Galaxy 3000 User & Install Man

Galaxy 300010 - 30 kVAUninterruptible

Power System

Installation and User’s Manual

For service call:1-800-438-7373

MGE UPS SYSTEMS1660 Scenic Avenue

Costa Mesa, CA 92626(714) 557-1636

www.mgeups.com

Revision HistoryGalaxy 3000 10-30 kVA Installation and User's Manual

86-172010-00 C00Copyright © 2002 MGE UPS Systems, Inc.

All rights reserved. Printed in USARevision A00 New Release 05/01Revision A01 ECN 002152 08/01Revision A02 ECN 002271 10/01Revision B00 ECN 002473 03/02Revision C00 ECN 002565 04/02

i

Safety, Standards and Symbols

Critical Safety Instructions: WARNING EXPOSURE TO HAZARDOUS VOLTAGES: OPENING ENCLO-SURES EXPOSES HAZARDOUS VOLTAGES. ALWAYS REFER SERVICEAND INSTALLATION TO QUALIFIED PERSONNEL ONLY.

WARNING BATTERY POWER SOURCE: THE UPS SYSTEM CONTAINS ABATTERY POWER SOURCE PRODUCING LETHAL VOLTAGES EVENWHEN THE UPS IS TURNED OFF. UPS SERVICE SHOULD ONLY BECONDUCTED BY AUTHORIZED AND TRAINED PERSONS.

WARNING: Changes or modifications to this unit not expressly approved by theparty responsible for compliance could void the user's authority to operate theequipment.

Standards and Regulation Compliance:

This Class A digital apparatus meets all requirements of the CanadianInterference-Causing Equipment Regulations.

Cet appareil numérique de la classe A respecte toutes les exigences duRèglement sur le matériel brouilleur du Canada.

Shielded cables must be used with this unit to ensure compliance with theClass A FCC limits. This equipment has been tested and found to comply withthe limits for a Class A digital device, pursuant to Part 15 of the FCC Rules.These limits are designed to provide reasonable protection against harmfulinterference when the equipment is operated in a commercial environment.This equipment generates, uses, and can radiate radio frequency energy and,if not installed and used in accordance with the instruction manual, may causeharmful interference to radio communications. Operation of this equipment ina residential area is likely to cause harmful interference in which case the userwill be required to correct the interference at his own expense.

This device complies with Part 15 of the FCC Rules. Operation is subject tothe following two conditions. (1) this device may not cause harmful interference,and (2) this device must accept any interference received, including interferencethat may cause undesired operation.

Symbol Usage:

A WARNING notebox indicates information provided to protect the user andservice personnel against safety hazards and/or possible equipment damage.

A CAUTION notebox indicates information provided to protect the user andservice personnel against possible equipment damage.

An IMPORTANT notebox indicates information provided as an operatinginstruction, or as an operating tip.

A NOTE notebox indicates information provided as an operating tip or anequipment feature.

Technical QUESTIONS notebox: If you encounter a problem while following theinstructions in this manual, we recommend that you contact our CustomerSupport Services at 1-800-438-7373.

Personnel SafetyA UPS has its own internal power source (the battery). Consequently, thepower outlets may be energized even if the UPS is disconnected from the AC-power source.

Dangerous voltage levels are present within the UPS. It should be openedexclusively by qualified service personnel.

The UPS must by properly grounded.

The battery supplied with the UPS contains small amounts of toxic materials.To avoid accidents, the following items should be observed:

Never operate the UPS if the ambient temperature and relative humidityare higher than the levels specified in this manual.

Never burn the batteries (risk of explosion)

Do not attempt to open the battery (the electrolyte is dangerous for theeyes and skin)

Comply with all applicable regulations for the disposal of the batteries.

Product SafetyA protection circuit breaker must be installed upstream of the UPS and beeasily accessible.

Never install the UPS near liquids or in an excessively damp environment.

Never let a liquid or a foreign substance penetrate inside the UPS.

Never block the ventilation grates of the UPS.

Never expose the UPS to direct sunlight or a source of heat.

Special PrecautionsThe UPS connection instructions contained in this manual must be followed in the indicated order.

Check that the power rating on the rating plate correspond to your AC-powersystem and to the actual electrical consumption of all the equipment to beconnected to the UPS.

If the UPS must be stored prior to installation, storage must be in a dry place.

The admissible storage temperature range is: -10º C to +45º C

If the UPS remains de-energized for a long period, we recommend that youenergize the UPS for a period of 24 hours, at least once every month. Thischarges the batteries, thus avoiding irreversible battery damage.

ii

Safety Rules

Safety, Standards & Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i

Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii

Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .QS-1

MGE Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .QS-9

Recommended Tools and Parts Required for Installation

Section Page

1.0 — Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

This section describes the 10-30 kVA Galaxy 3000 UninterruptiblePower Systems including a general description of the system andits internal components, a description of available options, and general UPS definitions.

1.1 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

2.0 — Installation

This section describes the installation of 10-30 kVA Galaxy 3000 UPS.It also includes receiving, handling, storage, and installation procedures.

2.1 Unpacking and Site Preparation . . . . . . . . . . . . . . . .2-1

2.2 Preparation for Storage . . . . . . . . . . . . . . . . . . . . . . .2-2

2.3 Preparation for Operation . . . . . . . . . . . . . . . . . . . . .2-2

2.3.1 Cabinet Descriptions and Placement . . . . . .2-3

2.3.2 Cabinet Clearance and Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2.3.2.1 Air flow / Heat Rejection . . . . . . . . . . . . . . . .2-4

2.3.2.2 Recommended Operating Environments . . .2-4

2.4 Cabinet Footprints and Electrical Entries . . . . . . . . .2-4

2.4.1 Conduit Plate Location (top entry) . . . . . . . .2-4

2.4.2 Conduit Plate Location (bottom entry) . . . . .2-5

2.5 Accessing Electrical Connections . . . . . . . . . . . . . .2-5

2.5.1 Electrical Connections (UPS Module) . . . . . .2-5

2.5.1.1 Main AC Input Connections . . . . . . . . . . . . . .2-6

2.5.1.2 Bypass AC Input Connections (optional) . . .2-6

2.5.1.3 AC Output Connections . . . . . . . . . . . . . . . . .2-7

2.5.2 Connecting “Remote Emergency Power Off” Cable Connections . . . . . . . . . . . . . . . . . . . . .2-6

c-1Contents

Contents

Section Page

2.5.3 Connection of Relay Communication Card . .2-7

2.6 Check Points Before and After Start Up . . . . . . . . . .2-8

3.0 — Operation

This section presents operating information for 10-30 kVA Galaxy3000 systems, including an overview of system operation, controlsand indications, and operating procedures.

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.1.1 Pre-Start Up Safety Check List . . . . . . . . . . .3-2

3.1.2 Normal Start Up Procedure . . . . . . . . . . . . . .3-2

3.1.3 Post Start Up Safety Check List . . . . . . . . . .3-3

3.2 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3.3 Operator Interface Screens . . . . . . . . . . . . . . . . . . . .3-4

3.3.1 Screen Saver Display . . . . . . . . . . . . . . . . . . .3-4

3.3.2 Operational Summary Display . . . . . . . . . . . .3-4

3.3.3 Main Menu Display . . . . . . . . . . . . . . . . . . . . .3-5

3.3.4 Battery Measurements Display . . . . . . . . . . .3-5

3.3.5 Power Measurements Display . . . . . . . . . . . .3-6

3.3.6 Current Measurements Display . . . . . . . . . . .3-6

3.3.7 Voltage Measurements Display . . . . . . . . . . .3-7

3.3.8 Frequency Measurements Display . . . . . . . .3-8

3.3.9 Ratios Display . . . . . . . . . . . . . . . . . . . . . . . .3-8

3.3.10 Mimic Diagrams . . . . . . . . . . . . . . . . . . . . . . .3-9

3.3.11 Status Display Menu . . . . . . . . . . . . . . . . . .3-10

3.3.12 Settings Menu . . . . . . . . . . . . . . . . . . . . . . .3-10

3.3.13 Commands Menu . . . . . . . . . . . . . . . . . . . . .3-11

3.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

4.0 — Maintenance

4.1 Servicing Batteries . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Glossary

Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Environmental Recommendations

Appendix C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Electrical Characteristics

c-2 Contents

Illustrations

Figure Page

1 Galaxy 3000 - Standard Cabinet . . . . . . . . . . . . . . .QS-2

2 Pallet Mounting Arrangement of Galaxy 3000 . . . .QS-3

3 Utility Power Connection . . . . . . . . . . . . . . . . . . . .QS-4

4 Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . .QS-5

5 Operator Input Panel . . . . . . . . . . . . . . . . . . . . . . .QS-7

6 Bypass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .QS-8

1.1 Galaxy 3000 UPS System with Options - Single LIne Diagram . . . . . . . . . . . . . . . . . . . . . . . . .1-2

2.1 Galaxy 3000 With Pallet . . . . . . . . . . . . . . . . . . . . . . .2-2

2.2 UPS Cabinet Showing the Airflow and Recommended Clearance . . . . . . . . . . . . . . . . . . . . .2-3

2.3 Diagram Showing the Footprint of All Cabinets . . . .2-5

2.4 Utility Power Connections . . . . . . . . . . . . . . . . . . . . .2-6

3.1 Operator Input Panel . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.2 Bypass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3.3 Operator Input Panel . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3.4 Screen Saver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3.5 Operational Summary . . . . . . . . . . . . . . . . . . . . . . . .3-4

3.6 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3.7 Battery Measurements . . . . . . . . . . . . . . . . . . . . . . .3-5

3.8 Power Measurements . . . . . . . . . . . . . . . . . . . . . . . .3-6

3.9 Current Measurements . . . . . . . . . . . . . . . . . . . . . . .3-6

3.10 Voltage Measurements . . . . . . . . . . . . . . . . . . . . . . .3-7

3.11 Frequency Measurements . . . . . . . . . . . . . . . . . . . . .3-8

3.12 Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3.13 Mimic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

3.14 Status Displays Menu . . . . . . . . . . . . . . . . . . . . . . .3-10

3.15 Settings Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3.16 Commands Menu . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Tables

2.1 Heat Rejection Data . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.2 Relay Contacts (communications card) . . . . . . . . . .2-7

c-3Contents

The following parts and tools are recommended for installation of the Galaxy3000 UPS module.

Tools

Digital volt meter (DVM)

1/8 inch slotted screwdriver

Pallet jack/forklift

Conduit installation tools

Nut driver set

Recommended Tools and Parts Required for Installation

Getting Started with Galaxy 3000This Quick Start guide describes the tasks you will need to complete to quicklysetup your new Galaxy 3000 UPS system. Installing the Galaxy 3000 UPS isa simple five (5) step procedure. These steps are:

Step 1. Unpack and position the unit

Step 2. Connect the main (utility) power

Step 3. Connect the output to the power distribution panel

Step 4. Call MGE Field Service Engineer for startup

Step 5. MGE Field Service Engineer finalizes installation and startup

Optional: Procedure for temporary power prior to the final startup.

To insure a successful installation, each of these steps should be followed inthe correct sequence.

Scheduling of the MGE Field Service Engineers typically should be done 7 to10 days before they are required on site. If the startup of the UPS is criticalto your installation, a quick call to the MGE toll free telephone number (800 438-7373) should be made first to insure that you maintain your schedule.

QS-1

Quick Start

IntroductionThe Galaxy 3000 UPS system is available in two different cabinet sizes, theMicro cabinet and the Standard cabinet. Dimensions for the cabinets are:

Micro cabinet: 48.6”H x 23.0”W x 38.1”D

Standard cabinet: 62.5”H x 32.8”W x 40.1”D

Both cabinets are designed to provide for top and bottom entry of the utilitypower feed. The Micro cabinet is typically supplied assuming bottom entryonly.

Operating internally on 208 VAC, the Galaxy 3000 UPS system can be purchased to accept 208 VAC, 220 VAC, 480 VAC, or 600 VAC utility feed withthe use of an internal input transformer contained in a Standard cabinet. TheMicro cabinet was designed to provide all of the features of the Galaxy 3000system in the smallest possible enclosure. Without an auxiliary cabinet, theGalaxy 3000 system in a Micro cabinet provides only 208 VAC input and 208VAC output.

An output voltage of 208 VAC is standard with the Galaxy 3000 and does notrequire any additional cabinetry. If output voltages of 240 VAC, 408 VAC or600 VAC are required, an auxiliary cabinet is required for the output transformer.

The complete list of additional cabinets that could be included with yourGalaxy 3000 system are: External Maintenance Bypass cabinet, ExtendedBattery cabinet, and Distribution cabinets.

Figure 1 Galaxy 3000 - Standard Cabinet

QS-2

Quick Start

1. Unpacking and Positioning - Once the Galaxy 3000 UPS System has beeninspected and received from the shipper, the unit should be moved with theuse of a fork lift or pallet jack to a position as close to the final installation locationas possible.

The casters on the unit will allow it to be positioned into the final installationlocation. At this point, the leveling legs can be adjusted to provide a level andstable footing for the Galaxy 3000 UPS system.

Figure 2 Pallet Mounting Arrangement of Galaxy 3000

QS-3

Quick Start

2. Connect Utility Power - All Galaxy 3000 UPS systems provide the option fordual (redundant) utility power inputs. Whether the single or dual inputs areselected, the connection of the utility feed is made to the same terminal blockstrip in the Galaxy 3000 UPS system.

From the diagram Figure 3 below, it can be seen that the main power feed tothe Galaxy 3000 system should be connected to the terminal blocks TB1 onthe right hand side of the strip. If a bypass AC source is available (and the unitwas specified to include a second AC source), this power should be connectedto the middle set of terminal blocks TB3.

The three phase power should be supplied as a Wye with a separate neutralthat will be connected to the input neutral bus bar.

If the second (bypass) AC source if provided from a source other than that ofthe main input, it is recommended to use isolation transformers so that theneutrals of both AC sources can be grounded to the same potential.

Figure 3 Utility Power Connection

If the Galaxy 3000 system was specified for a second (bypass) AC source, buta separate power source is not available, then jumpers should be installedfrom the primary AC source to the terminal blocks for the bypass AC source.

UPS OUTPUT(TB2)

(UTILITY2)BYPASS INPUT(TB3)(OPTIONAL)

MAIN INPUTCONNECTIONS(TB1)

TERMINAL BLOCK

INPUT NEUTRALTERMINAL POST1/4-20 X 3/4" DIA.

OUTPUT NEUTRALTERMINAL POST1/4-20 X 3/4" DIA.

GROUND TERMINAL POSTS(INPUT & OUTPUT)1/4-20 X 3/4" DIA.FRONT VIEW

BOTOM ENTRYCONDUIT PLATE

QS-4

Quick Start

3. Connect the Load - The Galaxy 3000 UPS system offers a standard 208 VACoutput voltage. Optionally, a transformer can be provided in an auxiliary cab-inet that will provide 240 VAC, 480 VAC or 600 VAC for the output.

Figure 4 Terminal Blocks

The output from either the Galaxy 3000 cabinet or from the external auxiliarytransformer cabinet should be wired to the existing power distribution panel,or to an appropriate power management panel.

The output from the Galaxy 3000 UPS system should be connected to the leftmost set of terminal blocks (see Figure 3).

4. Call MGE UPS Systems Field Engineer at 800 438-7373 to finalize theinstallation of the unit.

QS-5

Quick Start

5. Arrival of MGE Field Engineer - The MGE Field Engineer will finalize the initial Galaxy 3000 UPS start-up. To insure a successful installation and reliable UPS service, the MGE Field Engineer will verify all of the installationconnections, fusing, and then will examine the extensive set of Galaxy 3000UPS personalization parameters to insure that the operation of the UPSexactly matches your installation requirements.

Figure 5 Operator Input Panel

QS-6

Quick Start

Optional - Should you require AC power on site prior to the arrival of the MGEField Engineer, the following procedure will provide the AC power withoutpowering the UPS. Should you have any questions about this procedure, donot hesitate to contact the MGE Field Service support line at 800 438-7373.

A. Insure that the Bypass Switch is in the “BYPASS” position.

B. Insure that the battery breaker, QF1, is open.

C. Close the input power breaker to energize the AC power.

D. At this point, power will be available for site usage until the UPS is properlycommissioned.

E. Upon arrival of the MGE Field Service Engineer, the main power must bedisconnected so that a safe and proper commissioning of the unit may beaccomplished.

Do not, under any circumstance, rotate the switch to the “TRANSFER” or“NORMAL” position, or close the battery breaker, QF1, until the unit has beencommissioned by an MGE Field Engineer.

Figure 6 Bypass Switch

QS-7

Quick Start

Service and Factory Repair - Call 1-800-438-7373

Commitment: MGE UPS Systems is committed to providing easy to accessfactory trained experts that will provide responses to any questions that youmight have.

Who to contact: Questions about the operation, repair, or servicing of thisequipment should be directed to MGE UPS Systems, Inc. Customer SupportServices. To insure that your questions are correctly answered, please obtainthe part number, assembly number, and serial number of the unit and includethem in any discussions and/or correspondence.

Part Number:

Assembly Number:

Serial Number:

Return for repair: Should you require factory service for your equipment,contact MGE UPS Systems, Inc. Customer Support Services and obtain aReturn Materials Authorization (RMA) prior to shipping your unit. Never shipequipment to MGE UPS Systems, Inc. without first obtaining an RMA.

Date:

RMA Number:

Contact Name:

QS-8

MGE Service and Repair

1.1 Product DescriptionThe Galaxy 3000 is the world’s first data center grade Uninterruptible PowerSupply system designed specifically for mid-range enterprise level applications.The Galaxy 3000 family consists of units available in power ratings from 10 - 30kVA, and are optimized for compatibility with nonlinear computer-type loads.

By incorporating the Ultra High Availability Topology (UHAT), the Galaxy 3000family of UPS systems are designed to provide the optimal level of reliabilityand to react to any power disturbance in an inherently safe way to protect thecritical load. The Galaxy 3000 all-in-one design incorporates every featureinto one compact cabinet, including a graphical user interface, power factorcorrected input, batteries, and communication cards that support networkbased power management.

The Galaxy 3000 UPS and its auxiliary equipment are designed for installationin a room where humidity and temperature can be controlled. The recom-mended and maximum environmental parameters are listed in Appendix B,"Specifications", of this document.

Major components of the Galaxy 3000 UPS system include:

Rectifier - Converts AC input voltage to DC voltage. The rectifier usesIGBT (Insulated Gate Bipolar Transistor) power transistors and a PulseWidth Modulated (PWM) technique to provide input power factor correc-tion and to minimize any harmonics reflected onto the input power lines.

1-1Introduction

1.0 - Introduction

Inverter - Converts DC voltage from the rectifier or from the batteries intoAC output voltage to maintain the attached load. This module uses theIGBT technology to provide digital power quality.

Static Switch - Automatically supplies the attached load from the bypasssource when the inverter is off.

Battery System - Stores energy for utilization by the inverter and attachedload in the event that utility AC power is lost or is of unacceptable quality.

Figure 1.1 Galaxy 3000 UPS System with options - Single LIne Diagram

Figure 1-1 shows a single-line diagram of the Galaxy 3000 UPS system. Duringnormal operation, the utility power (Main input) is supplied to the UPS rectifier.The rectifier converts the AC power to DC that is supplied to the inverter. Theinverter converts the DC voltage to three-phase regulated AC voltage, whichis supplied to the attached load.

During power failure conditions, the inverter is supplied by the stored energyin the battery system, and the load is powered continuously with no interrup-tion.

The Galaxy 3000 UPS is designed for internal operation of 208 VAC input andoutput. When different input and/or output voltages are specified, transform-ers (either internal to the standard cabinet, or external to the micro or standardcabinet) provide step-up/down functions as required.

Additional (extended life) batteries, external maintenance bypass switches,and/or output distribution panel boards may be contained in auxiliary cabinetssimilar in design to the Galaxy 3000 cabinet, or may be contained in third partycabinets or wall mounted units.

The Galaxy 3000 UPS and auxiliary equipment is listed for safety byUnderwriters Laboratories, Inc. (UL) under UL Standard 1778 - UninterruptiblePower Systems; and also listed by Underwriters Laboratories (CUL) underCanadian Standards Association (CSA) standard C22.107.

OPTIONALMAINTENANCE

BYPASSINPUT

208Y/120VAC

MAINTENANCEBYPASSINPUT

BYPASSINPUTTB3

CB3 (OPTIONAL)

ABCN

G

ABCN

G

ABCN

G

KA2CONTACTOR

KA1CONTACTOR

INPUTSTATIC

SWITCHINPUTFUSES

BATTERYSTATIC

SWITCHBATTERY

CHARGER

QF1BATTERYCIRCUIT

BREAKER

INTERNAL BATTERIES(240VDC NOMINAL)

COMMUNICATIONCONNECTIONS

(SEE SCHEMATIC)DRY CONTACT I/O STD.

SNMPRS232RS485

SR1INTERNAL

MAINTENANCE BYPASS(ROTARY SWITCH)

CONTROLCONNECTIONS

(SEE SCHEMATIC)TB4

ON MBS REPO

OPTIONALOUTPUT

TRANSFORMERCABINET

OPTIONALWRAP-AROUNDMAINTENANCE

BYPASSCABINET

OPTIONAL24 OR 42

POLEDISTRIBUTION

CABINET

TOCRITICALLOAD

OUTPUTTB2

Q3BP

T2 (AUTO)

CB2

CB1 KA

KB

7 8 9 101 2 3 4

ABCNG

Q5N

PFCBOOST

RECTIFIER INVERTER OUTPUTFUSES

OUTPUTSTATIC

SWITCH

BYPASSSTATIC

SWITCH

OPTIONALINPUT

DELTA/ZIG-ZAGTRANSFORMER

UPS CABINET

5

MAININPUTTB1

OPTIONALBYPASS

INPUT208Y/120VAC

MAININPUT

208Y/120VAC

1-2 Introduction

1.2 DeÞnitionsThese definitions describe terms as they relate specifically to the Galaxy 3000installation, operation or maintenance.

Battery Cabinet - Although possible, the Galaxy 3000 system is designed toeliminate the standard need for this cabinet. The Galaxy 3000 system hasbeen designed with batteries contained in the UPS Module Cabinet. Onlywhen extended life batteries are required will a battery cabinet be found witha Galaxy 3000 system.

Bypass Switch - A rotary switch contained in the UPS cabinet which allowsthe UPS to be placed in "Bypass", "Transfer" or "Normal" operation. Withinthe Galaxy 3000 UPS system this switch is labeled "SR1".

Input Filter - Not present in the Galaxy 3000 system, this would normally beused to reduce the input current distortion that is reflected back onto the utilitypower lines and to improve the input power factor, but the advanced technologyused in the Galaxy 3000 system’s rectifier section eliminates the need for thiscomponent.

Input Power - Power provided by the electrical utility company (or generator)and connected to the UPS input. Also referred to an Main Input.

Inverter - UPS component containing equipment and controls for convertingDC power to regulated AC power required by the load.

Maintenance Bypass Line - Line conducting electricity from input power tothe critical load during maintenance or whenever the UPS is not completelyoperational.

Main Input - See Input Power.

Operator Interface Unit - Comprised of a 4" x 4" color graphic display andassociated keys, this unit allows the operator to determine operational status,to acknowledge any existing alarms, and to monitor the status of the UPS dur-ing normal and abnormal conditions.

Rectifier - UPS component containing equipment and controls for convertinginput AC power to regulated DC power. The DC power is then supplied to thebattery system and to the inverter.

Static Bypass Line - Line conducting unconditioned input power to the criti-cal load through the Static Transfer Switch. Transfer of the load between thisline and the UPS inverter output is managed by the UPS control circuitry.

Static Transfer Switch - Device transferring the critical load between UPSinverter output and Static Bypass Line.

Uninterruptible Power System (UPS) - All components within UPS ModuleCabinet and any auxiliary cabinets that function as a system to provide con-tinuous, conditioned AC power to a load.

UPS Module Cabinet - Metal enclosure containing rectifier, charger, inverter,static transfer switch, static bypass line, maintenance bypass line, externaloperator controls, batteries, and internal circuitry required to provide specifieduninterruptible AC power to a load.

Soft Keys - Programmable keys that can be used for several different func-tions depending on the display.

Dedicated Keys - Keys that have a single function, such as the “Main Menu” key.

1-3Introduction

1-4 Introduction

The following describes installation procedures and recommendations for theGalaxy 3000 10-30 kVA UPS including receiving, handling, and storage pro-cedures. Prerequisites prior to installation; installation procedures and start-up procedures are also included.

2.1 Unpacking and Site PreparationThis section describes installation of the Galaxy 3000 10-30 kVA UPS, includ-ing receiving, handling, and storage procedures; prerequisites to the installa-tion; installation procedures; and start-up procedures.

Note: Installation should be performed by a qualified electrician and shouldconform to local and national electrical codes.

Prior to any installation, the following items should be observed upon receiptof the Galaxy 3000 10-30 kVA UPS.

1) Inspect shipment for any damage prior to receipt. Damage claims shouldbe filed directly with the carrier. Replacements for damaged componentsshould be ordered through MGE Customer Support Services at 1-800-438-7373.

2) Verify that the equipment nameplate (located on the inside door of thecabinet) details a system that corresponds with the equipment ordered.

3) Leave equipment secured to the pallet and move as close to the final loca-tion as possible using a pallet jack or forklift.

4) Once equipment is close to the installation location, remove the Galaxy3000 UPS from the shipping pallet as illustrated in the following diagram.Use extreme caution rolling the cabinet off the pallet as its weight mayexceed 500 lbs.

5) All cabinets are equipped with casters allowing the equipment to beplaced into final position. Push cabinets very slowly into position to avoidany tipping hazard.

6) Once in position, adjust the leveling legs to provide a fixed and stable foot-ing for the Galaxy 3000 UPS system.

7) At this point, the UPS system can either be prepared for operation, or forstorage until such time as it may be required for service.

2-1Installation

2.0 Installation

Figure 2.1 Galaxy 3000 With Pallet

2.2 Preparation for StorageIf the equipment is to be stored prior to installation, it should be stored in acool, dry, well-ventilated location that is protected against rain, splashingwater, chemical agents, etc. The equipment should be covered with a tarpau-lin or plastic wrapper to protect it against dust, dirt, paint, or other foreignmaterials. See the section of this manual titled "Specifications" for recommended storage environmental conditions.

Note: Batteries should be stored no longer than three (3) months at 25° C(77° F) or lower prior to recharging. Exceeding the recommended ambientstorage temperature will reduce battery back-up time and may adversely affect battery life.

2.3 Preparation for OperationSeveral items must be considered when preparing the Galaxy 3000 UPS sys-tem for operation.

First – The UPS cabinet and its auxiliary cabinets must be arranged in therequired configuration to insure that the interconnection cables are located inthe correct adjacent cabinets.

Second – The cabinets must be situation in a location that provides for prop-er air flow and heat rejection.

Third – The room in which the Galaxy 3000 UPS system is located must main-tain environmental conditions within recommended tolerances

Forth – All electrical connections must utilize the top or bottom conduit entriesprovided.

The following sections discuss in more detail these items.

LEVELING JACKS

CASTERS

SEISMIC ANCHORSSECURE USING

3/8-16 X 1.0" BOLT

2-2 Installation

Figure 2.2 UPS Cabinet Showing the Airflow and Recommended Clearance

2.3.1 Cabinet Descriptions and PlacementThe complete UPS system may consist of one to four cabinets depending on theoptions selected. The UPS will be housed in either a "Standard" or "Micro"cabinet. The Micro cabinet is offered for applications where space is at a pre-mium, while the Standard cabinet is offered for either larger kVA requirementsor for applications with input transformer requirements. For the Micro cabinetto achieve the maximum space savings, the configuration must be offeredwith a minimum number of options. The Micro cabinet based Galaxy 3000 isavailable where the input/output voltage is 208/208 VAC and options such asan external maintenance bypass, output distribution, input isolation or extend-ed batteries are either not required or are accomplished with existing auxil-iaries or third party solutions. The Standard Cabinet allows all such systemoptions to be selected based on the application. When facing the Galaxy3000 UPS from the front, the standard arrangement provides for any externalbatteries to be located on the right hand side, and all other auxiliary cabinetsto be located on the left hand side of the UPS. See the following diagram forrecommended cabinet placement.

2.3.2 Cabinet Clearance and Environmental Requirements

2.3.2.1 Air Flow / Heat RejectionThe Galaxy 3000 UPS cabinets generate heat and exhaust air through the topportion of its enclosures. Air intake is through the bottom of the cabinet. Allother cabinets are convection cooled. To assist you in planning for your HVACneeds, heat rejection data is provided in Table 2.1 for a worst case scenario(i.e., 480 VAC input / 480 VAC output).

ALLOW 36"CLEARANCE FORFAN EXHAUST

AIR EXHAUST

GRAPHICALUSER INTERFACE

DOOR LATCH

LEVELING JACKS

CASTERS

EXTERNALMAINTENANCE

BYPASS CABINETOR AUXILIARY

CABINET(OPTIONAL)

OUTPUTTRANSFORMER

CABINETOR AUXILIARY

CABINET(OPTIONAL)

UPS MODULEEXTERNAL BATTERY

BANK(OPTIONAL)

FRONT VIEW

2-3Installation

Table 2.1 Heat Rejection Data

Heat Rejection Data @ 480/480 VAC

UPS Module BTU/Hr10 kVA 6,82415 kVA 10,23520 kVA 12,96530 kVA 19,447

See Appendix "C" for specific Heat Rejection data based on kVA sizing andvoltage requirements.

Note: To provide for adequate ventilation, a minimum of 36" clearance shouldbe maintained above the top of the Galaxy 3000 cabinet.

2.3.2.2 Recommended Operating EnvironmentsThe Galaxy 3000 is intended for use in an environment where control of temper-ature and humidity is provided. The maximum operating and recommended envi-ronmental parameters are provided below:

2.4 Cabinet Footprints and Electrical EntriesAs can be seen in the following illustration, the footprint for each cabinet isnominally 37.04" deep. However, when planning for an installation whereseismic requirements must be met, an additional two (2) inches at the rear ofthe cabinet must be included to accommodate the seismic anchors.

Additionally, adequate space must be included in the front of each cabinet(approx. 36") to allow the door of the cabinet to be opened for service andmaintenance procedures.

2.4.1 Conduit Plate Locations (top entry)The Standard cabinet for the Galaxy 3000 is capable of accepting power inputand output cables through a top entry. As can been seen in the following illus-tration, the conduit plate on the top of the cabinet provides six (6) knockoutsfor conduit and is secured to the cabinet with four (4) machine screws. TheMicro cabinet is supplied standard with bottom entry only, however, an optionalside mounted cable raceway can be specified to allow top entry for power con-nections.

2.4.2 Conduit Plate Locations (bottom entry)Cable entry through the bottom is the standard preferred design for both theGalaxy 3000 Standard cabinet as well as the Micro cabinet. The bottom entryconduit plate provides for six (6) separate conduit entries. The plate issecured with six (6) screws which should be retained for the conduit plate afterthe power connections are made. Please see the following figure for the loca-tion of the bottom entry conduit plate.

2-4 Installation

Figure 2.3 Diagram Showing the Footprint of All Cabinets

Note: To provide for adequate ventilation, a minimum of 36” clearance shouldbe maintained above the top of the Galaxy 3000 cabinet.

2.5 Accessing Electrical ConnectionsCAUTION: Only an authorized electrical professional should access electri-cal connections. A severe shock hazard exists.

The ONLY user serviceable items in the Galaxy 3000 unit are:

A. The main and bypass power connections

B. The load connection

C. Any cable connection to external or auxiliary module

D. The communication card options

The access method for connections made to the communication cards isclearly seen when the front door to the Galaxy 3000 unit is opened. However,access to the main, bypass and load connections is made through theremoval of the safety panel located in the lower left of the Galaxy 3000 front(with the door open). This safety panel is removed by first removing the four(4) screws securing the panel. It can then be removed by lifting the safetypanel away from the unit.

2.5.1 Electrical Connections (UPS Module)Electrical connections and cabinet interconnections will vary depending uponthe configuration and options selected with your Galaxy UPS system. Refer tothe installation drawings supplied with your equipment.

CAUTION: Before making any electrical connections, verify that all batterydisconnect circuit breakers (QF1) are in the "off" position. Customer-suppliedupstream protective devices and distribution circuits should be OFF.

UPS MODULE

OUTPUTTRANSFORMER

(OPTIONAL)11.005.88

9.045.06

26.24

35.56

1.00

14.19 14.19 24.19 24.19 4.36

3.50

5.54

14.2811.0011.00 17.58MAINTENANCE

BYPASS(OPTIONAL)

MINIMUMDISTANCETO WALL

AIRINTAKE

BOTTOM ENTRYCONDUIT PLATE BOTTOM ENTRY

CONDUIT PLATE

BOTTOM ENTRYCONDUIT PLATE

BOTTOM ENTRYCONDUIT PLATE

AIRINTAKE

AIRINTAKE

AIRINTAKE

2-5Installation

Connecting Power Cable Connections To access the connection terminalblocks, open the door to the Galaxy 3000 UPS. Remove the safety panellocated in the lower left hand section of the unit.

a) The ground conductors must be connected to the ground terminal posts.

b) Connect the three conductors of the Normal AC source to terminal blockTB1.

d) If bypass terminal block is present, connect the conductors of the BypassAC source to terminal block TB2.

e) Connect the four conductors supplying the load to terminal block TB2.

f) Secure all cables with cable ties

g) Put all panels and covers back in place

Fig 2.4 Utility Power Connections

2.5.1.1 Main AC Input Connections The connections to be made are the three phases, and ground cables fromthe utility AC power source to the UPS. The main AC input cables are termi-nated at the "Main Input" Terminal Blocks (TB1). Complete wiring instructionsfor your installation are provided on the installation drawings supplied with theequipment.

2.5.1.2 Bypass AC Input Connections (optional) The connections to be made are the three phases, and ground cables fromthe bypass AC input power source to the UPS. The bypass AC input cablesare terminated at the "Bypass Input" Terminal Blocks (TB3) if present. Thisoption provides a separate AC input source for bypass operation.

UPS OUTPUT(TB2)

(UTILITY2)BYPASS INPUT(TB3)(OPTIONAL)

MAIN INPUTCONNECTIONS(TB1)

TERMINAL BLOCK

INPUT NEUTRALTERMINAL POST1/4-20 X 3/4" DIA.

OUTPUT NEUTRALTERMINAL POST1/4-20 X 3/4" DIA.

GROUND TERMINAL POSTS(INPUT & OUTPUT)1/4-20 X 3/4" DIA.FRONT VIEW

BOTOM ENTRYCONDUIT PLATE

2-6 Installation

2-7Installation

2.5.1.3 AC Output Connections The connections to be made are the three phases, and ground cables fromthe load source to the UPS. The output cables are terminated at the OutputTerminal Blocks (TB2) for 15 kVA small module, and input/output connectionsfor 10-30 kVA large module. Load cables must be run separately from all othercables (power supply or computer-system interconnection cables). Theyshould not pass near interference-emitting equipment or sensitive loads.

2.5.2 Connecting "Remote Emergency Power Off" Cable ConnectionsThe control connections are available for "Remote Emergency Power Off"(REPO) through a customer-supplied normally closed pushbutton. WithREPO connected, the jumper on the "REPO" terminal blocks must beremoved. The UPS is also equipped with a local Emergency Power Off buttonon the front of the UPS cabinet. (Refer to Figure 1.1 - Page 1-2)

a) Remove the jumper from terminal block TB4 located across terminals 7and 8.

b) Connect the emergency power off NC contact to terminals 7 and 8.

2.5.3 Connection of Relay Communication CardThe relay communications card contains six programmable dry contact out-puts and two programmable dry inputs and is standard on the Galaxy 3000.The inputs and outputs are factory programmed according to functions listedin Table 2.2.

Table 2.2 Relay Contacts (communications card)

Inputs Factor Setting Options (available on both contacts)

1.A UPS ON - Room temperature fault- Transfer to bypass disabled

- Transfer to bypass disabled if Bypass AC1.B UPS OFF source out of tolerance

- Desynchronize UPS from Bypass AC source

Outputs Factor Setting Options (available on all contacts)

1.1 General alarm - Overload- PFC fault

- Inverter fault1.2 Battery fault - Charger fault

- Automatic-bypass fault- Bypass AC source out of tolerance

1.3 Load on UPS - Battery-temperature fault- Fan fault

- Emergency power off activated1.4 Load on automatic bypass - Battery circuit breaker(s) open

- Phase-sequence fault on Normal or BypassAC source

1.5 Load on battery power - Blown fuse(s)- Transfer to Bypass AC source disabled

- Operation in ECO mode1.6 Low battery warning - UPS on Bypass AC source

The indications 1.X become 2.X for a second card of the same type.

CAUTION: Isolate and lock-out all power sources for this card before makingconnections. Never connect ELSV (extra low safety voltage) and non-ELSVcircuits to the different outputs of the same card.

Removing the Cover

a) Remove the cover “3” secured by the screws “1”.

b) Run the communications cables through the cable entry holes “4”.

c) Connect the conductors to the input “6” and output “5” terminal blocks(see connection example in diagram below).

Replacing the Cover

d) Put the cover back in place and secure it with the screws “1”.

e) Tighten the screws “7” to block the cables.

f) Indicate the locations of the power sources on the labels.

g) Insert the card in its slot.

h) Secure the card with two screws “1”, “2”.

12

2

7

1 2 3 4 5 6

AB 4

3

5

6

1 2 3 4 5 6

AB

1

23

2

5

7

6

4

2-8 Installation

Characteristics of the output contacts

Relay Type: Normally Open.

Max. voltage: 250 V AC, 30V DC.

Max. current: 2 A.

Cable: 4 x 0.93 mm 2 , ¯ 6.6 ±0.3 mm.

Characteristics of the input contacts:

Switched voltage: 5 V DC.

Consumption: 10 mA.

Cable: 4 x 0.34 mm 2 , ¯ 5 ±0.5 mm.

Output alarms are always activated on the conditions stated unless request-ed by customer to operate on other conditions.

Input contacts are designed for remote UPS operation. Use extreme cautionwhen using these contacts so as not to endanger persons or compromise theUPS load.

2.6 Check Points Before and After Start UpBefore starting the Galaxy 3000, be certain that you fully understand the oper-ation of the indicators, controls, and operational sequences. MGE UPS SYS-TEMS offers professional start up services in most countries. It is suggestedthat before applying power to your Galaxy 3000, your contract with MGE for aprofessional start up with an MGE Field Engineer.

Pre-Start Up Safety Check List:

All power and control wires have been properly connected and securelytightened.

The upstream and downstream protective devices are not tripped, andhave been sized properly for the UPS and load requirements.

The input voltage is the same as indicated on the UPS nameplate, locat-ed inside the door of the Galaxy 3000 UPS module.

Make certain that no objects block the air intake underneath and aroundthe front bottom of the UPS module and the air exhaust on the top of theUPS module is free of obstructions.

6

5

4

3

2

1

B A

2-9Installation

The optional maintenance bypass circuit breakers QB1 and CB2 (if pre-sent) are in the OFF (open) position.

The battery disconnect circuit breaker QF1 is in the OFF (open) position.

Post-Start Up Safety Check List:

After initial start-up of the system, normal operation should be tested. At theminimum, the following tests should be performed as applicable to your instal-lation.

Emergency power off (EPO) test.

Remote emergency power off (REPO) test (if applicable).

Inverter start and stop.

Battery transfer test.

Maintenance bypass procedure.

2-10 Installation

The Galaxy 3000 system is simple to operate and yet provides a wealth ofcontinuous monitoring and diagnostic features to insure the proper operationof the unit.

Operators gain access to information in the Galaxy 3000 system through theoperator interface. This display panel and keyboard is conveniently locatedon the front of the UPS cabinet (see figure below).

Operator Interface - The Galaxy 3000 Operator Interface provides an easy touse method to access and control the Galaxy features. Through the use offour (4) "soft" keys and four (4) dedicated purpose keys, the operators canquickly move through the available displays, and control the performance ofthe unit.

Figure 3.1 Operator Input Panel

3.1 IntroductionBefore being able to use the operator interface to monitor and control yourGalaxy 3000 system, a number of items should be verified to insure that all con-ditions will provide for safe operation. The following "Check Points" are pro-vided to aid in the successful pre and post start-up of the Galaxy 3000. Theyinclude items to verify prior to applying power, and then tests that should beperformed (when appropriate) after startup to verify the health and functional-ity of all critical modules within the system.

Preparing for Startup

Before starting the Galaxy 3000, read this Installation and Users Manual thor-oughly. Be certain that you fully understand the operation of the indicators,controls, and operational sequences. MGE UPS SYSTEMS offers profes-

3-1Operation

3.0 Operation

Color Display

Dedicated Key(Main Menu Key)

LED Indicators

Dedicated Key(“On-line Help” Key)

“Soft” Keys

Dedicated Key(“Inverter Stop” Key)

Dedicated Key(“Inverter Start” Key)

sional start up services in most countries. It is strongly suggested that beforeapplying power to your Galaxy 3000, you contact MGE Field Services to prop-erly commission your system.

3.1.1 Pre-Start Up Safety Check List Insure all power and control wires have been properly connected and

securely tightened.

Check to see that the upstream and downstream protective devices arenot tripped, and have been sized properly for the UPS and load require-ments.

Check that the input voltage is the same as indicated on the UPS name-plate, located inside the door of the Galaxy 3000 UPS module.

Verify that the air filters located inside each the UPS module door areproperly installed and free of dust, dirt, and debris. Make certain that noth-ing is blocking the air intake underneath and around the front bottom of theUPS module and that the air exhaust on the top of the UPS module is freeof all obstructions.

Verify that the Manual Bypass Switch SR1 is set to the "NORMAL" position.

If present, check to see that the optional maintenance bypass circuitbreakers Q3BP and Q5N are in the OFF (open) position.

Check to see that the battery disconnect circuit breaker QF1 is in the OFF(open) position.

Check to see that the cabinet is resting on its the lifting levelers and noton the 4 wheels.

Check that the load-circuit breakers (where applicable) are in the "OFF"position.

3.1.2 Normal Start Up ProcedureWith all of the initial safety check points verified, the Galaxy 3000 UPS sys-tem can now be powered. The following procedure should be used after theGalaxy 3000 UPS system has been commissioned (typically by an MGE FieldService Engineer).

Figure 3.2 Bypass Switch

a) Check that the manual bypass (SR1) isin the NORMAL position.

b) Set the Normal AC source input (Switch14) to the ON position.

c) Wait 10 seconds while the circuits areinitialized.

d) Set the battery circuit breaker QF1 15(or the battery circuit breakers in theauxiliary cabinets) to the ON position.

e) The UPS should now start automaticallywith LED (29) lit to indicate that the loadis protected by the UPS.

3-2 Operation

3.1.3 Post Start Up Safety Check ListAfter initial start-up of the system, normal operation should be tested. At theminimum, the following tests should be performed as applicable to your instal-lation.

Emergency power off (EPO) test.

Remote emergency power off (REPO) test (if applicable).

Inverter start and stop.

Battery transfer test.

Maintenance bypass procedure.

CAUTION: As soon as AC input power is supplied to the Galaxy 3000 (cus-tomer supplied upstream circuit breaker is in the "ON" position), the load isinitially supplied via the "Static Switch." Verify that no error indications arepresent on the operator interface panel.

3.2 Shutdown ProcedureThe UPS remains energized unless it is shut down.

a) Press the OFF button

b) Confirm by pressing the function key marked.

c) The load is no longer protected by the UPS. It is supplied via the bypass.

d) The charger no longer operates to keep the batteries fully charged.

e) Set the battery circuit breaker QF1 to the OFF position.

Figure 3.3 Operator Input Panel

The LED indicator will light to indicate that the inverter is OFF, and finally willindicate that the UPS is shut down.

3-3Operation

Color Display

Dedicated Key(Main Menu Key)

LED Indicators

Dedicated Key(“On-line Help” Key)

“Soft” Keys

Dedicated Key(“Inverter Stop” Key)

Dedicated Key(“Inverter Start” Key)

3.3 Operator Interface Screens

3.3.1 Screen Saver DisplayThe screen displays contained on the Galaxy 3000 Operator Interface providean easy to use method to access and control the Galaxy features. After theGalaxy 3000 system has been in continuous operation, the operator interfacewill present a screen saver display. This display looks like:

Figure 3.4 Screen Saver

The product name, "Galaxy 3000", will be moving around the display screento provide an indication that the unit is functional.

3.3.2 Operational Summary DisplayPressing any of the keys will cause the unit to provide an operational sum-mary display with the following information:

Figure 3.5 Operational Summary

This display will quickly show the operator the time/date, the kVA load on allthree phases, as well as the battery level. Pressing the "Main Menu" dedi-cated key on the keyboard (shown below) will result in the display seen inFigure 3.6.

3-4 Operation

3.3.3 Main Menu Display

Figure 3.6 Main Menu

From this display the operator can access hundreds of different displayswhich will allow the ability to monitor the operating performance of Galaxy3000, obtain alarm information, change operational settings as well as issuesoftware based commands to various features in the unit.

From this "Main Menu" display, the available displays are convenientlygrouped according to function. By using one of the first two "soft keys" theselection cursor may be moved up and down unit the desired display group isselected. Then by pressing the fourth "soft key", the selected display (or dis-play group) will be summoned. Typically, operators will select the"Measurements" group. This selection results in the following display:

3.3.4 Battery Measurements Display The "Battery Measurements" provides a rapid assessment of the availablebattery voltage, current, battery charge, temperature as well as expected ser-vice life.

Figure 3.7 Battery Measurements

Any of these items may be examined further by using the "soft key" with thedouble arrows to select the item of interest and then pressing the "soft key"with the magnifying glass.

3-5Operation

Pressing the "soft key" showing the "multiple documents icon", will summonthe next "Measurements" display. In this case it will provide the "PowerMeasurements" display.

3.3.5 Power Measurements DisplayFrom the "Power measurements" display, we can see the power beingrequired by the load on each phase displayed in kVA and in kW. Additionally,the source AC "normal" (AC N) is shown with the current kVA.

Figure 3.8 Power Measurements

The additional "soft keys" provide:

Soft Key #1 - Multiple documents - indexing to the next Measurements display.

Soft Key #2 - Up/Down arrows - moving the selection cursor to a measure-ment of interest

Soft Key #3 - Graph - Once a measurement of interest has been selected, thisprovides either a single measurement line chart or a multiple value graph

Soft Key #4 - Magnifying glass - This key examines the selected variable(s).

Pressing the key associated with the "multiple documents icon", results in theCurrent Measurements display.

3.3.6 Current Measurements Display

Figure 3.9 Current Measurements

3-6 Operation

From the "Current Measurements" display we can see the current beingrequired by the two AC inputs (AC N and AC BP) as well as the current beingrequired on each of the three phases of the load.

The available soft keys provide:

Soft Key #1 - Multiple documents - indexing to the next Measurements dis-play.




Pressing Soft Key #1 again, results in the Voltage Measurements display.

3.3.7 Voltage Measurements Display

Figure 3.10 Voltage Measurements

From the "Voltage Measurements" display we can see the voltage currently onany one of the input phases (AC N and AC BP) and each phase of the load,as well as the differential voltage as measured between any two phases of theinputs and the load.






Pressing Soft Key #1 again, results in the Frequency Measurements display.

3-7Operation

3.3.8 Frequency Measurements Display

Figure 3.11 Frequency Measurements

From the "Frequency Measurements" display we can see the frequency cur-rently on any one of the input lines (AC N and AC BP) and the frequency ofthe power being supplied to the load.






Pressing Soft Key #1 again, results in the Ratios display.

3.3.9 Ratios Display

Figure 3.12 Ratios

From the "Ratios" display we can see the crest factor for each phase, the cur-rent % of full load for both each phase and for the total unit. Additionally, theload in kVA/kW is provided.

3-8 Operation


Soft Key #1 - Multiple documents - indexing to the next Measurements display.




Continuing to press the Soft Key #1 (Multiple Documents icon) will restart thedisplay sequence of all of the measurement displays, i.e., Battery, Power,Current, Voltage, Frequency and finally Ratios.

At this point, it would be appropriate to press the dedicated "Main Menu" keyand then select the Mimic Diagrams item. This is done by pressing either SoftKey #1 or Soft Key #2 until the item is backlit, and then pressing Soft Key #4to select the item for display.

3.3.10 Mimic Diagrams

Figure 3.13 Mimic Diagram

The "Mimic diagrams" display is unlike any of the other display we have exam-ined. This display is actually two displays in one. The top half of the displaycontains a single line representation of the current operating condition of theGalaxy 3000 unit. Through the use of color changes in the display, it will indi-cate whether the unit is operating normally, is on bypass, or is currently runningon batteries. The lower half of the display will show any existing alarm condi-tions that are present. The soft keys are now programmed to allow you toscroll up and down through the list of alarms (Soft Keys #1 and #2), to allowyou to delete a specific alarm message (Soft Key #3), or to allow you to exam-ine in further detail a specific alarm message (Soft Key #4). Although slightlydifferent in operation, the "detail" key must be held down to examine the mes-sage details.

To exit this display, it is necessary to press the dedicated "Main Menu" key.

From the Main Menu we can select the "Status" option.

3-9Operation

3.3.11 Status Displays Menu

Figure 3.14 Status Displays Menu

Selecting the "Status" option from the Main Menu results in another list ofavailable displays. As can been seen on the illustration, these displaysinclude:

1) Status and Alarms 3) Statistics

2) Event Log 4) History

The Soft Keys have been programmed to allow you to highlight one of theseavailable displays and then to select it (by pressing Soft Key #4). These avail-able displays are lists of events, actions, and statistics and will not be exam-ined in further detail within this manual. It is left for the operator to display andexamine these lists.

Again, to exit the Status Displays Menu, it is necessary to press the dedicated"Main Menu" key. From here we can select the "Settings" option.

3.3.12 Settings Menu

Figure 3.15 Settings Menu

3-10 Operation

From the "Settings" menu, we can select a variety of options for the operationof the Galaxy 3000 system. As can seen from the illustration, these optionsinclude:

1) Language 4) Buzzer

2) Date/Time 5) Personalization

3) Contrast

The first four (4) options are self explanatory.

With an opportunity for the Galaxy 3000 unit to be located in any country, it ispossible to select the language of preference from several options.

The Date/Time can be set to insure that the time stamps on the event andalarm logs reflect the current local time and date.

The Contrast option allows the contrast of the operator interface unit to beadjusted to maximize its visibility in the current ambient lighting conditions.

The Buzzer option allows the volume of the buzzer to be set.

Finally, the Personalization option allows the operator to select any number ofoperating parameters for the UPS.

Note: Do NOT adjust any parameters in the personalization section without aclear understanding of the implications to your operation. Should there be anyquestions about a current setting, please do not hesitate to contact theCustomer Support Center at MGE UPS Systems, Inc.

Returning to the Main Menu with the use of the dedicated Main Menu push-button, we can select the final option, "Commands".

3.3.13 Commands Menu

Figure 3.16 Commands Menu

Similar to the "Personalization" section, the "Commands" menu presentsoptions that impact the operation of the UPS system. Extreme care should beexercised when selecting ANY of these menu options. The "Commands"menu provides the following:

1) Fault reset

2) Battery equalization

3-11Operation

3) Forced transfer to UPS

4) Forced transfer to BP (Bypass)

5) Desynchronize / AC BP

Section 3.4 SummaryThe operation of the Galaxy 3000 10-30 kVA UPS system is designed to requireminimal operator interaction, and yet it provides, as can be seen the previoussections, a multitude of displays and menus to provide information about andcapabilities to control the system.

The final appendix sections of this manual are included to provide general andtechnical information concerning the Galaxy 3000 product line as well as ter-minology that will prove useful in discussions about UPS and power systemsin general.

MGE UPS Systems is pleased that you have selected our product to protectthe AC power in your facility or installation. Should you have any questionsabout this manual or the Galaxy 3000 product, please do not hesitate to con-tact the Customer Support Center at MGE.

3-12 Operation

4.1 Servicing BatteriesIMPORTANT SAFETY INSTRUCTIONS FOR SERVICING BATTERIES

A. Servicing of batteries should be performed or supervised by personnelknowledgeable of batteries and the required precautions. Keep unautho-rized personnel away from batteries.

B. When replacing batteries, use the same model and manufacturer of bat-teries.

C. CAUTION — Do not dispose of battery or batteries in a fire. The batterymay explode.

D. CAUTION — Do not open or mutilate the battery or batteries. Releasedelectrolyte is harmful to the skin and eyes. It may be toxic.

E. CAUTION — A battery can present a risk of electrical shock and highshort-circuit current. The following precautions should be observed whenworking with batteries:

1. Remove watches, rings, or other metal objects.

2. Use tools with insulated handles.

3. Wear rubber gloves and boots.

4. Do not lay tools or metal parts on top of batteries.

5. Disconnect charging source prior to connecting or disconnecting bat-tery terminals.

6. Determine if the battery is inadvertently grounded. If inadvertentlygrounded, remove the source of ground. Contact with any part of agrounded battery can result in electrical shock. The likelihood of suchshock will be reduced if such grounds are removed during installationand maintenance.

4-1Maintenance

4.0 Maintenance

4-2 Maintenance

GlossarySymbols

¶ Used to reference paragraph headings that are listed in the table ofcontents.

/ Used to represent “and/or.”

% Percent; of each hundred.

° F. Degrees Fahrenheit.

° C Degrees Celsius.

@ At.

± Plus or minus.

# Number.

Ø Phase.

Ω Ohms.

2nd Second.

A, B, C Normal sequence of phases (clockwise) in three-phase power.

AC or ac Alternating current.

Alphanumeric display The LCD display above the hidden panel (behind the drop-down cover) on

the UPS module and the SSC.

Ambient air temperature The temperature of the surrounding air.

Ambient noise The noise level of the environment.

Attached load The load attached to the UPS output, such as a computer system ormanufacturing system.

Audible alarm A buzzer, located behind the front panel on the UPS module and the SSC,that sounds when alarm conditions occur.

AWG American Wire Gauge, formerly Brown & Sharp gauge.

B or BAT. or BATT. Battery.

Breaker Circuit breaker.

British Thermal Unit A unit of heat equal to 252 calories (see BTU).

A-1Glossary

Appendix A

BTU or Btu British thermal unit. Defined as the amount of energy required to raise thetemperature of 1 pound of water by 1° F.

BYP Bypass.

BYPASS Maintenance bypass; wrap-around manual maintenance bypass using theoptional bypass circuit breaker Q3BP in conjunction with circuit breakerQ4S and isolation circuit breaker Q5N.

Bypass AC input Mains 2.

Calorie A unit of heat. One calorie is the amount of energy required to raise thetemperature of one gram of water by one degree Celsius.

Carrier The company or individual responsible for delivering goods from one areato another.

CB Circuit breaker.

Conduit A flexible or rigid tube surrounding electrical conductors.

C.S.S. Customer Support Services.

CT Current transformer.

Curr. Current.

Current rating The maximum current that a piece of electrical equipment is designed tocarry.

DC or dc Direct current.

Earth ground A ground circuit that has contact with the earth.

Electrician Refers to an installation electrician qualified to install heavy-duty electricalcomponents in accordance with local codes and regulations. Notnecessarily qualified to maintain or repair electrical or electronic equipment.Compare to technician.

EPO Emergency power off.

Free running Indicates that the inverter frequency is stable and independent of thebypass AC input (mains 2) frequency.

FREQ Frequency.

Fusible Capable of being melted with heat.

GND Ground

Hz Hertz, a measure of frequency; one cycle per second equals one Hertz.

I Current.

Input branch circuit The input circuit from the building power panel to the equipment.

Inverter An electrical circuit that generates an AC sinewave output from a DC input.

kVA Kilovolt-Ampere; a measure of apparent power.

A-2 Glossary

kW Kilowatt; a measure of real power.

LCD Liquid-crystal display.

LED Light-emitting diode.

LEG or Leg Inverter leg.

Load protected The attached load is being supplied by the UPS module inverter output,and the battery is available in the event that incoming (utility) power is lost.

Load not protected The attached load is being supplied, but the battery system is unavailable.

Low battery shutdown The battery has reached the lowest permitted operating voltage, and the

inverter has shut down (disconnecting the load) to protect the battery fromdamage due to further discharge.

Mains or mains 1 Main AC input source.

Mains 2 Bypass AC input source.

MAX Maximum.

MBC Optional maintenance bypass cabinet that attaches to the SSC (in sharedsystems) or to the UPS (single module systems).

MCM Thousand circular mil; standard wire sizes for multiple stranded conductorsover 4/0 AWG in diameter. M is from the Roman numeral system; it is thesymbol for 1,000.

MG Motor-generator set.

MGE MGE UPS Systems, Inc.

module Refers to an EPS 6000 UPS module (rectifier/battery charger, inverter, andattached battery cabinet).

MOV Metal-oxide varistor.

NEC National electrical code.

NFPA National fire protection association.

NO. or No. Part number.

OSHA Occupational safety and health act.

OF Over-frequency.

On-battery operation The attached load is being supplied by the stored energy in the battery

system.

OV Over-voltage.

Packing list The list of articles included in a given shipment.

P.F. Power factor.

A-3Glossary

Q1 UPS input isolation circuit breaker.

Q3BP Optional maintenance bypass circuit breaker (in single-module UPSsystem); optional maintenance bypass circuit breaker in MBC cabinet (inshared systems).

Q4S Control or bypass circuit breaker (in single-module UPS systems); user-supplied bypass AC input circuit breaker supplying the SSC (in sharedsystems).

Q5N Optional UPS isolation circuit breaker (in single-module UPS systems);UPS module isolation circuit breaker (in shared systems); optional SSCisolation circuit breaker (in MBC).

QF1 Battery disconnect circuit breaker.

Remote emergency power off A switch used for shutting down electrical equipment from a location away

from the equipment.

REPO Remote emergency power off.

SCR Silicon-controlled rectifier.

Security bypass (key) Pushbutton on the hidden panel (UPS modules and SSC) allowing forced

transfers and other commands to be issued. The security key pushbuttonmust be held down while the desired function is executed.

SEQ Sequence.

Shipping damage Any damage done to an article while it is in transit.

Shipping pallet A platform on which articles are fixed for shipping.

Specific gravity The ratio of the weight of a given volume of substance (such as electrolyte)to that of an equal volume of another substance (such as water) used as areference.

SSC Static switch cabinet (in shared systems).

Sync or synch Synchronization.

Technician Refers to an electronic technician qualified to maintain and repair electronicequipment. Not necessarily qualified to install electrical wiring. Comparewith electrician.

Test connector DB-9 type connector on the hidden panel (UPS modules and SSC) allowingan EPE Customer Support Services technician to access programmableand diagnostic features of the system.

U Voltage.

UF Under frequency.

UL Underwriters Laboratories, Inc.

A-4 Glossary

UPS Uninterruptible power system.

UV Under voltage.

VAC Volts of alternating current.

Vb Battery voltage (in volts DC).

VDC Volts of direct current.

Via By way of.

VPC Volts per cell, the measure of the electrical potential of a storage cell, suchas a battery.

XFMR Transformer.

A-5Glossary

Environmental RecommendationsRecommended environment: 20° to 25° C (68° to 77° F.); 50% relativehumidity; computer room or other temperature- and humidity-controlled envi-ronment

Operating temperature: 0° to 40° C (32° to 104° F.) except battery

Storage: -20° to 50° C (-4° to 122° F.)

Humidity: up to 90% non-condensing (operating)

Altitude: sea level to 3,000 meters without derating

Acoustic noise: 78 dBA Acoustic noise at rated load as measured 5 feet fromthe front of the UPS module

B-1

Appendix B

C-1

Appendix C

Out

put P

ower

Rat

ing

(0.8

PF

)U

PS

Vol

tage

(in

put /

out

put)

208/

208

220/

220

480/

208

480/

480

600/

208

208/

208

220/

220

480/

208

480/

480

600/

208

Inpu

t / O

utpu

t Req

uire

men

ts &

Fre

quen

cyIn

put P

hase

Rot

atio

nIn

put P

ower

Fac

tor

Max

. Nom

inal

Inpu

t Cur

rent

(-15

% In

put L

ine

at 1

00%

Loa

d)31

A31

A14

A14

A11

A46

A46

A21

A21

A17

AO

utpu

t Cur

rent

28 A

26 A

28 A

12 A

28 A

42 A

39 A

42 A

18 A

42 A

DC

Vol

tage

Max

. Bat

tery

Cur

rent

at N

omin

al B

atte

ry V

olta

ge(2

40 V

DC

at 1

00%

Loa

d)39

AD

C41

AD

C39

AD

C41

AD

C39

AD

C59

AD

C61

AD

C59

AD

C61

AD

C59

AD

CM

ax. B

atte

ry C

urre

nt a

t Bat

tery

End

-Vol

tage

(198

VD

C a

t 100

% L

oad)

48 A

DC

49 A

DC

48 A

DC

49 A

DC

48 A

DC

71 A

DC

74 A

DC

71 A

DC

74 A

DC

71 A

DC

Bat

tery

Dis

conn

ect C

urre

ntM

ax. S

yste

m H

eat G

ener

atio

n (B

TU

/hr)

4777

6824

5800

6824

5800

7165

1023

588

7110

235

8871

SR

1 M

aint

enan

ce B

ypas

san

d Is

olat

ion

Sw

itch

Rat

ing

50 A

50 A

50 A

50 A

50 A

50 A

50 A

50 A

50 A

50 A

Inpu

t / O

utpu

t Fus

e C

urre

nt70

A70

A70

A70

A70

A70

A70

A70

A70

A70

AIn

put a

nd O

ptio

nal B

ypas

s C

onta

ctor

Cur

rent

40A

40A

40A

40A

40A

40A

40A

40A

40A

40A

Out

put P

ower

Rat

ing

(0.8

PF

)U

PS

Vol

tage

(in

put /

out

put)

208/

208

220/

220

480/

208

480/

480

600/

208

208/

208

220/

220

480/

208

480/

480

600/

208

Inpu

t / O

utpu

t Req

uire

men

ts &

Fre

quen

cyIn

put P

hase

Rot

atio

nIn

put P

ower

Fac

tor

Max

. Nom

inal

Inpu

t Cur

rent

(-15

% In

put L

ine

at 1

00%

Loa

d)61

A61

A27

A28

A22

A91

A91

A41

A42

A33

AO

utpu

t Cur

rent

56 A

53 A

56 A

24 A

56 A

83 A

79 A

83 A

36 A

83 A

DC

Vol

tage

Max

. Bat

tery

Cur

rent

at N

omin

al B

atte

ry V

olta

ge(2

40 V

DC

at 1

00%

Loa

d)78

AD

C80

AD

C78

AD

C80

AD

C78

AD

C11

6 A

DC

120

AD

C11

6 A

DC

120

AD

C11

6 A

DC

Max

. Bat

tery

Cur

rent

at B

atte

ry E

nd-V

olta

ge(1

98 V

DC

at 1

00%

Loa

d)94

AD

C97

AD

C94

AD

C97

AD

C94

AD

C14

1 A

DC

146

AD

C14

1 A

DC

146

AD

C14

1 A

DC

Bat

tery

Dis

conn

ect C

urre

ntM

ax. S

yste

m H

eat G

ener

atio

n (B

TU

/hr)

8871

1296

510

918

1296

510

918

1330

619

447

1637

719

447

1637

7S

R1

Mai

nten

ance

Byp

ass

and

Isol

atio

n S

witc

h R

atin

g10

0 A

100

A10

0 A

100

A10

0 A

100

A10

0 A

100

A10

0 A

100

AIn

put /

Out

put F

use

Cur

rent

125A

125A

125A

125A

125A

125A

125A

125A

125A

125A

Inpu

t and

Opt

iona

l Byp

ass

Con

tact

or C

urre

nt11

0A11

0A11

0A11

0A11

0A11

0A11

0A11

0A11

0A11

0A

125

A

10 k

VA

15 k

VA

20 k

VA

30 k

VA

198

VD

C E

nd V

olta

ge

2

40 V

DC

Nom

inal

2

77 V

DC

Max

. Mai

nten

ance

Vol

tage

Gal

axy

3000

Ele

ctri

cal C

har

acte

rist

ics

Thr

ee P

hase

, Thr

ee W

ire +

N +

G

60

Hz

63 A

(7

min

. bac

k-up

tim

e)

7

0 A

(>

7 m

in. b

ack-

up ti

me)

>.9

8

198

VD

C E

nd V

olta

ge

2

40 V

DC

Nom

inal

2

77 V

DC

Max

. Mai

nten

ance

Vol

tage

A,B

,C C

lock

wis

e

A,B

,C C

lock

wis

e>

.98

Thr

ee P

hase

, Thr

ee W

ire +

N +

G

60

Hz

to order additional copies of this document, or to report any errors, omissions, orother problems you have experienced.

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Uninterruptible Power System

Installation and User’s ManualWarranty Seller warrants to the Ultimate Purchaser (the purchaser who buys for use, and not for resale) that all products furnishedunder this order and which are manufactured by Seller will conform to final specifications, drawings, samples and other writtendescriptions approved in writing by Seller, and will be free from defects in materials and workmanship. These warranties shallremain in effect for period of twelve (12) months after delivery to the Ultimate Purchaser. But if the Seller installs the equipment orsupplies technical direction of installation by contract, said one year shall run from the completion of installation, provided installa-tion is not unreasonably delayed by Ultimate Purchaser. Parts replaced or repaired in the warrant period shall carry the unexpiredportion of the original warranty. A unit placed with the Purchaser on consignment and then later purchased will be warranted fortwelve (12) months from the time the Seller receives notification of the Purchaser’s intent to purchase said consigned item. Theforegoing in its entirety is subject to the provision that in no case will the total warranty period extend beyond 18 months from dateSeller ships equipment from point of manufacture. The liability of Seller hereunder is limited to replacing or repairing at Seller’sfactory or on the job site at Seller’s option, any part or parts which have been returned to the Seller and which are defective or donot conform to such specifications, drawings or other written descriptions; provided that such part or parts are returned by theUltimate Purchaser within ninety (90) days after such defect is discovered. The Seller shall have the sole right to determine if theparts are to be repaired at the job site or whether they are to be returned to the factory for repair or replacement. All items returnedto Seller for repair or replacement must be sent freight prepaid to its factory. Purchaser must obtain Seller’s Return GoodsAuthorization prior to returning items. The above conditions must be met if warranty is to be valid. Seller will not be liable for anydamage done by unauthorized repair work, unauthorized replacement parts, from any misapplication of the item, or for damage dueto accident, abuse, or Act of God. In no event shall the Seller be liable for loss, damage, or expense directly or indirectly arisingfrom the use of the units, or from any other cause, except as expressly stated in this warranty. Seller makes no warranties, expressor implied, including any warranty as to merchantability or fitness for a particular purpose or use. Seller is not liable for andPurchaser waives any right of action it has or may have against Seller for any consequential or special damages arising out of anybreach of warranty, and for any damages Purchaser may claim for damage to any property or injury or death to any person arisingout of its purchase of the use, operation or maintenance of the product. Seller will not be liable for any labor subcontracted orperformed by Purchaser for preparation of warranted item for return to Seller’s factory or for preparation work for field repair orreplacement. Invoicing of Seller for labor either performed or subcontracted by Purchaser will not be considered as a liability by theSeller. This warranty shall be exclusive of any and all other warranties express or implied and may be modified only by a writingsigned by an officer of the Seller. This warranty shall extend to the Ultimate Purchaser but to no one else. Accessories suppliedby Seller, but manufactured by others, carry any warranty the manufacturers have made to Seller and which can be passed on toUltimate Purchaser. Seller makes no warranty with respect to whether the products sold hereunder infringe any patent, U.S. orforeign, and Buyer represents that any specially ordered products do not infringe any patent. Buyer agrees to indemnify and holdSeller harmless from any liability by virtue of any patent claims where Buyer has ordered a product conforming to Buyer’s specifi-cations, or conforming to Buyer’s specific design. Buyer has not relied and shall not rely on any oral representation regarding theProduct sold hereunder and any oral representation shall not bind Seller and shall not be part of any warranty. There are nowarranties which extend beyond the description on the face hereof. In no event shall MGE UPS Systems, Inc. be responsible forconsequential damages or for any damages except as expressly stated herein.

Service and Factory Repair - Call 1 - 800 - 438 - 7373 Direct questions about the operation, repair, or servicing of this equipmentto MGE UPS Systems, Inc. Customer Support Services. Include the part number, assembly number, and serial number of the unitin any correspondence. Should you require factory service for your equipment, contact MGE UPS Systems, Inc. Customer SupportServices and obtain a Return Materials Authorization (RMA) prior to shipping your unit. Never ship equipment to MGE UPSSystems, Inc. without first obtaining an RMA.

Proprietary Rights Statement The information in this manual is the property of MGE UPS Systems, Inc., and represents aproprietary article in which MGE UPS Systems, Inc., retains any and all patent rights, including exclusive rights of use and/ormanufacture and/or sale. Possession of this information does not convey any permission to reproduce, print, or manufacture thearticle or articles shown herein. Such permission may be granted only by specific written authorization, signed by an officer of MGEUPS Systems, Inc. IBM, PC-AT, ES/9000, and AS/400 are trademarks of International Business Machines Corporation. MGE andMGE UPS Systems are trademarks of MGE UPS Systems, Inc. Other trademarks that may be used herein are owned by theirrespective companies and are referred to in an editorial fashion only.

Galaxy 3000 10-30 kVA Uninterruptible Power System Installation and User’s Manual 86-172010-00 C00

Copyright © 2002 MGE UPS Systems. All rights reserved. Printed in U.S.A.

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