7 "Power Loss Recovery" concerning configuration of the AS 400®.
1. On the AS/400® side, use a 9 or 15-pin SUB-D connector. (Depending on the type of AS/400®.)
2. Certain values on the AS/400® must be configured to enable operation of the Galaxy PW™ — AS/400® link.
The values requiring modification and the corresponding procedures are presented in chapter 7 "Power Loss
Recovery" of the "Back-up and Recovery Guide" for the AS/400®.
Configuration values:
A — 14 86-133060-00 A00
MGE Warranty & Proprietary Rights for Three Phase Products
MGE Warranty
The liability of MGE UPS SYSTEMS, INC. hereunder is limited to replacing or repairing at MGE UPS SYSTEMS,
INC.’s factory or on the job site at MGE UPS SYSTEMS, INC.’s option, any part or parts which are defective, including
labor, for a period of 12 months from the date of purchase. The MGE UPS SYSTEMS, INC. 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 UPS SYSTEMS, INC. for repair or replacement must be sent freight
prepaid to its factory. Purchaser must obtain MGE UPS SYSTEMS, INC.’s Return Materials Authorization prior to
returning items. The above conditions must be met if warranty is to be valid. MGE UPS SYSTEMS, INC. will not be
liable for any damage done by unauthorized repair work, unauthorized replacement parts, from any misapplication of
the item, or for damage due to accident, abuse, or Act of God.
In no event shall the MGE UPS SYSTEMS, INC. be liable for loss, damage, or expense directly or indirectly arising
from the use of the units, or from any other cause, 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. MGE UPS SYSTEMS, INC. is not liable for and Purchaser waives any right of action it has or may
have against MGE UPS SYSTEMS, INC. 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 of the use, operation or maintenance of the product. MGE UPS SYSTEMS, INC. will not
be liable for any labor subcontracted or performed by Purchaser for preparation of warranted item for return to MGE
UPS SYSTEMS, INC.’s factory or for preparation work for field repair or replacement. Invoicing of MGE UPS
SYSTEMS, INC. for labor either performed or subcontracted by Purchaser will not be considered as a liability by the
MGE UPS SYSTEMS, INC.
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 officer of the MGE UPS SYSTEMS, INC. This warranty shall extend to the Purchaser but to no
one else. Accessories supplied by MGE UPS SYSTEMS, INC., but manufactured by others, carry any warranty the
manufacturers have made to MGE UPS SYSTEMS, INC.. 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 the Product 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 damages except as expressly stated herein.
The information in this manual is the property of MGE UPS SYSTEMS, INC., and represents a proprietary article in
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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.
86-133060-00 A00
MGE Customer Care Center
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 part number, assembly number, and serial
number of the unit and include them in any discussions or correspondence.
Who To Contact
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 of 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, to insure a safe installation and startup that will maintain
the MGE warranty and insure smooth performance
Should you require factory service for your equipment, contact MGE’s Customer Support Services and obtain a Return
Materials Authorization (RMA) prior to shipping your unit. Never ship equipment to MGE without first obtaining an RMA.
Date: ______________________________________________________
/ And/or.
# Number.
°C Degree Celsius.
°F Degree Fahrenheit.
Ø Phase angle.
® Trade Mark.
2nd Second.
BTU or Btu British thermal unit. Defined as the amount of heat required to raise the temperature of one
pound of water by 1°F.
Carrier The company or individual responsible for delivering goods from one location to another.
C Common.
CB Circuit breaker.
cm Centimeter.
dB Decibels.
DC Direct current.
Current rating The maximum current that a conductor or equipment can carry reliably without damage.
Digital Meter The LCD display on the front panel of inverter system.
Earth ground A ground circuit that has contact with the earth.
Freq. Frequency.
Frequency slew rate The change in frequency per unit of time. Given in term of Hz per second (Hz/sec.).
I Current.
Input branch circuit The input circuit from the building power panel to the equipment.
Inverter An electrical circuit that generates an AC voltage source from a DC voltage source.
L Line.
mA Milliampere.
MAX. Maximum.
MCM Thousand circular mil. standard wire sizes for multiple stranded conductors over 4/0
AWG in diameter. M is from Roman numerical system indicating 1000.
N Neutral.
NC Normally close.
NO Normally open.
On-line mode Inverter output power is the primary energy source to load.
Off-line mode Inverter output is off, and the load connected at the inverter output receives power
from utility line via a static transfer switch or maintenance bypass relay.
Static Transfer An solid state switching mechanism electronically controlled to pass AC power direct-
ly from the utility to an output load.
Technician Refers to an electronic technician qualified to maintain and repair electronic equip-
ment. Not necessarily qualified to install electrical wiring.
Test connector DB-9 type connector on the LCD panel allowing MGE UPS SYSTEMS Customer
Support Service technician to access programmable and diagnostic features of the
system.
V Volts
VA Volt amperes
ve Battery voltage.
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 Representative for assistance.
NAME _______________________________________________________________________________________
COMPANY ___________________________________________________________________________________
Contact MGE
United States
MGE UPS SYSTEMS
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Costa Mesa, CA 92626
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MGE UPS SYSTEMS
#9, 2789 Thamesgate Drive
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