MGE UPS Systems Galaxy PW 20 kVA, Galaxy PW 60 kVA, Galaxy PW 40 kVA, Galaxy PW 50 kVA, Galaxy PW 80 kVA Installation Manual

...

Download

E-51028231XU/BH - 1

Installation manual

www.mgeups.com

MGE UPS SYSTEMS

Galaxy PW™

20 - 200 kVA

2 - E-51028231XU/BH

E-51028231XU/BH - 3

Contents

All products in the Galaxy PW range are protected by patents. They implement original technology not available to competitors of MGE UPS SYSTEMS.

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 MGE UPS SYSTEMS.

This document may be copied only with the written consent of MGE UPS SYSTEMS. Authorised copies must be marked "Galaxy PW installation Manual, N° 51028231XU".

Characteristics

General characteristics of Galaxy PW UPSs ......................................................... 4

UPS cubicles........................................................................................................... 5

Empty battery cubicles ............................................................................................ 5

Electrical parameters for selecting protective devices ............................................ 5

Normal AC source ............................................................................................. 5

Bypass AC source............................................................................................. 6

Recommended protection ....................................................................................... 7

Protection upstream of Galaxy PW................................................................... 7

Protection downstream of Galaxy PW .............................................................. 7

Electrical parameters for determining cable cross-sections.................................... 7

Installation

Positioning the cubicles .......................................................................................... 9

Floor load ................................................................................................................ 9

Cubicle layout on a false floor or a normal floor...................................................... 9

Power-circuit wiring diagrams ................................................................................. 10

Connection of power circuits ................................................................................... 12

UPS cubicle....................................................................................................... 12

Battery cubicle................................................................................................... 15

Connection through the top ............................................................................... 16

External bypass cubicle 150 kVA ...................................................................... 17

External bypass cubicle 360 kVA ...................................................................... 18

External bypass cubicle 600 kVA ...................................................................... 19

Connection of the hot-swap option.................................................................... 20

Galaxy PW cubicle with a built-in harmonic filter .............................................. 20

Galaxy PW cubicle with a built-in bypass AC source isolation transformer...... 20

Bypass AC source isolation transformer in an auxiliary cubicle ........................ 21

THM filter........................................................................................................... 22

Connection of "Media Contacts 11" standard auxiliary circuits ............................... 23

Connection to battery circuit breaker "QF1" ...................................................... 23

Emergency power off ........................................................................................ 23

Connections between cubicles (parallel-connected configurations) ....................... 24

Connections between APOZ boards ................................................................. 24

Connections between MISI boards ................................................................... 24

Connections between UPS cubicles and the external bypass .......................... 25

Installation of communications options ................................................................... 25

Installation of boards ......................................................................................... 25

Passage of wires ............................................................................................... 25

Connection of the battery "Temperature Monitor"................................................... 26

Connections ...................................................................................................... 26

Installation of the "Temperature Monitor" in an MGE UPS SYSTEMS empty

battery cubicle ................................................................................................... 27

"Temperature Monitor" installation in a battery room ........................................ 27

Link to an IBM AS/400

computer........................................................................... 28

Connections ...................................................................................................... 28

Configuration of the AS/400

............................................................................. 28

Connection of the LED indications unit (optional) ................................................... 29

Final installation steps............................................................................................. 29

4 - E-51028231XU/BH

Characteristics

General characteristics of Galaxy PW UPSs

UPS power rating in kVA 20 30 40 50 60 80 100 120 160 200 Normal AC input

number of conductors 3 phases rated voltage and tolerances 380 V or 400 V or 415 V ± 10% (adjustable to ± 15%) rated frequency and tolerances 50 Hz or 60 Hz / ± 10% THDI with THM filter < 4% power factor with THM filter up to 0,96

Bypass AC input

number of conductors 3 phases + neutral rated voltage and tolerances 380 V or 400 V or 415 V / ± 10% rated frequency and tolerances 50 Hz or 60 Hz / ± 10%

Load

number of conductors 3 phases + neutral Ph/Ph voltages 380 V or 400 V or 415 V (according to setting) Ph/N voltages 220 V or 230 V or 240 V (according to setting) voltage fluctuations ± 1% adjustable frequency and tolerances (on battery power) 50 Hz or 60 Hz ± 0,05 Hz synchronisation with bypass ± 0,5 Hz (adjustable from ± 0,25 Hz to ± 2 Hz) voltage variation for 0 to 100% load step change ± 2% ((with battery) permissible overloads 150% for 1 minute, 125% for 10 minutes Isc Ph/Ph (% of I rated) 4.2 2.8 2.1 2.5 2.1 3.1 2.5 2.1 2.6 2.1 Isc Ph/N (% of I rated) 6.6 4.4 3.3 4 3.3 5 4 3.3 4 3.3 THDU Ph/Ph and Ph/N for linear load < 1,5% Ph/Ph, < 2% Ph/N THDU Ph/Ph and Ph/N for non-linear load < 2% Ph/Ph, < 3% Ph/N (at 80% of Pn) (1)

Battery

standard battery type gas-recombination sealed lead-acid battery

UPS characteristics

active power (kW) 16 24 32 40 48 64 80 96 128 160 efficiency at 50% load (%) 87.5 90.5 91.5 92.5 93 91 91.5 92 93 93.2 (values ± 1%) efficiency at 100% load (%) 91.5 92 91.5 93 92 92.5 92 91.5 92.8 92.5 (values ± 1%) heat losses (2) in KW 1.5 2.1 3.4 3.6 4.7 6.2 8.1 10.1 12.2 14.8

in cal./s 360 504 816 864 984 1488 1950 2420 2930 3550 storage temperature range -25 °C to +70 °C operating temperature range 0 °C to 35 °C (40 °C for 8 hours) relative humidity 95% maximum maximum operating altitude without derating < 1000 meters noise level (dBA) 58 58 58 60 60 62 64 65 67 68 dimensions (mm) width 715 1015 1215

depth 825

height 1400 or 1900 ± 10 1900 ± 10 weight (kg) (3) 450 450 450 490 490 800 800 800 1200 1200 recommended upstream earth-fault protection 1 A standards design IEC 146

product ENV 50091 safety IEC 950, ENV 50091 protection IEC 521 (cubicles 1400 mm high = IP 21, cubicles 1900 mm high = IP 20) electromagnetic compatibility IEC 62040, ENV 50091

(1): As per standards ENV 50091-3 / IEC 62040-3. (2): The losses indicated are those produced at full rated load with the battery float charging. They must be taken into account when sizing the ventilation system. (3): Not including any built-in options, such as harmonic filters or a bypass AC-source isolation transformer.

E-51028231XU/BH - 5

Empty battery cubicles

Characteristics of empty battery cubicles

Cubicle width Cubicle height Cubicle depth Maximum weight (1) in mm in mm in mm in kg

715 1400 ± 10 825 145

1900 ± 10 825 180

1015 1400 ± 10 825 185

1900 ± 10 825 230

Electrical parameters for selecting protective devices

Normal AC source

The parameters given in the table opposite can be used to determine the required rating of the upstream protective circuit breaker on the normal AC input for one single-UPS or parallelUPS unit, a unit in economy mode or a frequency converter.

Important:

It is essential to choose the type of circuit breaker according to its breaking capacity and the prospective shortcircuit current at its place of installation (see Schneider Electric LV documentation).

Note:

For normal AC source power supply voltages of 380, 400 and 415 V, the normal AC source current is the same because it is a function of the DC voltage.

Electrical parameters for the normal AC source

Rated Current normal AC source UPS Rated current In for unit: for 25% for 50% output with battery at start without battery (2) overload (3) overload (3)

in kVA of charge cycle (1)

20 36 33 41 50 30 53 49 62 74 40 71 66 83 100 50 88 83 103 124 60 107 100 125 150 80 142 133 166 200 100 179 166 208 249 120 214 199 249 299 160 282 262 329 397 200 358 329 414 501

UPS cubicles

Characteristics (cont.)

◗ the cubicles are cooled by forced

ventilation. The air enters via the doors and grids at the bottom and is discharged through the back, or through the roof for the 1900 mm high cubicles (except the 160 and 200 kVA units from which the air is discharged through the roof only, which means the cubicles can be positioned against the back wall).

◗ connections are made through the

bottom. Connections through the top are available on option for all 1900 mm high cubicles (except the 160 and 200 kVA units).

◗ the connection cables may be run in

three ways:

◗ in a trench running under the

cubicles,

◗ under a false floor, ◗ on the floor under the cubicles, in the

free space equal to the height of the feet; in this case the cables should be run side by side to avoid blocking the flow of air for ventilation;

◗ the cables for connections between:

◗ the battery and UPS cubicles (power

and control cables);

◗ the bypass AC-source transformer in

an auxiliary cubicle and the UPS cubicle can be supplied on option. Layout must comply with figures 5, 6 and 7. The other power cables for connections between cubicles are not supplied.

◗ only the wires for the intercubicle

control connections between parallelconnected UPS units are supplied;

◗ the cubicle doors are secured by

SOUTHCO locks (key CH751).

(1) the indicated weights are for the empty cubicles, without the batteries because the total battery weight may vary widely.

(1) the rated normal AC source currents (In) have been determined for a rated phase-to-phase voltage of 400 V, a battery with a 10 minute backup time at the beginning of its charge with 206 cells at 2 Volts per cell (412 Volts) and full rated load with a power factor of 0.8. (2) The rated normal AC source currents (In) have been determined for a minimum float charging voltage of 423 V and full rated load with a power factor of 0.8.

(3) the normal AC source currents given for an overload of 25% or 50% are maximum values. They have been determined for a battery with minimum float charging voltage and a load power factor of 0.8. When choosing the circuit breaker rating, use the "rated current" column and check that the circuit breaker tripping curves are compatible with the values in the overload columns.

6 - E-51028231XU/BH

Electrical parameters for bypass AC source (415 V)

Rated UPS Current bypass AC source (1) output in kVA Rated current for 25% for 50%

In overload overload

20 29 36 43 30 43 53 64 40 58 73 87 50 72 90 108 60 87 108 130 80 116 145 174 100 144 180 216 120 174 218 261 160 231 289 347 200 289 362 434

Bypass AC source

The parameters given in the table opposite can be used to determine the required rating of the upstream protective circuit breaker on bypass AC input.

Important:

It is essential to choose the type of circuit breaker for bypass AC input according to its breaking capacity and the prospective short-circuit current at its place of installation (see Schneider Electric LV documentation). This choice must also be made so as to protect the static-switch semiconductors with respect to the maximum permissible currents (see table opposite) and ensure discrimination between the UPS output fuses (see the fuse curves in figures 1 and 2) and the downstream protection devices.

Remark:

If the installation includes a transformer on the bypass AC input, allow for the inrush current caused by magnetisation of the transformer windings.

UPS output Maximum permissible current in kVA

20 43 In for 20 ms 30 29 In for 20 ms 40 21 In for 20 ms 50 20 In for 20 ms 60 16 In for 20 ms 80 27 In for 20 ms 100 21 In for 20 ms 120 18 In for 20 ms 160 23 In for 20 ms 200 19 In for 20 ms

(1) the bypass AC source currents have been determined for a rated phase-to-phase voltage of 400 V, a load power factor of 0.8 and for full rated load as well as overloads of 25% or 50%. When choosing the circuit breaker rating, use the "rated current" column and check that the circuit breaker tripping curves are compatible with the data in the overload columns.

For a bypass AC source voltage of 380 V, multiply the currents indicated in this table by 1.09. For a bypass AC source voltage of 400 V, multiply the currents indicated in this table by 1.04.

Fig. 1

Fig. 2

t(s)

I(A)

Galaxy PW 20 - 30 - 40 kVA

10-

10210310

Galaxy PW 50 - 60 kVA

t(s)

I(A)

10-

10210310

Galaxy PW 160 - 200 kVA

t(s)

I(A)

10-

10210310

Galaxy PW 80 - 100 - 120 kVA

t(s)

I(A)

10-

10210310

10-

Characteristics (cont.)

E-51028231XU/BH - 7

Electrical parameters for determining cable cross-sections

Characteristics (cont.)

◗ this table has been drawn up for

rated phase-to-phase AC source and load voltages of 400 V. For voltages of 380 V or 415 V, multiply the currents for the bypass AC source and the load by

1.05 and 0.96 respectively;

◗ the current values and cable cross-

sections for the normal AC source are given for full rated load with a power factor of 0.8 and a battery consuming its minimum float charging voltage.

◗ the battery current values and cable

cross-sections have been determined for a battery at the end of discharging;

◗ the current values and cable sections

for the bypass AC source and load are given for full rated load with a power factor of 0.8. For frequency converters, the parameters concerning the bypass AC source are not applicable.

Parameters for cables for a single-UPS unit

Rated UPS Line currents absorbed in Amps Cross-sectional area of Cu cables in mm2 (2) output Normal AC source 400 V Battery Normal AC source 400 V Battery in kVA with or bypass AC with or without battery bypass AC

without battery (1) source and load source and load

20 33 29 52 16 16 16 30 49 43 72 25 25 25 40 66 58 103 35 35 35 50 83 72 128 50 35 50 60 100 87 154 50 50 70 80 133 116 205 95 or 2x50 70 95 or 2x50 100 166 144 256 95 or 2x50 70 2x70 120 199 174 308 95 or 2x50 70 2x70 160 262 231 410 95 95 2x95 200 329 289 512 120 120 2x95

(1) The rated normal AC source currents (In) have been determined for a minimum float charging voltage of 423 V and full rated load with a power factor of 0.8.

(2) the cable cross-sections are given for copper conductors (increase by 30% for aluminium conductors). They are calculated according to permissible temperature rise and allow for line voltage drops over a maximum length of 100 m (AC circuits) or 25 m (DC circuits if cables not

Recommended protection

provided). For greater lengths, the cross-sections should be chosen to limit voltage drops to 3% (AC) or 1% (DC).

protection upstream of Galaxy PW

The information provided here is purely indicative, for a single-UPS unit supplied by a 380 to 415 V, 50 to 60 Hz distribution system. Check that all the criteria mentioned in the previous section are taken into account (shortcircuit current and protection of the static-switch semiconductors on the bypass AC input).

Ratings of recommended protection devices upstream of a single-UPS unit (Merlin Gerin circuit breakers)

Rated UPS Circuit breaker on normal Circuit breaker on bypass output AC input AC input in kVA Circuit breaker Control unit Circuit breaker Control unit

20 NS 100N 3P TM 63D NS 100N 4P TM 63D 30 NS 100N 3P TM 63D NS 100N 4P TM 63D 40 NS 100N 3P TM 80D NS 100N 4P TM 80D 50 NS 100N 3P TM 100D NS 100N 4P TM 100D 60 NS 125E 3P TM 125D NS 125E 4P TM 125D 80 NS 160N 3P TM 160D NS 160N 4P TM 160D 100 NS 250N 3P TM 200D NS 250N 4P TM 200D 120 NS 250N 3P TM 250D NS 250N 4P TM 250D 160 NS 400N 3P STR 23 SE NS 400N 4P STR 23 SE 200 NS 400N 3P STR 23 SE NS 400N 4P STR 23 SE

Protection downstream of Galaxy PW

These protection devices ensure discrimination for each of the Galaxy PW output circuits. If the recommended downstream protection is not installed and a short-circuit occurs, the result may be a break longer than 20 ms on all the other output circuits.

Ratings of recommended protection devices downstream of a single-UPS unit (Merlin Gerin circuit breakers)

Rated UPS Downstream circuit output breaker(s) in kVA Circuit breaker Control unit

20 to 40 kVA C60N C 10A

B 20A

50 to 60 kVA C60N C 20A

B 32A

80 to 120 kVA C60N C 50A

NC100 B 63A

160 to 200 kVA NC100 C 63A

B 100A

8 - E-51028231XU/BH

Parameters for bypass AC source and load cables for a parallel UPS configuration

Rated unit Number of Total UPS Bypass AC Cable crossoutput parallel- rated output source or load section (1) in kVA connected in kVA line current in mm

units in Amps

20 2 405835

3 608750 4 80 116 50

30 2 608650

3 90 129 70 4 120 172 70

40 2 80 116 50

3 120 174 70 4 160 232 120

50 2 100 144 70

3 150 216 95 4 200 288 150

60 2 120 174 70

3 180 261 120 4 240 348 185

80 2 160 232 120

3 240 348 185 4 320 464 2x95

100 2 200 288 150

3 300 432 185 4 400 576 2x120

120 2 240 348 185

3 360 522 2x120 4 480 696 2x150

160 2 320 462 2x95

3 480 693 2x150 4 640 924 3x120

200 2 400 578 2x120

3 600 866 2x185 4 800 1155 3x185

(1) cable cross-sections are given for copper conductors of the U1000 R02V type (increase by 30% for aluminium conductors). They are calculated according to permissible temperature rise and allow for line voltage drops over a

The table opposite serves as an example for a parallel-connected installation comprising up to four UPS units.

◗ for installations with redundant units,

take into account only the units required to supply the load power (e.g. for an installation made up of 3 parallelconnected UPS units, one being redundant, only 2 UPS units are used to determine bypass AC source and load currents and cable crosssections);

◗ this table has been drawn up for

rated phase-to-phase bypass AC source and load voltages of 400 V and full rated load with a power factor of

0.8. For voltages of 380 V or 415 V, multiply the indicated currents by 1.05 and 0.96 respectively, then modify the cable cross-sections accordingly, if necessary. The cable cross-sections in this table concern the parts illustrated in bold in the simplified diagram in figure 3, where:

1: normal AC source, 2: bypass AC source, A: external bypass.

maximum length of 100 m. For greater lengths, the cross-sections should be chosen to limit voltage drops to 3%.

Fig. 3

Galaxy 2

Galaxy 3

Galaxy 1

Characteristics (cont.)

E-51028231XU/BH - 9

Installation

(qualified personnel only)

Positioning the cubicles

◗ prior to moving the cubicles to their

final position, remove the packing material and the base panels which were shipped on top of the cubicle. The panels will be installed at the end of the installation procedure;

◗ after moving them to their installation

location on their pallets, cubicles can be moved short distances using a forklift or pallet-mover when the front, rear and side base panels are not mounted. The forks can be inserted from all four sides into 100 mm ±10 mm high openings;

◗ adjust the front foot pads to make the

cubicle vertical and align the subsequent cubicles.

Note:

Dispose of packing materials in compliance with applicable legislation.

Floor loads

See figure 4, where:

A: the rear panel of the cubicle, B: the width of the cubicle, minus

139 mm (see page 5),

C: the four foot pads (diameter

40 mm),

D: the front panel of the cubicle.

◗ to determine the stresses applied by

the cubicle on the floor, divide the cubicle weight (see the first 3 tables of this manual) by the total area of the 4 footpads (50 cm

Fig. 4

Cubicle layout on a false floor or a normal floor

◗ see figure 5 for a single-UPS Galaxy

PW unit with a single battery cubicle;

◗ see figure 6 for a single-UPS Galaxy

PW unit with several battery cubicles;

◗ see figure 7 for two parallel-connected

Galaxy PW units with battery and auxiliary cubicles.

◗ an overall clearance of 400 mm must

be left above the entire surface of the cubicles for ventilation;

◗ in rooms with unrestricted access,

install a fire-protection system under the UPS cubicle.

Key for figures 5 to 7: A: the width W of the cubicle (see the

table in the Characteristics section on page 5),

B: the openings to be made for cables

coming up through a false floor: 65 x 430 mm for 20 to 60 kVA UPS, 200 x (L-160) mm for 80 to 200 kVA UPS,

C: the position of a trench under the

cubicles, if applicable,

D: front of cubicles E: back of cubicles 1: the battery cubicle containing circuit

breaker QF1,

2: a second battery cubicle, 3: the UPS cubicle, 4: an auxiliary cubicle, if applicable.

Fig. 5 Fig. 6

Fig. 7

69,5

676

6767

69,5

3413

2 13

(*) :

◗ The Galaxy PW 20 to 120

kVA must be installed at a distance of at least 250 mm

from a wall;

◗ Galaxy PW 160 and 200 may be

positioned against a wall;

◗ It is advised that, whenever

possible, the units be installed at a distance of 400 mm from a wall, in order to facilitate their inspection during preventive maintenance.

(*)

825

> 850

10 - E-51028231XU/BH

Q4S

–

QF1

Q1 Q5N

Galaxy PW

Q3BP

Power-circuit wiring diagrams

The single-wire diagrams for typical UPS installations are given in figures 8 to 11. The heavy lines represent the cables that must be connected (see the table in the previous chapter for the required cross-sectional areas of the cables).

◗ see figure 8 for a single-UPS

Galaxy PW unit;

◗ see figure 9 for a two parallel Galaxy

PW units combined for redundancy.

◗ see figure 10 for a two parallel Galaxy

PW units combined for higher output;

◗ see figure 11 for a Galaxy PW

frequency converter without a battery;

Key for figures 8 and 9: 1: normal AC source, 2: bypass AC source, A: the rectifier/charger module, B: the inverter module, C: the static-bypass module, D: the battery cubicle next to the

Galaxy PW UPS cubicle, E: any additional battery cubicles, F: the equipotential-bonding

connection between cubicles, G: K3N contactor or output static-

switch module.

Fig. 8

Fig. 9

Q4S

–

QF1

Q1 Q5N

Galaxy PW

Q4S

–

QF1

Q1 Q5N

Galaxy PW

Q3BP

Galaxy PW single-UPS unit

Galaxy PW parallel connection for redundancy

Installation (cont.) (qualified personnel only)

E-51028231XU/BH - 11

Key for figures 9 and 10: 1: normal AC source, 2: bypass AC source, A: the rectifier/charger module, B: the inverter module, C: the static-bypass module, D: the battery cubicle next to the

Galaxy PW UPS cubicle, E: any additional battery cubicles, F: the equipotential-bonding

connection between cubicles, G: K3N contactor or output static-

switch module.

Fig. 11

Fig. 10

Q4S

–

QF1

Q1 Q5N

Galaxy PW

Q4S

QF1

Q1 Q5N

Galaxy PW

Q3BP

Q5N

Q4S

–

Q1 Q5N

Galaxy PW

Galaxy PW parallel connection for greater capacity

Galaxy PW frequency converter without a battery

Installation (cont.)

(qualified personnel only)

12 - E-51028231XU/BH

Connection of power circuits

Before making connections, check that switches Q1, Q4S, Q3BP, Q5N and QF1 are in the

"open" position.

General:

Remark. See page 4 for information on the supplied cables and wires.

◗ open the doors and remove the lower

terminal shields (secured by screws to the cubicle chassis) of the UPS cubicles;

◗ connect the power cables; ◗ each cubicle must be earthed; ◗ all the cubicles must be

interconnected for equipotential bonding, forming a mesh which is itself connected to the building structure and earthing electrode;

◗ the connection drawings hereafter

show the cubicles with doors open and terminal shields removed.

Important:

For parallel UPSs with an external bypass unit, the power connections between each UPS cubicle and the external bypass unit must imperatively be of the same length. Outside the cubicles, separate the auxiliary wiring from the power cables.

UPS cubicle

See figure 12 for 20 to 60 kVA units, and figure 13 for 80 to 120 kVA units, and figure 14 for 160 to 200 kVA units. Battery + and - cables are connected by lugs on 8 mm diameter pins for 20 to 120 kVA units, or by lugs on 12 mm diameter holes for 160 to 200 kVA units. Normal/Bypass AC input and load cables are connected by tunnel terminals to the 20 to 60 kVA units, or by lugs on 10 mm diameter holes to the 80 to 120 kVA units. Elevation of connections from ground for 20 to 60 kVA units:

◗ normal/bypass AC input and load: 310

mm;

◗ battery: 280 mm.

Elevation of connections from ground for 80 to 120 kVA units:

◗ normal/bypass AC input and load: 340

mm;

◗ battery: 310 mm.

Elevation of connections from ground for 160 to 200 kVA units:

◗ normal/bypass AC input and load: 410

mm;

◗ battery: 410 mm.

Installation (cont.) (qualified personnel only)

E-51028231XU/BH - 13

1, 2, E

I J

L1L2L3N

L1L2 L3

S M

BAA

80 - 100 - 120 kVA

Q4S

Q5NQ3BP

L1L2L3N

Fig. 12

Key to figures 12 and 13: AA: cross-sectional view of the cubicle, B: front view of the cubicle, C: front panel, D: rear panel, 1: normal AC input connection, 2: bypass AC input connection, E: load connection, F: battery connection, G: air inlets, H: air outlets, I: cable exit through the bottom, J: trough, if applicable, K: rectifier/charger module, L: inverter module, M: static-bypass module, N: rack containing electronic boards, O: Media Contacts 11 board, P: slot for communications boards, Q: FUE input fuses, R: FUS output fuses, S: ETOI board (20 to 60 kVA UPS) or

RELI board (80 to 200 kVA UPS),

T: APOZ board, U: MISI board, V: modem socket switch, W: trough (20 to 60 kVA) or binding bar

(80 to 200 kVA) for fine wiring, X: fuses for overvoltage protection RC

circuit on bypass, Y: control-wire connection (auxiliary

"Media Contacts 11" circuits and

communications options).

Notes:

Figure 12. Switch Q3BP does not exist in parallel Galaxy PW cubicles interconnected for greater capacity. Figure 13. Switch Q3BP and "X" (protection fuses) do not exist in parallel Galaxy PW cubicles interconnected for greater capacity. The bypass AC source ("2") connects to switch Q4S.

Fig. 13

Installation (cont.)

(qualified personnel only)

Q1 Q5N

L1L2 L3N

L1L2L3

Q4S

L1L2 L3N

Q3BP

O P

BAA

20 - 30 - 40 - 50 - 60 kVA

1, 2, E

F G

K, L, M

I J

Q1 Q5N

L1L2 L3N

L1L2L3

Q4S

L1 L2 L3

Q3BP

Galaxy PW cubicle with built-in bypass AC-input isolation transformer (option)

14 - E-51028231XU/BH

160 - 200 kVA

Q4S

Q5NQ3BP

L2L3N

L1L2L3

L2L3N

M Q

1, 2, E,F

Key to figure 14: AA: cross-sectional view of the cubicle, B: front view of the cubicle, C: front panel, D: rear panel, 1: normal AC input connection, 2: bypass AC input connection, E: load connection, F: battery connection, G: air inlets, H: air outlets, I: cable exit through the bottom, J: trough, if applicable, K: rectifier/charger module, L: inverter module, M: static-bypass module, N: rack containing electronic boards, O: Media Contacts 11 board,

Fig. 14

P: slot for communications boards, Q: FUE input fuses, R: FUS output fuses, S: ETOI board (20 to 60 kVA UPS) or

RELI board (80 to 200 kVA UPS),

T: APOZ board, U: MISI board, V: modem socket switch, W: trough (20 to 60 kVA) or binding bar

(80 to 200 kVA) for fine wiring,

X: fuses for overvoltage protection RC

circuit on bypass,

Y: control-wire connection (auxiliary

"Media Contacts 11" circuits and communications options).

Note:

Figure 14. Switch Q3BP does not exist in parallel Galaxy PW cubicles interconnected for greater capacity. The bypass AC source ("2") connects to switch Q4S.

Installation (cont.) (qualified personnel only)

E-51028231XU/BH - 15

Battery cubicle

See figure 15. The battery cubicle shown is an example only, given that characteristics of these cubicles vary greatly from one cubicle to another.

◗ remove the cardboard covers and all

the hooping (used only for transport);

◗ remove the terminal shield from the

battery circuit breaker "QF1" to make the connections to this circuit breaker;

◗ in the case of installations having

several battery cubicles, the connections to be made between cubicles are indicated in the instructions accompanying the cubicles (or in the drawing file for complicated installations);

◗ in the case of a UPS with a power

rating from 80 to 120 kVA and connection via the top, the battery cubicle containing circuit-breaker QF1 cannot be connected to the UPS cubicle via the bottom. A roof equipped with a cable gland can be installed on this battery cubicle in order to connect it directly via the top to the inverter cubicle. Please contact our after-sales service.

Important:

◗ the cubicle is supplied with a fixture

locking circuit breaker "QF1"in the open position. Do not remove this fixture before commissioning. Accidental closing of "QF1" will power up the downstream circuits which could be hazardous for personnel and permanently damage the battery by deep discharge;

◗ connections between battery cubicles

should be made in compliance with applicable regulations. Take all protective measures associated with working on live equipment and in particular use only qualified personnel equipped with gloves, protective

goggles, insulated tools, etc. Cables are connected to copper

terminals by lugs.

Note:

The optional "Temperature Monitor" unit is located at the top in one of the battery cubicles. The cubicles not fitted with a battery circuit breaker include an additional shelf for battery cells.

Key to figure 15: AA: cross-sectional view of the cubicle, B: front view of the cubicle, C: front panel, D: rear panel, E: cable ties to duckboard shelf, F: cable exit through the bottom, G: trough, if applicable, H: connection of exposed conductive

parts to duckboard shelf, I: cable exit to battery connection

point in UPS cubicle, J: cable exit to an additional battery

cubicle, if applicable,

K: cable ties to duckboard shelf, L: fixture locking circuit breaker "QF1"

in the open position.

Fig. 15

XR1

QF1

F G

BAA

Installation (cont.)

(qualified personnel only)

16 - E-51028231XU/BH

Connection through the top

(20 to 120 kVA units) This type of connection is possible on

1900 mm high cubicles. See figure 16.

Key to figure 16: AA: cross-sectional view of the cubicle, B: front view of the cubicle, C: front panel, D: rear panel, 1: normal AC input connection, 2: bypass AC input connection, E: load connection, F: battery connection, I: air outlet grid, J: passageway for cables exiting

through the top (opening 460 x 197 mm with cable-gland plate),

K: top view of the cubicle. Note:

For 160 to 200 kVA units, this option is not available because air is discharged through the top. However, it is possible to run normal/bypass AC input and load cables through an auxiliary cubicle (empty or containing an optional harmonic filter or bypass AC-input isolation transformer). In this case, the cables enter through the standard opening in the top and exit through the bottom of the cubicle.

Fig. 16

L+L-1L3L2 L1

L2L1 NL3

F, 1, 2, E

20 - 30 - 40 - 50 - 60 - 80 - 100 - 120 kVA

Installation (cont.) (qualified personnel only)

E-51028231XU/BH - 17

15,5

750

800

857,5

XM8

"MISI" 1

1 2

Q3BP + Q3BP –

XM9

1 2

Q4S + Q4S –

XM8

"MISI" 2

1 2

Q3BP + Q3BP–

XM9

1 2

Q4S + Q4S –

"MISI" 3 "MISI" 4

Q4S

Q3BP

150 kVA

1000950 1057,5

120

303

317

1234

Q4S

Q3BP

Q5N

317

Q5N

Fig. 17

External bypass cubicle 150 kVA

See figure 17.

Key to figure 17: A: bottom view of the unit, B: front view of the unit, C: passageway for cables

(317 x 120 mm), D: bypass AC input connection for the

UPS units, E: connections for auxiliary wiring

indicating the position of the Q4S

and Q3BP switches,

F: connection for the UPS-unit outputs, G: bypass AC input connection, H: load connection.

Installation (cont.)

(qualified personnel only)

18 - E-51028231XU/BH

Fig. 18

External bypass cubicle 360 kVA

See figure 18.

Key to figure 18: AA: cross-section AA of cubicle, B: cubicle front view, C: front panel, D: bypass AC input connection for the

UPS units,

E: connection of the auxiliary position

wires of switches "Q4S" and "Q3BP",

F: connection of UPS load outputs, G: bypass AC input connection, H: connection of load, I: air outlet grid, J: opening of 460 x 197 mm for cable

insertion,

K: fuses for overvoltage protection RC

circuit on bypass (to be replaced when the indicator light is on).

L: top view of cubicle

1900

B AA

XM8

"MISI" 1

1 2

Q3BP + Q3BP -

XM9

1 2

Q4S + Q4S -

XM8

"MISI" 2

1 2

Q3BP + Q3BP -

XM9

1 2

Q4S + Q4S -

"MISI" 3 "MISI" 4

Q4S

Q3BP

1234

360 kVA

Q4S

Q3BP

Q5N

Installation (cont.) (qualified personnel only)

E-51028231XU/BH - 19

Fig. 19

External bypass cubicle 600 kVA

See figure 19.

Key to figure 19: AA: cross-section AA of cubicle, B: cubicle front view, C: front panel, D: bypass AC input connection for the

UPS units, E: connection of the auxiliary position

wires of switches "Q4S" and

"Q3BP",

Q4S

Q3BP

Q5N

XM8

"MISI" 1

1 2

Q3BP + Q3BP -

XM9

1 2

Q4S + Q4S -

XM8

"MISI" 2

1 2

Q3BP + Q3BP -

XM9

1 2

Q4S + Q4S -

"MISI" 3 "MISI" 4

Q4S

Q3BP

1234

600 kVA

F: connection of UPS load outputs, G: bypass AC input connection, H: connection of load, I: air outlet grid, J: opening of 460 x 197 mm for cable

insertion,

L: top view of cubicle

Installation (cont.)

(qualified personnel only)

20 - E-51028231XU/BH

Connection of the Hot Swap option

The external bypass may be used to construct a bypass outside the UPS, thus making it possible to shutdown the UPS for maintenance purposes. The option may be used for single-UPS units and redundant parallel UPSs.

◗ control-wire connections are not

required between the bypass unit and the UPS unit(s);

◗ see figure 20 for the power-circuit

connections of a single-UPS unit and figure 21 for the power-circuit connections of redundant parallel UPSs. Power cables for UPS-to-bypass connections are not supplied.

Galaxy PW cubicle with built-in bypass AC-input isolation transformer

(20 to 60 kVA UPSs) For this option, the cubicle is 1900 mm

high. This isolation transformer is installed in the top part of the cubicle. Power connections are not modified by this option (see figure 22).

Installation (cont.) (qualified personnel only)

Q4S

Q1 Q5N

Galaxy PW

Q3BP

–

QF1

Q4S

Q3BP

Q5N

Q4S

Q1 Q5N

Galaxy PW

Q3BP

–

QF1

Q4S

Q3BP

Q5N

Fig. 20

Fig. 21

Q4S

Q1 Q5N

Galaxy PW

Q3BP

–

QF1

–

QF1

Q4S

Q1 Q5N

Galaxy PW

Q3BP

Q4S

Q3BP

Q5N

Fig. 22

E-51028231XU/BH - 21

Fig. 23

Mains 2 isolation transformer in an auxiliary cubicle

The cubicle is 1900 mm high. See figure 23 (20 to 120 kVA units) and figure 24 (160 to 200 kVA units).

Key to figures 23 and 24: AA: cross-sectional view of the cubicle, B: front view of the cubicle, C: front panel, D: rear panel, E: bypass AC input connection

(terminals A, B, C or A1, B1, C1

(+ 5%), F: bypass AC input connection to

UPS(s) - terminals n, a, b, c,

G: air inlets, H: air outlets, I: cable exit through the bottom, J: trough, if applicable, K: bypass AC input isolation

transformer,

L: passage of cables through the top, M: passageway for cables exiting

through the top (opening 460 x

197 mm with cable-gland plate),

N: air outlet grid, O: top view of the cubicle.

L1L2 L3

L1L2L3N

E F

M N

715

20 - 30 - 40 - 50 - 60 80 - 100 - 120 kVA

Fig. 24

1015

160 - 200 kVA

L1L2 L3

L1L2L3N

E,F

Installation (cont.)

(qualified personnel only)

22 - E-51028231XU/BH

Fig. 25

THM filter

This option is installed on the normal AC input upstream of the Galaxy PW UPS cubicle. The cubicle is 1900 mm high.

◗ 20 to 120 kVA units, width of auxiliary

cubicle = 715 mm

◗ 160 to 200 kVA units, width of

auxiliary cubicle = 1015 mm For THM-filter installation and connections, see manual No. 51024338.

Key to figure 25: 1: normal AC input 2: bypass AC input A: Galaxy PW UPS cubicle B: THM filter.

Galaxy PW

THM

Installation (cont.) (qualified personnel only)

E-51028231XU/BH - 23

Fig. 26

Connection of "Media Contacts 11" standard auxiliary circuits

See figure 26 below for information on connecting the auxiliary circuits to the three connectors on the "Media Contacts 11" board in the Galaxy PW UPS cubicle. See the position of this board, marked "O" in figures 12 to 14.

◗ recommended cable cross-section:

1mm2;

◗ the male connectors that fit the female

connectors on the board (XR2 to XR5) are supplied;

◗ the contacts are volt-free and are

shown in the diagram under the following conditions: UPS on, contact at rest;

◗ contact breaking capacity: 250 V, 5 A.

Connection to battery circuit breaker "QF1"

◗ connect the cable from connector

XR3 (pins 2 to 8) on the "Media Contacts 11" board in the UPS cubicle to connector XR1 in the battery cubicle containing battery circuit breaker QF1.

Emergency power off

The UPS emergency shutdown function is generally wired to a "mushroomhead" type emergency-off button.

Important:

In the case of a complex installation with a number of units, there should be only one emergency shutdown pushbutton and this pushbutton must interrupt all the active conductors of all the units. For the same reason, it is essential for the pushbutton to open the upstream protective circuit breakers on the normal and bypass inputs. Each type of unit (single UPS, parallel UPS, frequency converter) must have an independent, volt-free contact connected to the emergency shutdown pushbutton. This pushbutton must therefore have as many contacts as there are units in the installation, as well as the contact or contacts required to open the upstream protective circuit breakers on the normal and bypass inputs. The emergency shutdown pushbutton turns off the rectifier/ chargers and inverters, opens the battery circuit breakers and activates a contact on the "Media Contacts 11" board (terminals 1 to 3 on connector XR4). The emergency shutdown signal will be cleared when the emergency shutdown pushbutton contact has been reset.

Media Contacts 11" board

XR2 XR3

XR4

XR5

XR2

XR3

XR4

XR5

XR1

9 8 7 6 5

4 3 2 1

XR4 connector

output signals:

general alarm

low-battery shutdown warning

8 7

3 2 1

XR5 connector

output signals:

load on battery

load on inverter

+12V

24V CC

–12 V

XR3 connector

input or output signals:

4 3

QF1 battery circuit-breaker closed

QF1 battery circuit-breaker opening command

battery cubicle

XR1 terminal block

9 8 7 6 5 4 3 2 1

free auxiliary contact

+12 V

QF1 battery circuit-breaker opening command

XR2 connector

input or output signals:

connection with optional electronic board for measuring battery temperature

battery-room ventilation fault

emergency-shutdown button contact (jumper if not used)

temperature signal

power supply

earth

NC NC

9 8 7 6 5 4 3 2 1

2 1

thermal monitoring of the harmonics-filter inductor

harmonic-filter cubicle

XR1 terminal block

and/or harmonics filter temperature fault

+12 V

–12 V

complete system shutdown

maintenance position

Installation (cont.)

(qualified personnel only)

24 - E-51028231XU/BH

Connections between cubicles (parallel-connected configurations)

These connections are made on the APOZ board (marked T in figures 12 to

14) and MISI board (marked U).

Important:

Outside the cubicles, group the "APOZ" inter-board and "MISI" interboard connections with the inter-cubicle auxiliary connections, and separate

this assembly using power cables.

Connections between APOZ boards

See figure 27.

◗ these connections are made using the

cables (A) supplied;

◗ the purpose of the connection is to

make a loop. Connector XM137 on the APOZ board of one UPS unit must be connected to connector XM136 on the APOZ board of the next UPS unit and so on until the first board is returned to.

Connections between MISI boards

See figures 28, 29 and 30.

◗ these connections are made using the

special cables (A) supplied;

◗ connectors XM5, XM6 and XM7 on

the MISI board are used to transmit signals;

◗ connectors XM10, XM11 and XM12

on the MISI board are used to receive signals;

◗ connector XM5 is associated with

connector XM10 for communication with one UPS unit; similarly, XM6 is associated with connector XM11 for communication with a second UPS unit and XM7 is associated with connector XM12 for communication with a third UPS unit;

◗ situation with two parallel UPS units:

see figure 28;

◗ situation with three parallel UPS units:

see figure 29;

◗ situation with four parallel UPS units:

see figure 30.

Fig. 27

Fig. 28

Fig. 29

XM137

XM136

XM137

XM136

XM137

XM136

"APOZ" Galaxy PW 1

"APOZ" Galaxy PW 2

"APOZ" Galaxy PW 3

"MISI" Galaxy PW 1

"MISI" Galaxy PW 2

XM5

XM6 XM7

XM10

XM11

XM12

XM5

XM6

XM7

XM10

XM11

XM12

"MISI" Galaxy PW 1

"MISI" Galaxy PW 2

XM5

XM6

XM7

XM10

XM11

XM12

XM5

XM6

XM7

XM10

XM11

XM12

"MISI" Galaxy PW 3

XM5

XM6

XM7

XM10

XM11

XM12

Installation (cont.) (qualified personnel only)

E-51028231XU/BH - 25

Fig. 30

Connections between UPS cubicles and the external bypass

◗ the recommended cross-sectional

area of control wires is 1 mm

. Wires

are not supplied;

◗ in non-redundant parallel UPS

systems (increased output), the UPS units must be connected to the external bypass unit (see figures 17, 18 and 19):

◗ terminals 1 and 2 on connector XM8

of the MISI board of the UPS to terminals 1 and 2 on the external bypass for indications on the position of switch Q3BP,

◗ terminals 1 and 2 on connector XM9

of the UPS to terminals 3 and 4 on the external bypass for indications on the position of switch Q4S.

Installation of communications options

Three slots are available on the "Media Contacts 11" board for communications options. See the position of these slots marked "P" in figures 12 to 14.

Installation of boards

◗ boards may be installed with the UPS

on, without removing the protective covers;

◗ boards must be pushed to the end of

the slots to ensure correct installation;

◗ board front plates must be screwed to

the protective "Media Contacts 11" board cover.

Passage of wires

◗ holes are provided in the support for

the "Media Contacts 11" board for tying down the wires;

◗ the control wires must then be routed

through the cableway marked "W" in figures 12 to 14.

"MISI" Galaxy PW 1

"MISI" Galaxy PW 2

XM5

XM6

XM7

XM10

XM11

XM12

XM5

XM6

XM7

XM10

XM11

XM12

"MISI" Galaxy PW 3

XM5

XM6

XM7

XM10

XM11

XM12

"MISI" Galaxy PW 4

XM5

XM6

XM7

XM10

XM11

XM12

Installation (cont.)

(qualified personnel only)

26 - E-51028231XU/BH

Connection of the battery "Temperature Monitor"

Connections

This unit must be connected to the XR2 connector on the remote indications "Media Contacts 11" board of the UPS cubicles. See the location of the "Media Contacts 11" board, marked "O" in figures 12 to 14 in the Appendix.

◗ use a shielded cable made up of 2

twisted telephone pairs with a conductor cross-section of at least

0.1 mm

, not longer than 100 m in

length;

◗ do not forget to connect the cable

shield to ground pin 12 on connector XR2;

◗ in the case of a parallel UPS

configuration, the connections between cubicles may be made by means of a shielded cable made up of 1 or 2 twisted telephone pairs. In this case, the total length of all the connecting cables must not exceed 100 m;

◗ a "Temperature Monitor" unit can be

connected to several UPS cubicles only when the batteries of these cubicles are located in the same room at the same ambient temperature.

Connection of the battery "Temperature Monitor" (single-UPS unit)

Fig. 31

Fig. 32

Connection of the battery "Temperature Monitor" (n parallel UPS units with batteries in same room)

XR2 connector on "Media Contacts 11" board:

12 11 10

9 8 7 6 5 4 3

battery "Temperature Monitor"

XR2

XR1

(unit shown open)

–12 +12

BC+ BC–

shielded cable (2 twisted telephone pairs)

temperature signal

–

12V

earth

–

power supply

2 1

temperature signal

earth

–

temperature signal

BC + BC –

XR2 connector on "Media Contacts 11" board in Galaxy PW unit 1:

12 11 10

8 7 6

battery "Temperature Monitor"

XR2

XR1

(unit shown open)

–12 +12

BC+ BC–

shielded cable (2 twisted telephone pairs)

11 10

9 8 7

XR2 connector on "Media Contacts 11" board in Galaxy PW unit 2:

XR2 connector on "Media Contacts 11" board in Galaxy PW unit n:

12 11 10

7 6

temperature signal

–12V +12V

earth

BC + BC –

power supply

5 4

shielded cable (1 or 2 twisted telephone pairs)

earth

Installation (cont.) (qualified personnel only)

E-51028231XU/BH - 27

QF1

to UPS cubicle

battery cubicle

tie the cable to the cubicle upright

"Temperature Monitor" unit

Installation of the "Temperature Monitor" in an MGE UPS SYSTEMS empty battery cubicle

The "Temperature Monitor" unit is placed inside the battery cubicle housing circuit-breaker QF1 (see figure

33):

◗ open the unit cover; ◗ before fixing, break the self-cleavable

seal on the base of the unit for insertion of the connecting cable;

◗ fix the unit on the plate using the self-

adhesive sticker and a screw (nut and washer combination, diameter 4 mm, length 16 mm, not supplied);

◗ connect and put back the cover; ◗ the temperature sensor MUST be

placed at the top of the cubicle to work properly;

◗ tie the connecting cable to the cubicle

upright so that it does not pull on the unit.

Installing the "Temperature Monitor" in a battery cubicle

Fig. 33

"Temperature Monitor" installation in a battery room

The "Temperature Monitor" should be secured against a wall or any vertical support.

◗ choose a location near the batteries

and away from draughts which adversely affect the accuracy of temperature measurements;

◗ use the holes provided in the base

plate to screw the unit to the vertical support (see figure 34);

◗ unless the connecting cable runs on

the surface, break the knock-out in the unit base plate provided for cable entry,

◗ secure the cable by suitable means

so that it does not pull on the unit.

"Temperature Monitor" base

dimensions du coffret : 75 x 75 x 21 mm

Fig. 34

board

oblong hole for fastening screw

knock-out for lateral cable entry

oblong hole for fastening screw

Installation (cont.)

(qualified personnel only)

28 - E-51028231XU/BH

Link to an IBM AS/400® computer

The Galaxy PW can dialogue with an IBM AS/400

computer via this link in compliance with IBM communications recommendations, thus enhancing the protection provided by your Galaxy PW. The IBM AS/400

computer must be configured for the link. This document presents the physical connections required as well as the system values that must be modified on the AS/400

. For further information, consult the following IBM documents:

◗ "Planning Guide, Appendix E"

concerning physical connections;

◗ "Back-up and Recovery Guide",

chapter 7 "Power Loss Recovery" concerning configuration of the AS 400

Connections

◗ connections are made to the female

client connector XR5 on the "Media Contacts 11" board;

◗ the corresponding male connector is

supplied;

◗ see figure 35 below for the wiring

diagram. A five-wire cable (not supplied) is required;

◗ on the AS/400

side, use a 9 or 15-pin SUB-D connector, depending on the type of AS/400

Configuration of the AS 400

Certain values on the AS/400® must be configured to enable operation of the Galaxy PW - AS/400

link. The values requiring modification and the corresponding procedures are presented in chapter 7 "Power Loss Recovery" of the "Back-up and Recovery Guide" for the AS/400

The values are the following:

◗ QUPSMSGQ: UPS message queue; ◗ QUPSDLYTIM: Uninterruptible power

supply delay time;

◗ QPWRRSTIPL: Power restore IPL.

Connection to the "Media Contacts 11" board

Fig. 35

9 8 7 6 5 4 3 2 1

XR5 connector

output signals:

low-battery shutdown warning

(low battery)

)

load on battery

(utility failure)

load on inverter

(ON)

load on bypass

(bypass active)

common 0 V

(system ground)

male 9-pin SUB-D connector

male 15-pin SUB-D connector

IBM AS/400



Galaxy PW

Note: the corresponding IBM AS/400® signal names are

given in parentheses.

2 3 4

6 7 8 9

2 3

4 5 6 7 8

9 10 11

2 3

12 13 14 15

"Media Contacts 11" remote indications board

XR2 XR3

XR4

XR5

XR2

XR3

XR4

XR5

1 10

XR1

Installation (cont.) (qualified personnel only)

E-51028231XU/BH - 29

Final installation steps

After making the connections:

◗ install the front and rear base plates

of the cubicles, clipping them to the feet of the cubicles (unless the connecting cables are fed through these openings);

◗ refit the terminal shields of the

terminal blocks, switches and circuit breakers.

Connection of the LED indications unit (optional)

This unit connects to the XR4 and XR5 connectors (see the position of the board in the figures in the "connection of "Media Contacts 11" standard auxiliary circuits" section). For information on unit installation and

details on connections to the unit, see the manual included with the LED indications unit, document No.

5102990400.

◗ the recommended cable cross-

section is 1 mm2 .

Installation (cont.)

(qualified personnel only)

30 - E-51028231XU/BH

MGE UPS Systems Galaxy PW 20 kVA, Galaxy PW 60 kVA, Galaxy PW 40 kVA, Galaxy PW 50 kVA, Galaxy PW 80 kVA Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual