MGETM GalaxyTM 5000 20 - 120 kVA Installation and user manual
Introduction Thank you for selecting an APC by Schneider Electric product to protect your electrical equipment. The MGE™ Galaxy™ 5000 range has been designed with the utmost care. We recommend that you take the time to read this manual to take full advantage of the many features of your UPS. APC by Schneider Electric pays great attention to the environmental impact of its products.
Safety Safety rules Safety of persons The UPS must be installed in a room with restricted access (qualified personnel only, according to standard 62040-1-2). A UPS has its own internal power source (the battery). Consequently, the power outlets may be energised even if the UPS is disconnected from the AC-power source. Dangerous voltage levels are present within the UPS. It should be opened exclusively by qualified service personnel. The UPS must be properly earthed.
Foreword Pictograms Document Display Danger, these instructions are imperative.
Contents 1. Presentation 1.1 MGE -™ Galaxy ™ 5000 ................................................................................................................ 8 UPS cabinet .................................................................................................................................. 8 External battery cabinet / auxiliary cabinet ................................................................................... 8 1.2 Inside the UPS cabinet, access to connections .....................
Contents 2.16 Power connections for an external battery cabinet ...............................................................38 2.17 Assembly and connection of an empty battery cabinet ........................................................38 Mounting the battery circuit breaker kit ........................................................................................38 Mounting the shelves and the battery cells .................................................................................39 2.
Contents NMC (Network Management Card) option .................................................................................. 59 Optional communications card with additional power relay ........................................................ 59 Optional serial communications card .......................................................................................... 59 Telpac Power Services option .....................................................................................................
1. Presentation 1.
1. Presentation 1.
1.
1. Presentation 1.4 User-machine interface (30) Graphical display (31) Load protected LED (32) Minor fault LED (33) Major fault LED ~ ? (34) Help key (35) Function keys (36) Menu key I O (38) OFF button 3s (37) ON button (42) Load supplied LED (40) UPS ON LED (41) Operation on battery power LED (43) Bypass in operation LED (39) PFC ON LED 1.
2. Installation 2.1 Location To ensure correct ventilation, leave nothing on top of the UPS. Leave one meter of free space in front of the UPS for door opening. The cabinet rests on four cylindrical feet, 40 mm in diameter, positioned in the four corners of the cabinet to spread the weight. >500 mm 0 - 600 mm* If 500 mm of free space is not maintained above the UPS, abnormal temperature rise may occur. ~ ? I O 3s The UPS must be installed in a room with restricted access (qualified personnel only).
2. Installation 2.3 Removing the cardboard protecting the batteries In the UPS The cardboard protecting the batteries must always be removed once the equipment is installed in its final location. 1 - Remove the ties holding the cardboard (1). 2 - Remove the cardboard (2). ~ 3 - Remove the struts (3). ? I O 3s 1 2 3 In the external battery cabinet The cardboard protecting the batteries must always be removed once the equipment is installed in its final location.
2. Installation 2.
2. Installation Required cable sizes Cable sizes are determined for copper conductors (for aluminium conductors, increase the size by 30%). Size calculations also take into account a voltage of 400 V and grouping of four cables.
2.
2. Installation 2.5 System earthing arrangements This chapter lists the main system earthing arrangements and their wiring requirements. For system earthing arrangements which are not listed in this document, please refer to the “SEA guide” reference 34002636XT.. TNS upstream and TNS downstream installation For separate Normal AC and Bypass AC lines from a single source.
2. Installation TNC upstream, TNC,TNS or TT downstream For separate Normal AC and Bypass AC lines from a single source 1.the UPS internal PEN bar must be connected to the Q4S neutral upstream of Q4S 2.The UPS internal PEN bar must be connected to the Q5N neutral downstream of Q5N 3.
2. Installation Frequency converter (without Bypass AC input) The UPS installation may be equipped with earth-leakage protection upstream on the condition that the protection apply to: - the normal and Bypass AC inputs - all the parallel-connected UPSs.
2. Installation Parallel configuration without external bypass cabinet and with separate normal and Bypass AC inputs (maximum two units in parallel) If the UPS installation is equipped with earth-leakage protection upstream then you must install an isolated transformer on each Bypass AC (A) and each Normal AC (B) sources. Upstream and downstream earth protection cables must be connected in compliance with the single UPS system earthing arrangement.
2. Installation Parallel UPS with external bypass cabinet and separate Normal and Bypass AC network inputs (6 UPS in parallel for 4PN) If the UPS installation is equipped with earth-leakage protection upstream then you must install an isolated transformer on both Bypass AC (A) and Normal AC (B) sources. Upstream and downstream earth protection cables must be connected in compliance with the single UPS system earthing arrangement. For TNC upstream configuration, TNC option must be connected into each UPS.
2. Installation 2.6 Connection of power cables in a single UPS unit Interconnecting the cabinet earths All the cabinet earths must be interconnected: external Bypass cabinet, external battery cabinet, etc. UPS units with common normal and Bypass AC inputs 16 14 15 L1 L2 L3 N L1 L2 L3 N L1 L2 L3 370 mm 17 18 To access the connection terminal blocks, see section 1.2. 1 - The earthing conductors must be connected to the UPS earthing-plate connectors (17) and (18).
2. Installation 2.7 Earth-cable connection for a TNC earthing system This operation must be done for single UPS, parallel UPSs and external bypass. 16 14 15 N L1 L2 L3 N L1 L2 L3 370 mm 17 1.Connect the power network cable PEN to the UPS earthing terminal 2.Connect the usage cable PEN to the UPS earthing terminal 3.Connect the Q4S (15) neutral terminal to the UPS earth using the cable supplied 4.
2. Installation 2.8 Connection of power cables for parallel UPS units Equipotential bonding between parallel-connected units Connect the exposed conductive parts (ECP) of the parallel-connected UPS units using an additional earthing cable (not supplied) with the following characteristics: - size equivalent to that of the supply cables, - as short as possible.
2. Installation Redundant parallel configuration (maximum two UPS units for Pn) This configuration does not have an external bypass. For TNC upstream installation, you must connect the earth-cable, See “Earth-cable connection for a TNC earthing system”, page 23. UPS units with common normal and Bypass AC inputs To access the connection terminal blocks, see section 1.2.
2. Installation Frequency converter For TNC upstream installation, you must connect the earth-cable, See “Earth-cable connection for a TNC earthing system”, page 23. UPS 1 16 UPS 2 15 16 14 L1 L2 L3 N 15 14 N L1 L2 L3 370 mm 17 To normal AC source 18 To load 17 18 To access the connection terminal blocks, see section 1.2. 1 - The earthing conductors of each UPS must be connected to the UPS earthing plate.
2. Installation UPS units with separate normal and Bypass AC inputs For TNC upstream installation, you must connect the earth-cable, See “Earth-cable connection for a TNC earthing system”, page 23.
2. Installation 2.9 Connection of the 150 kVA external bypass cabinet For TNC upstream installation, you must connect the earth-cable, See “Earth-cable connection for a TNC earthing system”, page 23.
2. Installation 2.10 Connection of the 360 kVA external bypass cabinet For TNC upstream installation, you must connect the earth-cable, See “Earth-cable connection for a TNC earthing system”, page 23.
2. Installation 2.11 Connection of the 600 kVA external bypass cabinet For TNC upstream installation, you must connect the earth-cable, See “Earth-cable connection for a TNC earthing system”, page 23.
2. Installation 2.12 Auxiliary interconnections between UPS units in parallel configurations For security reasons, the connections of the auxiliary interconnections of the parallel UPSs must be carried out whilst all the UPSs are de-energised.
2. Installation Parallel configuration for increased capacity (maximum four UPS units) UPS 1 UPS CAN // CAN // XMS06 XMS07 XMS02 XMS03 XMS04 XMS05 XMS06 XMS07 Blue plug 11 11 External bypass cabinet Jumpers connected to aux.
2. Installation Fitting the protection cover for the auxiliary interconnection cables The protection cover supplied with the parallel connected UPS units protects the user against direct contact with voltages other than SELVs and ensures the auxiliary interconnection cables are maintained in position. Note. Tie down the cables as indicated in the diagram in section 2.10. 2.
2. Installation 2.14 Connection of the relay communications card Isolate and lock-out all power sources for this card before making connections. Never connect SELV (safety extra low voltage) and non-SELV circuits to the different outputs of the same card. 1 - Remove the cover (52) secured by the screws (50). 2 - Run the communications cables through the cable entry holes (53). 3 - Connect the conductors to the input (55) and output (54)terminal blocks.
2. Installation Characteristics of the contacts on the relay communications card. Low battery warning Characteristics of the output contacts: Permissible voltage: 250V AC, 30V DC. Permissible current: 2 A. 2 Cable : 4 x 0.93 mm , Ø 6.6 ± 0.3 mm. 6 Load on battery power Load on automatic bypass 5 Load on UPS 4 Battery fault 3 General alarm 2 Characteristics of the input contacts: Switched voltage: 5 V DC Consumption: 10 mA. 2 Cable: 4 x 0.34 mm , Ø 5 ± 0.5 mm.
2. Installation 2.15 Running the control/communications cables Single UPS The following assembly recommendations must be followed to ensure correct positioning and support of the various strands of the control and communication cables on the front face of the UPS. Separate the control and communication cables from the power cables. Run the cables together in front of the protection panels and tie them to the panels as indicated in the figure opposite.
2. Installation Parallel UPS 1 Parallel-connection cables for connection to the external bypass cabinet (not supplied max. 2.5 mm2). The CAN and I exchange cables are supplied. 3 4 Relay communication card Optional communications cards Ties 6 7 General-shutdown cable (not supplied, max. 2.
2. Installation 2.16 Power connections for an external battery cabinet The earth on an external battery cabinet must be connected to the UPS 1 Q1 Q4S Q3BP Q5N +- 2.17 Assembly and connection of an empty battery cabinet Mounting the battery circuit breaker kit The coil control wires and the position contact wires of circuit-breaker QF1 must be connected to the UPS (see page 24). You must install Temperature sensor to obtain battery warranty and to optimize battery lifetime.
2. Installation Mounting the shelves and the battery cells 1 1 1 Caution. Assembly of the battery cabinet must be carried out by certified personnel (standard EN 50091-1-2). Caution. The minimum clearance between the top of battery cells and the next shelf is 150 millimeters. 1 - Secure the angle supports (6 screws per support). 2 For each shelf: 2 - position the shelf, 3 - secure the shelf with two screws in each angle, 4 - install the battery cells, secure and interconnect them.
2. Installation 2.18 Control connections for an external battery cabinet 1 - Connect wires 1-2-3-4 on connector XR1 (QF1 position and coil) in the external battery cabinet to connector XMB07 (6) (SELV) and wires 7-8-9-10 (temperature sensor) to connector XMD3 (22) (SELV). +12V BC+ BC 12V 22 XMD3 XMD3 Pass through three times 5 XMB 08 XMB 07 XMB 06 XR1 -12V +12V BC+ BC- Circuit breaker 2 Circuit 6 breaker 1 QF1 8 7 6 5 4 3 2 1 Common Open-close contact QF1 command Note.
2. Installation 2.19 Connection of an input isolating transformer A 16 L1 L2 L3 Option 14 15 N L1 L2 L3 N L1 L2 L 17 B Q1 15 Q4S Q3BP Q5N N L1 L2 L3 QF1 AC input 17 Cable not supplied Cable not supplied C 16 L1 L2 L3 17 A - Connection of an input transformer for common normal and Bypass AC source. B - Connection of a Bypass AC input transformer for separate normal and Bypass AC sources. C - Connection of a Normal AC input transformer for separate normal and Bypass AC sources. 2.
3. Operation All operations concerning system start-up and compliance with standards and regulations, including those related to the battery cabinet, must be carried out by trained and certified personnel before using the UPS. 3.1 Shutting down a single UPS The UPS remains energised unless it is shut down. 1 - Press a button to exit sleep mode. 2 - Confirm by pressing the function key (38) for 3 seconds. I O 38 3s Q1 Q4S Q3BP Q5N The load is no longer protected by the UPS.
3. Operation 3.3 Shutting down a parallel configuration 1 - Press a button on each unit to exit sleep mode. 2 - Press the OFF button (38) on each unit for 3 seconds. I O 38 3s Q1 8 Q4S Q3BP Q5N The load is no longer protected by the UPSs. It is supplied via the bypass. 3 - Set the battery circuit breaker QF1 (13) in each UPS unit to the OFF position (or trip the battery circuit breakers in the auxiliary cabinets if applicable). 4 - Set the input switch Q1 (8) in each UPS unit to the OFF position.
3. Operation 3.
3. Operation 3.6 Operating modes Normal (double conversion) mode This is the standard operating mode, set by default in the factory. Two possible cases: 1 - Normal AC source available: LED (31) is ON. The load is protected by the UPS. 31 32 33 2 - Normal AC source not available: LED (32) is ON. The buzzer sounds intermittently. The load is supplied by the UPS from battery power.
3. Operation 3.7 Load on battery power The load continues to be protected by the UPS when the Normal AC source is not available. Power is supplied by the battery. Transfer to battery power LED (32) is ON. The buzzer sounds intermittently. The load is supplied by the battery. 31 32 33 End of battery power LED (33) is ON. The buzzer sounds intermittently. The load is transferred on the Bypass AC input if it is present. 31 32 33 3.
3. Operation Operating mode Function Factory setting Options UPS operating mode NORMAL ECO UPS automatic start Disabled Enabled Authorised number of starts 4 1 to 255 Delay before reset of number of executed automatic starts 4 seconds 1 to 60 seconds UPS output frequency 50 Hz 60 Hz Tolerance for Bypass AC source 8% 0.
3. Operation 3.9 Relay contacts (communications card) Inputs Factory setting 1.A UPS ON 1.B UPS OFF Outputs Options (available on all contacts) - Room temperature fault - Transfer to bypass disabled - Transfer to bypass disabled if Bypass AC source out of tolerance - Desynchronise UPS from Bypass AC source Factory setting 1.1 General alarm 1.2 Battery fault 1.3 Load on NORMAL source 1.4 Load on automatic bypass 1.5 Load on battery power 1.6 Low battery warning The indications 1.
3. Operation 3.10 Display functions Main menu Welcome screen Load protected 01/Jan./2000 kVA 8.8 8.8 8.
4. Maintenance 4.1 Identification of alarms Alarm conditions are identified by LEDs (31), (32), (33) and the buzzer. LED (31) LED (32) LED (33) - - Buzzer Signification Intermittent Normal AC source not available - - Intermittent UPS shut down following end of battery power - - Intermittent UPS shut down on fault requiring servicing by after-sales support Detailed information on all alarms is supplied on the display. 1 - On the screen, select the alarm for which information is required.
4. Maintenance 4.3 UPS isolation Single UPS To isolate the UPS from the electrical power source and supply the load directly by the normal or Bypass AC source, follow the instructions below. 1 - Press a button to exit sleep mode. 2 - Shut down the UPS by pressing the OFF button (38) for 3 seconds. The load is no longer protected by the UPS. I O 38 3s Q1 Q4S Q3BP Q5N 10 11 9 8 QF1 13 3 - Set bypass switch Q3BP (10) to ON. 4 - Set output switch Q5N (11) to OFF.
4. Maintenance If the load is supplied by the UPS with Bypass AC source present: Q1 Q4S Q3BP Q5N 10 11 1 - Press a button to exit sleep mode. 2 - Shut down the UPS by pressing the OFF button (38) for 3 seconds. 3 - Set bypass switch Q3BP (10) to ON. 4 - Set output switch Q5N (11) to OFF. 5 - Set the battery circuit-breaker QF1 (13) (or set the battery circuitbreakers of the auxiliary cabinets if any) to OFF. 6 - Set the input circuit-breaker Q1 (8) to OFF.
4. Maintenance Parallel UPS configuration with external bypass cabinet Shutdown and isolation of one UPS unit 1 - First check that the total capacity of the remaining UPS units is sufficient to supply the connected load. 2 - Press a button to exit sleep mode. 3 - Shut down the UPS by pressing the OFF button (38) for 3 seconds. I O 38 3s Q1 Q4S Q3BP Q5N 10 11 9 8 QF1 13 4 - Set output switch Q5N (11) to OFF.
4. Maintenance 4.4 Return to the normal position Single UPS Q1 Q4S Q3BP Q5N 10 11 1 - Check that bypass switch Q3BP (10) is ON and that all other switches are OFF. 2 - Set input switch Q4S (9) to ON. 3 - Set output switch Q5N (11) to ON. 4 - Wait until the display goes on and check that there are no faults on the static-switch on the bypass line. 5 - Set bypass switch Q3BP (10) to OFF. 6 - Set the input circuit-breaker Q1 (8) to ON.
4. Maintenance Parallel UPS configuration without external bypass cabinet Restart the UPS unit for which switch Q3BP (10) is ON and the other switches are OFF. Caution. It is imperative to restart this UPS unit. Otherwise, load power is cut if the other two UPSs are shut down. Q1 Q4S Q3BP Q5N 10 11 1 - Set the input circuit-breaker Q4S (9) to ON. 2 - Set output switch Q5N (11) to ON. 3 - Check that the UPS is listed by the display, then confirm by pressing the function keys (35).
4. Maintenance Parallel UPS configuration with external bypass cabinet Q1 Q4S Q3BP Q5N 10 11 1 - Check that all switches on the UPS units are set to OFF. 2 - Set switch Q4S in the external bypass cabinet to ON. 3 - Set switch Q4S (9) on each UPS unit to ON. 4 - Set output switch Q5N (11) on each UPS unit to ON. 5 - Check that all the UPS units present in the installation are included in the list on the display and confirm by pressing the function button (35) on each UPS unit.
4. Maintenance 4.5 Training centres To allow you to use APC by Schneider Electric products effectively and carry out basic maintenance, we offer a complete range of technical training courses in English and French. Schneider Critical Power & Cooling Services 50 Hz training centres Schneider Critical Power & Cooling Services 5060 Hz training centre France Training Centre 140, Avenue Jean Kuntzmann Innovallée 38334 - St Ismier Cedex - FRANCE Brazil Training Centre Al.
5. Environment APC by Schneider Electric has implemented an environmental-protection policy. Products are developed according to an eco-design approach. Substances This product does not contain CFCs, HCFCs or asbestos. Packing To improve waste treatment and facilitate recycling, separate the various packing components. The cardboard we use includes over 50% of recycled cardboard. Sacks and bags are made of polyethylene. Packing materials are recyclable and bear the appropriate identification symbol .
6. Available options Backfeed option This option opens the Bypass AC input or the Normal AC input if power fails. This option is mandatory to meet standard IEC 62040-1-2. If an external backfeed protection system is used, it must comply with the requirements indicated in Annex L of standard IEC 62040-1-2. NMC (Network Management Card) option This option is a communications card for supervision and protection of a three-phase device. Each UPS can be equipped with a maximum of four NMC communications cards.
7. Appendices 7.1 Technical sheets Center of gravity H H L P UPS power rating (kVA) H (mm) 712 mm W (mm) D (mm) 20/30/40/60 kVA 950 350 360 80/100/120 kVA 950 350 360 Tip angle (to the rear) UPS power rating (kVA) 34001813EN/AF - Page 60 UPS on feet UPS on pallet 20/30/40/60 kVA 17.5° 22° 80/100/120 kVA 17.
7.
7. Appendices Line current values Rated power of each UPS unit Continuous input current at U=400V Input current at U=400V overload = 1.25 In limited to 10 min. Input current at U=400V overload = 1.5 In limited to 1 min.
7.
7. Appendices The maximum allowable power for 4 parallel UPS units is limited to 4 x Pn. Restrictions to parallel operation Single UPS Parallel UPS EMC level Category C3 Category C3 ECO mode Yes No Frequency converter Yes Yes (for two UPSs) Compatibility with the synchronisation module Yes Yes (*) : except in ECO mode or bypass mode.
7. Appendices General characteristics of MGE ™ Galaxy ™ 5000 UPSs UPS power in kVA 20 30 40 60 80 100 120 Normal AC input Number of conductors 3 phases Reference voltage at Pn 380 V to 443 V Reference frequency 45 Hz to 65 Hz THDI Typically 3% at Pn Power factor >0.
7. Appendices General characteristics of MGE ™ Galaxy ™ 5000 UPSs (cont.
7. Appendices 7.2 Options IP32 installation Install the protection cover above the UPS. Install the spacers. The longer spacers must be positioned toward the front of the UPS. Install the roof. Install the side deflectors.
7. Appendices 7.3 Glossary 3400181300/AF Backup time Time that the connected loads can operate on battery power. Bypass AC source Source supplying the bypass line. The load can be transferred to the bypass line if an overload occurs on the UPS output, for maintenance or in the event of a malfunction. ECO mode Operating mode by which the load is supplied directly by the AC source if it is within the tolerances defined by the user. This mode reduces the consumption of electrical power.
