APC MGE 6739380EN-JC User Manual

MGETM GalaxyTM 6000

50, 60 Hz 250 - 600 kVA

User manual

Single-unit UPS

Modular UPS

Parallel UPS with SSC

Frequency converter

Static Switch Cubicle

6739380EN/JC - Page 1

Page 2 - 6739380EN/JC

Contents

Introduction

System performance ................................................................................................. 5

System description .................................................................................................... 5

Different types of MGE

Isolation and protection devices ................................................................................ 8

Main operating modes .............................................................................................. 9

Description of MGETMGalaxyTM 6000 cubicles

Inverter cubicle ........................................................................................................ 13

Battery cubicle ........................................................................................................ 14

Static Switch Cubicle .............................................................................................. 15

External maintenance bypass cubicle ..................................................................... 15

Control panel

Visible control panel ................................................................................................ 16

Hidden control panel ............................................................................................... 18

Start-up

System start-up ....................................................................................................... 20

Start-up of a unit ..................................................................................................... 22

GalaxyTM 6000 systems ................................................... 6

Shutdown

Shutdown of a unit .................................................................................................. 24

System shutdown .................................................................................................... 25

Buzzer reset ............................................................................................................ 26

Alarms

Maintenance bypass ............................................................................................... 27

Environment information

Standard information "Media Contacts 9" ............................................................... 28

"LED" signalling box ................................................................................................ 29

Additional information "Media Contacts 15" ............................................................ 29

Maintenance

Maintenance configuration ...................................................................................... 31

Battery maintenance ............................................................................................... 33

Autodiagnostics ....................................................................................................... 34

Visual check ............................................................................................................ 34

Functional check ..................................................................................................... 34

Training center ........................................................................................................ 34

"Monitor" alphanumeric display

General ................................................................................................................... 36

Control panel ........................................................................................................... 36

Lights 1 to 8 ............................................................................................................ 37

Alarm display and buzzer reset ............................................................................... 38

Measurement system .............................................................................................. 41

Voltage measurements ........................................................................................... 42

Current measurements ........................................................................................... 42

Frequency and power measurements .................................................................... 43

Battery measurements ............................................................................................ 43

Inverter "On/Off" commands ................................................................................... 45

Language, display contrast and buzzer volume settings ........................................ 45

Display system configuration .................................................................................. 46

6739380EN/JC - Page 3

Contents (cont.)

Options

"LED" signalling box ................................................................................................ 47

Media Contacts 15 additional auxiliary transmission .............................................. 47

"Tele Monitor" remote indications unit..................................................................... 47

"GTC link" communications system ........................................................................ 47

"Vision" display........................................................................................................ 48

"Remote vision" display........................................................................................... 48

Insulating and Mains 1, 2, and load voltage matching transformer ......................... 48

Harmonics filter and power factor improvement ..................................................... 48

Double bridge rectifier-charger ............................................................................... 49

Battery "Temperature Monitor"................................................................................ 49

Empty cubicles ........................................................................................................ 49

Page 4 - 6739380EN/JC

All MGE

GalaxyTM 6000 products are protected by patents. They implement original APC by Schneider Electric technology

not available to other manufacturers.

To take into account evolving standards and technology, equipment may be modified without notice. Indications concerning technical characteristics and dimensions are not binding unless confirmed by APC by Schneider Electric.

This document may be copied only with the written consent of APC by Schneider Electric. Authorized copies must be marked "APC by Schneider Electric MGE

GalaxyTM 6000 User Manual N° 6739380EN.

System performance

A MGE uninterruptible power supply (UPS) delivers 3-phase power with the following characteristics:

◗ stable voltage (+/-0.5% under steady

state conditions and +/-5% under transient conditions for load step changes of 25 to 100% or of 100 to 25%);

◗ stable frequency (+/-0.05Hz without

Mains 2);

◗ or frequency synchronized with

Mains 2 to 50/60Hz +/-2Hz (value may be configured in 0.25 HZ steps);

◗ free of micro-breaks and outages for

the duration of the battery time (10, 15 or 30 minutes);

◗ less than 4% distortion in all system

configurations with linear loads;

◗ less than 5% distortion for a 100%

non-linear load with a peak factor of up to 3.5. The acoustic noise level of a

MGE

70dBA.

GalaxyTM 6000

GalaxyTM 6000 UPS is under

Single-line diagram of the MGE

mains 2 (bypass input)

mains 1 (normal input)

isolation

isolation and protection

GalaxyTM 6000 system

maintenance bypass

emergency bypass

AC/DC conversion

isolation and protection

battery

DC/AC conversion

Introduction

isolation and protection

load

System description

◗ a rectifier-charger (RC) module

converts 3-phase AC power from the Mains 1 supply into DC power for the normal inverter input and float charges or recharges the batteries;

◗ a battery unit provides backup power

for the inverter in the event of a voltage drop or a Mains 1 failure;

◗ an inverter module converts the DC

power supplied by the rectifier-charger module or the battery unit into 3-phase AC power for the load;

◗ an emergency bypass module

ensures the instantaneous transfer of the load via the static switch to the Mains 2 bypass line in the event of an inverter shutdown (initiated by the user or by a protective device) or a sudden overload;

◗ a maintenance bypass which isolates

the UPS for maintenance and transfers the load without interrupting the supply of power. The maintenance bypass is made up of three manual switches.

Note:

◗ the Mains 1 normal input and the

Mains 2 bypass input have different functions and, depending on the installation, may be protected differently upstream and/or come from different sources;

◗ frequency converters are available

without backup batteries;

◗ the emergency bypass line and the

maintenance bypass line do not exist in installations where the load frequency and the Mains 2 frequency are different (for example in frequency converters);

◗ for reasons of redundancy and/or

increased power, the rectifier-charger, inverter and battery modules (the UPS, part A in the MGE

GalaxyTM 6000

schematic diagram above) may be arranged in parallel lines. In this case, an isolation function is added to the output of each UPS for maintenance without disrupting the load. In this type of system, the components of part B in the diagram are located in a separate cubicle referred to as the "Static Switch Cubicle".

The system may also include:

◗ an isolating transformer on the

Mains 2 line;

◗ a harmonics filter on the Mains 1

input;

◗ different remote control, indication

and display systems;

◗ a double bridge rectifier-charger

module.

6739380EN/JC - Page 5

Introduction (cont.)

Different types of MGETMGalaxyTM 6000 systems

◗ Single-unit or modular UPS:

(figure 1)

mains 2

mains 1

Fig. 1

◗ Multi-bypass modular UPSs:

(figure 2)

Note:

2 modular UPSs (identical ratings) can be parallel-connected in this way.

mains 2

mains 1

rectifiercharger

Q3BP

static switch

inverter

load

battery

static switch

inverter

◗ Modular UPSs with external

maintenance bypass: (figure 3)

Note:

Up to 4 UPS (identical ratings) can be parallel-connected.

Fig. 2

mains 2

mains 1

mains 2

mains 1

mains 2

rectifiercharger

Q3BP

rectifiercharger

battery

Q3BP

static switch

inverter

battery

static switch

inverter

load

Q5N

Page 6 - 6739380EN/JC

Fig. 3

mains 1

rectifiercharger

inverter

battery

Introduction (cont.)

◗ Frequency converter with battery

backup power: (figure 4)

◗ Frequency converter without backup

power: (figure 5)

◗ Frequency converters with backup

power: (figure 6)

Fig. 4

Fig. 5

mains 1

rectifiercharger

inverter

load

battery

inverter

load

inverter

battery

inverter

load

◗ Parallel UPSs with SSC: (figure 7)

Note:

Up to 6 UPS (identical ratings) can be parallel-connected in this way.

Fig. 6

mains 2

mains 1

rectifiercharger

Q3BP

Static Switch Cubicle

rectifiercharger

battery

inverter

load

Fig. 7

battery

6739380EN/JC - Page 7

Introduction (cont.)

Isolation and protection devices

UPS or converter cubicles

(figure 8)

◗ Q1 (switch):

◗◗ isolation from Mains 1, ◗◗ RC start-up;

◗ QF1 (circuit breaker):

◗◗ battery protection and isolation;

◗ Q5N (switch):

◗◗ isolation of the inverter, frequency

converter or static switch module from the load;

◗ Q4S (switch):

◗◗ isolation of the static switch from

Mains 2;

◗ Q3BP (switch):

◗◗ bypass switch for maintenance;

◗ FU1-2-3 (fuses):

◗◗ protection of the RC from Mains 1;

◗ FU5-6-7 (fuses):

◗◗ protection of the inverter from the

load.

Note:

◗◗ switches Q4S and Q3BP do not exist

on frequency converters,

◗◗ circuit breaker QF1 does not exist on

frequency converters without a battery.

Example of a single-unit UPS or single modular UPS

static switch

mains 2

mains 1

rectifier-

FU1-2-3 FU5-6-7

charger

Q4S

inverter

QF1

battery

Fig. 8

Q3BP

Q5N

load

Static Switch Cubicle

(figure 9)

◗ Q4S (switch):

◗◗ isolation of the static switch (and

mechanical contactor K2S) from Mains 2;

◗ Q3BP (switch):

◗◗ bypass switch for maintenance;

◗ Q5N (switch):

◗◗ isolation of the load from the parallel

UPSs;

◗ Q1 (fuse switch):

◗◗ protection of the cubicle control

electronics from the parallel-connected inverter outputs;

◗ Q2 (fuse switch):

◗◗ protection of the cubicle control

electronics from Mains 2.

External maintenance bypass cubicle (figure 10)

◗ Q3BP (switch):

◗◗ bypass switch for maintenance;

◗ Q5N (switch):

◗◗ isolation of the load from the parallel-

connected UPSs.

Fig. 9

mains 2

parallel UPSs

maintenance bypass line

parallel modular UPSs

Q2 Q1

Q4S

Q3BP

Q5N

static switch

control electronics

Q3BP

Q5N

load

Page 8 - 6739380EN/JC

Fig. 10

Main operating modes

Normal operation

Mains 1 power is available: (see figure 11). The green "load protected" light 5 on the control panel is on.

+–

Introduction (cont.)

static switch

mains 2

rectifiercharger

mains 1

inverter

load

légend :

off on

The power necessary for the load is provided by Mains 1 through the rectifier-charger and the inverter. The rectifier-charger also supplies the power to float charge and recharge the battery (1). The rectifier-charger output voltage (DC) is regulated for the different battery types and charging modes:

◗ vented lead-acid or Ni/Cd batteries:

two different voltages, one for float charging and one for recharging;

◗ sealed lead-acid batteries: a single

voltage for both charge functions.

Operation with Mains 1 down

(figure 12) In the event of a Mains 1 failure or Mains 1 voltage outside specified tolerance of –10% in amplitude (–15% optionally), the rectifier-charger stops and the battery supplies the necessary backup power to the load via the inverter. The battery, float-connected between the rectifier-charger and the inverter, discharges during this operating mode. The green "load protected" light 5 on the control panel is on. The user is warned of battery operation by a buzzer and the orange "load on battery" light 4 on the control panel.

beep...beep...

+–

Fig. 11

The voltages depend on the number of battery cells and the battery manufacturer. They can be factory set and are adjustable by the after-sales support technicians. An optional electronic board may be used to continuously measure the battery temperature and automatically adjust the voltages.

mains 2

mains 1

Fig. 12

This information is also available via volt-free changeover contacts for remote control devices.

In this case, there is a 30 seconds delay.

rectifiercharger

battery

Parallel UPS systems:

the power drawn by the load is equally shared between the different UPSs.

(1) Except for frequency converters without a battery

static switch

inverter

load

battery

Note:

In the event of a Mains 1 failure, frequency converters without a battery shut down and the load is no longer supplied.

6739380EN/JC - Page 9

Introduction (cont.)

Battery time

The available battery time during a Mains 1 outage depends on the:

◗ rated capacity of the battery; ◗ power consumed by the load; ◗ temperature of the battery; ◗ age of the battery.

The specified battery time corresponds to a minimum duration at full rated load. The actual backup time can therefore be greater if the system operates below its full rated load during the Mains 1 outage. Operation on battery power can be extended beyond the specified time by reducing the load power consumption (by disconnecting noncritical loads). A "low battery shutdown" warning signal is sent via volt-free changeover contacts for remote control devices when the battery voltage reaches a level slightly above the minimum level.

Operation with Mains 1 restored

(figure 13) When Mains 1 power is restored or its voltage returns to within specified tolerances, the system automatically returns to its normal operating mode described above (on the condition it did not reach the end of battery power). If the end of battery power was reached (with the resulting inverter shutdown), the RC restarts automatically, but the inverter must be restarted manually, either locally or remotely in systems equipped with a remote-control unit. The rectifier-charger recharges the battery which was discharged during the Mains outage.

Note:

In frequency converters without battery power, the return of Mains 1 power results in the automatic restart of the RC and the inverter.

The battery charge cycle takes place in two steps (see figure 14):

◗ step 1: the battery is recharged at a

constant current limited to 0.1C10 (i.e. 1/10th of the battery capacity specified for a 10 hour discharge). The DC voltage increases with the battery charge until the charge level is reached;

◗ step 2: the battery is recharged at

constant voltage equal to the charge level (maximum value 463V). The charging current gradually decreases until reaching a specified low value (floating current). For vented lead-acid batteries, the rectifier-charger supplies the charging voltage for 0 to 255 hours (parameter defined by the after-sales support department) and then the floating voltage. For sealed lead-acid batteries,

This signal warns the user of the imminent end of battery power. On the device itself, the buzzer beeps increasingly rapidly and loudly. Battery power stops when the voltage supplied by the battery reaches the voltage minimum (340V). This results in inverter shutdown and transfer of the load without interruption to Mains 2. The red "load not protected" light 2 on the control panel is on.

beep...beep...

mains 2

mains 1

+–

rectifiercharger

Fig. 13

Battery charge cycle

U/I

current limiting

0.1 C10

constant voltage decreasing current

voltage

current

Fig. 14

the charging and floating voltages are the same.

Note:

If the Mains 1 failure is shorter than 0 to 255 seconds (parameter defined by the after-sales support department), the

If Mains 2 also fails, the load is no longer supplied. Normally, the inverter shuts down when the time on the battery power exceeds three times the specified backup time.

Note:

As an optional function (battery time estimator), the "low battery shutdown" warning signal can be sent with an adjustable time delay prior to the effective end of battery power.

static switch

inverter

load

battery

U charge/floating (sealed batteries)

U "floating" (vented batteries)

charger does not initiate a complete charge cycle but automatically supplies the floating voltage.

Page 10 - 6739380EN/JC

Introduction (cont.)

Installation with an engine generator set

(figure 15) If a stand-by generator is included in the installation, it is generally started automatically in the event of a Mains failure and connected to the main low voltage switchboard. It is disconnected when Mains power is restored. With such a system, the required battery time may be reduced to the time necessary for starting and bringing on line the stand-by generator. The battery supplies power to the inverter during the transfers: Mains ➔ generator and generator ➔ Mains. The transfer sequences described: Mains ➔ battery ➔ generator and generator ➔ battery ➔ Mains are fully automatic. They in no way affect the load and require no manual operation by the user.

UPS shutdown or overload

(systems with a static switch module)

(figure 16)

Single-unit UPSs, modular UPSs or UPSs with an SSC:

◗ in the event of a UPS shutdown

(initiated by the user or by an internal protective device), the load is automatically transferred to the Mains 2 bypass line. If transfer conditions are correct, transfer takes place instantly, without interruption to the load.

Note:

Transfer conditions are not correct when Mains 2 characteristics are outside tolerances (voltage: +/-10%; frequency as per personalization; phase sync with inverter +/-3°);

◗ in the event of a major transient

overload (greater than 160% of the full load), immediate transfer takes place as above, without interruption to the load. When the overload disappears, the load is automatically returned to the inverter depending on the configured value of the re-transfer counter: no return to inverter, or 1 to 255 (personalized value) overloads accepted before the load is permanently transferred to Mains 2. This operating mode allows start-up of load devices causing high inrush currents.

Example of an installation with an engine generator set

Galaxy

HV network

generator

main LV switchboard

mains 2

mains 1

Fig. 15

Note:

To avoid load surges on the generator, the rectifier/charger is started with a 10 second maximum current consumption walk-in.

static switch

mains 2

mains 1

rectifiercharger

inverter

battery

Fig. 16

This system requires correct transfer conditions. If the conditions are not correct, the inverter will current limit to 160% of its rated current for 1 second

beep...beep...

before stopping;

◗ in the event of a small but extended

overload (i.e. a continuous level of

power exceeding the full rated load), the inverter will continue to supply power for a period depending on the magnitude of the overload (10 minutes for a 125% overload, 1 minute for a 150% overload). See figure 17 (Overload curve);

◗ in all three of the above cases, the

inverter shutsdown and supplies the load via Mains 2 with the following information on the control panel:

◗◗ green "load protected" light 5 off, ◗◗ buzzer 1 on, ◗◗ red "load not protected" light 2 on.

+–

load

6739380EN/JC - Page 11

Introduction (cont.)

Frequency converters without redundancy

◗ in the event of a shutdown, the load

is no longer supplied with power;

◗ in the event of a major transient

overload (greater than 160% of the rated load), the inverters will current limit to 160% of their rated current for 1 second before stopping;

◗ in the event of a small but extended

overload (i.e. a continuous level of power exceeding the full rated load), the inverters will continue to supply power for a period depending on the magnitude of the overload (10 minutes for a 125% overload, 1 minute for a 150% overload, see figure 17), and then stop;

◗ in all three of the above cases,

inverter shutdown results in the following on the control panel of the concerned unit:

◗◗ green "load protected" light 5 off, ◗◗ buzzer 1 on, ◗◗ red "load not protected" light 2 on.

Frequency converters with redundancy

◗ the shutdown of one unit is of no

consequence for the load. The other lines each take up an equal amount of load power and the load continues to be supplied normally; Inverter shutdown results in the following on the control panel of the concerned unit:

◗◗ green "load protected" light 5 off, ◗◗ buzzer 1 on, ◗◗ red "load not protected" light 2 on.

Overload curve

1,5 In

1,35 In

1,25 In

1,15 In 1,10 In 1,05 In

12345678910

◗ in the event of an overload, the

system only loses its redundancy as long as the overload is less than the total rated power of the functioning units. If the overload is greater, the operating mode is that previously described for systems without redundancy.

30 120

(minutes)

Output voltage quality and continuity

The output voltage is stable in amplitude and frequency and is free of interruptions or transients outside specified tolerances, irrespective of Mains 1 or load disturbances (outages, load step changes, etc.).

Steady state voltage regulation:

For stable or slowly varying load conditions, the inverter output voltage is regulated to within +/-0.5% in amplitude. The frequency of the output voltage can theoretically be regulated to within

0.1% of the rated value, however the output frequency range may be intentionally extended to a maximum of +/-2Hz so that the inverter can remain synchronized with Mains 2 and its inherent frequency fluctuations, thus enabling transfer of the load to the bypass line at any time.

Fig. 17

Note:

The output frequency range can be personalized and if necessary modified on the customer site by a qualified support technician from +/-0.25Hz to +/-2Hz in 0.25Hz steps. When the Mains 2 voltage moves outside this frequency range, the inverter is desynchronized and operates in "free running" mode, with the output frequency regulated to a high level of accuracy by a quartz oscillator. When the Mains 2 frequency returns to within the specified tolerances, the inverter is gradually re-synchronized to the bypass line at a rate of 0.5Hz to 2Hz/s (as per the value personalized by the after-sales support department), thus avoiding exposing the load to sudden frequency variations.

Transient voltage regulation:

The inverter output voltage is not notably affected by instantaneous major variations in load characteristics. This is due to the PWM (Pulse Width Modulation) chopping technique and the microprocessor-based regulation system that instantly compensates for any variation. In particular, the inverter output voltage remains within +/-5% of the rated voltage for load step changes of 25 to 100% or of 100 to 25%.

Page 12 - 6739380EN/JC

Inverter cubicle

Description of MGETMGalaxyTM 6000 cubicles

The rated outputs for

MGE

GalaxyTM 6000 UPS’s (without

parallel connection) or frequency converters are 160, 200, 250, 300, 400, 500, 600 kVA.

Legend for figures 18 to 21: 1-rectifier-charger (RC) module 2-inverter stack modules 3-rack for electronic control boards 4-static switch module (Single-unit or

modular UPS) 4' - output static switch module (modular UPS, frequency converter or parallel UPS with SSC)

5-RC input fuses FU1-2-3 6-Mains 1 input switch Q1 7-protection fuses FU8 for the

Mains 2 resistance/capacitance voltage surge protection network 8-Mains 2 input switch Q4S (Singleunit or modular UPS) 9-maintenance bypass switch Q3BP (Single-unit or modular UPS)

10 - output switch Q5N 11 - inverter output fuses FU 5-6-7 12 - "Media Contacts 9" remote

indications board 13 - additional "Media Contacts 15" remote indications board (optional).

250 to 400kVA UPS or frequency converter

front view, doors open, protective covers removed

8 9 10

Fig. 18

450 to 500kVA UPS or frequency converter

front view, doors open, protective covers removed

Fig. 19

600kVA UPS or frequency converter

front view, doors open, protective covers removed

22 2

Fig. 20

8 9 10

1312

6739380EN/JC - Page 13

Description of MGETMGalaxyTM 6000 cubicles (cont.)

800 kVA UPS

front view, doors open, protective covers removed

Fig. 21

Battery cubicle

(for a 250 to 300kVA UPS)

Figure 22 is an example of component layout in a battery cubicle and a battery circuit breaker enclosure.

Legend for figure 22: 1-battery isolation and protection

circuit breaker QF1.

22 2

front view, doors open, protective covers removed

battery cells

1312

Fig. 22

battery cells

battery circuit breaker enclosure: front view, door open

Page 14 - 6739380EN/JC

Description of MGETMGalaxyTM 6000 cubicles (cont.)

Static Switch Cubicle

Static Switch Cubicles are rated 500, 800, 1200 and 2000 kVA. Figure 23 presents the layout of components in these cubicles.

Legend for figure 23: 2-Mains 2 input switch Q4S,

3-maintenance bypass switch Q3BP, 4-output switch Q5N, 5-static switch module, 6-electronic control boards for the

backup function, 7-protection fuses FU1 for the

Mains 2 resistance/capacitance voltage surge protection network,

8-fuse switch Q1 (protection of the control electronics power supply against Mains 1),

9-fuse switch Q2 (protection of the control electronics power supply against Mains 2),

10 - "Media Contacts 9" remote indications board,

11 - additional "Media Contacts 15" remote indications board (optional).

front view, doors open, protective covers removed

500 or 800kVA cubicle

1200kVA cubicle

897

11 10

External maintenance bypass cubicle

Legend for figure 24: 1-connection of auxiliary wires to

indicate the positions of switches Q5N and Q3BP,

2-maintenance bypass switch Q3BP, 3-output switch Q5N.

Fig. 23

2000kVA cubicle

Fig. 24

1200kVA cubicle

6739380EN/JC - Page 15

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