MGE UPS Systems Galaxy 3000 Page 5 Installation And User Manual Download

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Installation and User Manual

Section 4

Maintenance

4.0

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 —1

4.1

Servicing Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 —1

MGE Warranty & Proprietary Rights for Single Phase Products

MGE Warranty
Proprietary Rights Statement

Warranty and Product Registration

User Information
Product information
Warranty Extension (W) not available on products

MGE Customer Care Center

Technical Support and Product Services
Who To Contact
Scheduling Field Service Engineer Support
Return Policy for Repair (RMA)

Glossary

Index

Reorder Form

Contents

iii

86-172010-00 C05

Summary of Contents for Galaxy 3000

Page 1: ...Galaxy 3000 10 30kVA Uninterruptible Power Systems Installation and User Manual w w w m g e u p s c o m ...

Page 2: ...N 002473 03 02 C01 ECN 002565 02 03 C02 ECN 003280 05 03 C03 ECN 003507 08 03 C04 ECN 003723 01 04 C05 ECN 004064 10 04 Copyright 2004 MGE UPS SYSTEMS INC All rights reserved Printed in U S A MGE UPS SYSTEMS INC 1660 Scenic Avenue Costa Mesa CA 92626 714 557 1636 Technical Support 1 800 523 0142 during business hours Customer Care Center 1 800 438 7373 Hours 24 7 Galaxy 3000 10 30kVA ii 86 172010 ...

Page 3: ...bution Panel Load QS 4 STEP 4 Call MGE UPS Systems for Field Engineer Service QS 4 STEP 5 Arrival of MGE Field Engineer QS 4 Operator Interface Panel QS 5 Quick Start Notes QS 6 Section 1 Introduction 1 0 Scope 1 1 1 1 General Description 1 1 1 1 1 Major Components 1 2 1 1 2 Galaxy 3000 Micro and Standard Cabinets 1 2 1 1 3 Preparation for Operation 1 2 1 1 4 Cabinet Descriptions and Placement 1 3...

Page 4: ... Contacts 2 6 2 4 3 Characteristics of the Input Contacts 2 6 2 5 Check Points Before and After Start Up 2 6 Section 3 Operation 3 0 Scope 3 1 3 1 Preparing for Start Up 3 1 3 1 1 Pre Start Up Safety Check List 3 1 3 1 2 Normal Start Up Procedure 3 2 3 1 3 Post Start Up Safety Check List 3 3 3 1 4 Normal Shutdown Procedure 3 3 3 2 Operator Interface Screens 3 4 3 2 1 Screen Saver Display 3 5 3 2 2...

Page 5: ...y Proprietary Rights Statement Warranty and Product Registration User Information Product information Warranty Extension Warranty not available on products MGE Customer Care Center Technical Support and Product Services Who To Contact Scheduling Field Service Engineer Support Return Policy for Repair RMA Glossary Index Reorder Form Contents iii 86 172010 00 C05 ...

Page 6: ... 2 3 2 2 Remove Cover Diagram 2 5 3 1 Bypass Switch 3 2 3 2 Operator Input Panel Indicators 3 4 3 3 Screen Saver Movement within the display indicates the unit is active 3 5 3 4 Operational Summary Display 3 5 3 5 Main Menu 3 6 3 6 Battery Measurements 3 6 3 7 Power Measurements 3 7 3 8 Current Measurements 3 7 3 9 Voltage Measurements 3 8 3 10 Frequency Measurements 3 8 3 11 Ratios 3 9 3 12 Mimic...

Page 7: ...ese limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely...

Page 8: ...rds Three Phase UPS IEEE 587 1980 ANSI C62 41 1980 Standards for Surge Withstand Ability FCC rules and regulations of Part 15 Subpart J Class A UL listed under 1778 Standards for Uninterruptible Power Supply Equipment NEMA PE 1 National Electrical Manufacturers Association Uninterruptible Power Systems NEMA 250 National Electrical Manufacturers Association Enclosures for Electrical Equipment 1000 ...

Page 9: ...top of batteries Product Safety Upstream protectioin must be installed and be easily accessible The UPS can be disconnected from the AC power source by opening the input protective devices UPS must be connected to a nearby power source that is easily accessible Never block the ventilation openings of the UPS The UPS must be installed in a controlled environment Special Precautions The UPS connecti...

Page 10: ...____________ BATTERY SERIAL NUMBER ____________________________________________________ AUXILIARY SERIAL NUMBER ___________________________________________________ ADDITIONAL SERIAL NUMBERS ____________________________ ______________________________ ____________________________ ______________________________ ____________________________ ______________________________ ____________________________ _...

Page 11: ... an operating tip NOTE Indicates information provided as an operating tip or an equipment feature Section Descriptions Quick Start This section is a quick start guide to unpack setup and make necessary connections before installation of the Galaxy 3000 UPS 1 Introduction Provides a general description of the Galaxy 4000 systems intended use major components and environmental and mechanical specifi...

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Page 13: ... will insure a quick installation for the initial safe startup and configuration of your Galaxy 3000 Final installation and start up should be completed by a qualified MGE Field Service Engineer First steps by an on site qualified Technical Engineer Step 1 Unpack and position the unit Step 2 Connect the main utility power Step 3 Connect the output to the power distribution panel Final steps by MGE...

Page 14: ...level and stable footing for the Galaxy 3000 UPS system See Figure QS 1 1 Inspect shipment for any damage prior to receipt Damage claims should be filed directly with the courier Replacements for damaged components should be ordered through MGE Customer Support Services at 1 800 438 7373 2 Move equipment as close to the final location as possible using a pallet jack or forklift 3 Once equipment is...

Page 15: ...s specified for a second bypass AC source but a separate power source is not available then jumpers should be installed from the primary AC source to the terminal blocks for the bypass AC source NOTE The three phase power should be supplied as a Wye with a separate neutral that will be connected to the input neutral busbar If the second bypass AC source if provided from a source other than that of...

Page 16: ... for Field Engineer Service Call MGE Field Engineer Service support at 800 438 7373 to finalize the installation of the unit STEP 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 installation connections fusing and then will examine the...

Page 17: ...Operator Interface provides an easy to use method to access and control the Galaxy features Through the use of four 4 soft keys and four 4 dedicated purpose keys the operators can quickly move through the available displays and control the performance of the unit Figure QS 4 Operator Input Panel Quick Start QS 5 86 172010 00 C05 OPERATOR INPUT PANEL GALAXY 3000 FRONT VIEW Galaxy 3000 COLOR DISPLAY...

Page 18: ...wer D At this point power will be available for site usage until the UPS is properly commissioned E Upon arrival of the MGE Field Service Engineer the main power must be disconnected so that a safe and proper commissioning of the unit may be accomplished WARNING Do not under any circumstance rotate the switch to the TRANSFER or NORMAL position or close the battery breaker QF1 until the unit has be...

Page 19: ... disturbance in an inherently safe way to protect the critical load The Galaxy 3000 all in one design incorporates every feature into one compact cabinet including a graphical user interface power factor corrected input batteries and communication cards that support network based power management The Galaxy 3000 UPS and its auxiliary equipment are designed for installation in a room where humidity...

Page 20: ... 208 VAC 220 VAC 480 VAC or 600 VAC utility feed with the use of an internal input transformer contained in a Standard cabinet The Micro cabinet was designed to provide all of the features of the Galaxy 3000 system in the smallest possible enclosure Without an auxiliary cabinet the Galaxy 3000 system in a Micro cabinet provides only 208 VAC input and 208 VAC output An output voltage of 208 VAC is ...

Page 21: ...ement provides for any external batteries to be located on the right hand side and all other auxiliary cabinets to be located on the left hand side of the UPS 1 1 5 Cabinet Clearance and Environmental Requirements 1 1 5 1 Air Flow Heat Rejection The Galaxy 3000 UPS cabinets generate heat and exhaust air through the top portion of its enclosures Air intake is through the bottom of the cabinet All o...

Page 22: ... CLEARANCE FOR FAN EXHAUST AIR EXHAUST GRAPHICAL USER INTERFACE DOOR LATCHES LEVELING JACKS CASTERS AUXILIARY CABINET UPS MODULE EXTERNAL BATTERY BANK Optional FRONT VIEW 2nd AUXILIARY CABINET Auxiliary Cabinet optional may contain 2 or 3 CB MBP Output Transformer 24 Pole Distribution 2nd Auxiliary Cabinet optional 42 Pole distribution ...

Page 23: ...om entry Cable entry through the bottom is the standard preferred design for both the Galaxy 3000 Standard cabinet as well as the Micro cabinet The bottom entry conduit plate provides for five 5 separate conduit entries The plate is secured with six 6 screws which should be retained for the conduit plate after the power connections are made Please see the following figure for the location of the b...

Page 24: ...d be covered with a tarpaulin or plastic wrapper to protect it against dust dirt paint or other foreign materials See the section of this manual titled 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 ambient storage temperature will reduce battery back u...

Page 25: ...nt at Nominal Battery Voltage 240 VDC at 100 Load 39 ADC 41 ADC 39 ADC 41 ADC 39 ADC 59 ADC 61 ADC 59 ADC 61 ADC 59 ADC Max Battery Current at Battery End Voltage 198 VDC at 100 Load 48 ADC 49 ADC 48 ADC 49 ADC 48 ADC 71 ADC 74 ADC 71 ADC 74 ADC 71 ADC Battery Disconnect Current Max System Heat Generation BTU hr 4777 6824 5800 6824 5800 7165 10235 8871 10235 8871 SR1 Maintenance Bypass and Isolati...

Page 26: ...oved by lifting the safety panel away from the unit 2 2 1 Electrical Connections UPS Module Electrical connections and cabinet interconnection will vary depending upon the configuration and options selected with your Galaxy UPS system Refer to the installation drawings supplied with your equipment Connecting Power Cable Connections to access the connection terminal blocks open the door to the Gala...

Page 27: ...l battery disconnect circuit breakers QF1 are in the off position Customer supplied upstream protective devices and distribution circuits should be OFF Figure 2 1 Typical Power Connections 2 2 1 3 AC Output Connections The connections to be made are the three phases and ground cables from the load source to the UPS The output cables are terminated at the Output Terminal Blocks TB2 for 15 kVA small...

Page 28: ...ons listed in 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 AC 1 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 I...

Page 29: ...le entry holes 4 3 Connect the conductors to the input 6 and output 5 terminal blocks see connection example in diagram below Figure 2 2 Remove Cover Diagram 2 4 1 Replacing the Cover 1 Put the cover back in place and secure it with the screws 1 2 Tighten the screws 7 to block the cables 3 Indicate the locations of the power sources on the labels 4 Insert the card in its slot 5 Secure the card wit...

Page 30: ...Engineer Pre Start Up Safety Check List All power and control wires have been properly connected and securely tightened The upstream and downstream protective devices are not tripped and have been sized properly for the UPS and load requirements The input voltage is the same as indicated on the UPS nameplate located inside the door of the Galaxy 3000 UPS module Make certain that no objects block t...

Page 31: ...y the health and function ality of all critical modules within the system Before starting the Galaxy 3000 read this Installation and Users Manual thoroughly Be certain that you fully under stand the operation of the indicators controls and operational sequences MGE UPS SYSTEMS offers professional start up services in most countries It is strongly suggested that before applying power to your Galaxy...

Page 32: ... set for automatic start 3 If inverter is on then turn it off by pressing the gray button See step 1 of Normal Shutdown Procedure in this page 4 Rotate SR1 switch to normal position and close battery circuit breaker CB1 or QF1 older UPS 5 Press the green button to start the inverter The Green LED will turn on 6 The display will show the load is being protected NORM Load Protected Figure 3 1 Bypass...

Page 33: ...e load is initially supplied via the Static Switch Verify that no error indications are present on the operator interface panel 3 1 4 Normal Shutdown Procedure 1 Press the gray inverter off button The display will show Confirm UPS Shutdown Toggle the up and down scroll arrows button to Yes and press the return or enter button The Yellow LED will turn on 2 The UPS is now feeding the load from the s...

Page 34: ...ey 2 Up Down arrows moving the selection cursor to a measurement of interest or to allow you to examine in further detail a specific alarm message Soft Key 3 Graph Once a measurement of interest has been selected this provides either a single measure ment line chart or a multiple value graph Soft Key 4 Magnifying glass This key examines the selected variable s or to allow you to examine in further...

Page 35: ... 3 Figure 3 3 Screen Saver Movement within the display indicates the unit is active 3 2 2 Operational Summary Display Pressing any of the keys will cause the unit to provide an operational summary display with the following informa tion This display will quickly show the operator the time date the kVA load on all three phases as well as the battery level Figure 3 4 Operational Summary Display Oper...

Page 36: ...Measurements Display The Battery Measurements provides a rapid assessment of the available battery voltage current battery charge temperature as well as expected service life See Figure 3 6 Any of these items may be examined further by using the soft key with the double arrows to select the item of interest and then pressing the soft key with the magnifying glass Pressing the soft key showing the ...

Page 37: ... Power Measurements 3 2 6 Current Measurements Display From the Current Measurements display we can see the current being required by the two AC inputs AC N and AC BP as well as the current being required on each of the three phases of the load See Figure 3 8 Pressing Soft Key 1 results in the Voltage Measurements display See Figure 3 9 Figure 3 8 Current Measurements Operation 3 7 86 172010 00 C0...

Page 38: ...2 8 Frequency Measurements Display From the Frequency Measurements display we can see the frequency currently on any one of the input lines AC N and AC BP and the frequency of the power being supplied to the load See Figure 3 10 Pressing Soft Key 1 results in the Ratios display See Figure 3 11 Figure 3 10 Frequency Measurements Galaxy 3000 10 30kVA Operation 3 8 86 172010 00 C05 Voltage Measuremen...

Page 39: ...em for display See Figure 3 11 Figure 3 11 Ratios 3 2 10 Mimic Diagrams The Mimic Diagrams display is unlike any of the other display we have examined This display is actually two displays in one The top half of the display contains a single line representation of the current operating condition of the Galaxy 3000 unit Through the use of color changes in the display it will indicate whether the un...

Page 40: ...splays menu it is necessary to press the dedicated Main Menu key From here we can select the Settings option See Figure 3 14 Figure 3 13 Status Displays Menu 3 2 12 Commands Menu Similar to the Personalization section the Commands menu presents options that impact the operation of the UPS system Extreme care should be exercised when selecting ANY of these menu options The Commands menu provides th...

Page 41: ... interface unit to be adjusted to maximize its visibility in the current ambient lighting conditions Buzzer Allows the volume of the buzzer to be set Personalization Allows the operator to select any number of operating parameters for the UPS NOTE Do NOT adjust any parameters in the personalization section without a clear understanding of the implications to your operation Should there be any ques...

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Page 43: ... electrolyte is harmful to the skin and eyes It may be toxic A battery can present a risk of electrical shock and high short circuit current The following precautions should be observed when working with batteries Remove watches rings or other metal objects Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of batteries Disconnect charging source p...

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Page 45: ...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 manufac...

Page 46: ...er Information Last name ________________________________________ First name ________________________________________ Company name ________________________________________ Address ________________________________________ Zip code ________________________________________ City ________________________________________ State Province ________________________________________ Country ___________________...

Page 47: ...ter 1 800 438 7373 Hours 24 7 Customer FAQ or International calls 1 714 557 1636 Commitment MGE UPS SYSTEMS INC is committed to providing easy to access factory trained experts that will provide responses to any questions that you might have Scheduling Field Service Engineer Support Scheduling of the MGE Field Service Engineers typically should be done 7 to 10 days before they are required on site...

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Page 49: ...unit for measuring wire cross sectional area Breaker Electrical circuit interrupter BTU or Btu British thermal unit Defined as the amount of heat required to raise the tempera ture of one pound of water by 1 F BYPASS mode Load is powered by the Bypass input line through the static switch Carrier The company or individual responsible for delivering goods from one location to another CB Circuit brea...

Page 50: ...d Hz Hertz frequency measurement unit 1Hz is one cycle per second Inverter mode See on line mode I Current IEC International Electrotechnical Commission IEEE Institute of Electrical and Electronic Engineers 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 IGBT Insulated ...

Page 51: ...pment Power Off REPO Remote Emergency Power Off SCR Silicon controlled rectifier Shipping damage Any damage done to an article while it is in transit SCR Silicon controlled rectifier Shipping Pallet A platform on which articles are fixed for shipping Static Transfer An solid state switching mechanism electronically controlled to pass AC power directly from the utility to an output load Technician ...

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Page 53: ...d 2 2 Conduit Plate Locations bottom entry 1 5 Conduit Plate Locations top entry 1 5 Connect the Main Utility Power QS 3 Contrast 3 11 Current Measurements Display 3 7 D Date Time 3 11 E Electrical Connections 2 2 Electrical Specifications 2 1 Environmental Recommendations 2 1 External auxiliary transformer cabinet QS 4 F Frequency Measurements Display 3 8 G General Description 1 1 Getting Started...

Page 54: ...Notes QS 6 R Ratios Display 3 9 Recommended Operating Environments 1 3 Rectifier 1 2 Relay Communication Card 2 4 R Remote Emergency Power Off 2 4 Remote Emergency Power Off REPO 2 4 Removing the Cover 2 5 Replacing the Cover 2 5 S Scheduling of the MGE Field Service QS 1 Screen Saver Display 3 5 Servicing Batteries 4 1 Settings Menu 3 11 Single Line Diagram 1 6 Soft Keys 3 4 Standard cabinet 1 2 ...

Page 55: ...___________________________________________________________________________ COMPANY ___________________________________________________________________________________ STREET ADDRESS ____________________________________________________________________________ CITY ________________________________________ STATE __________________ ZIP ___________________ I would like to order______ quantity 75 00 ea...

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