Schneider Electric MGE GALAXY 5000 User Manual

APC by Schneider Electric

MGE GALAXY 5000

Data Center Grade Three Phase Uninterruptible Power Supply

Parallel Module - Guide Specifications

40-130 kVA UPS

1.0 GENERAL

1.1 SUMMARY

This specification describes a three-phase, on-line, double conversion, solid state Uninterruptible
Power System hereafter referred to as the UPS. The UPS shall operate in conjunction with the
existing building electrical system to provide high quality power conditioning, back-up power
protection and distribution for electronic equipment loads. The system shall consist of a solid state
IGBT rectifier/inverter, power factor corrected rectifier, a 100% rated for continuous duty static
switch, battery plant, graphical status/control panel, and synchronizing circuitry as described herein.

1.2 STANDARDS

The UPS shall meet the requirements of the following standards:

A. UL listed under 1778, standards for uninterruptible power supply equipment
B. UL Canada (cUL)
C. FCC rules and regulations of part 15, subpart J, class A
D. IEC 1004/ANSI C62.41 Standards for Surge Withstand Ability
E. ISO 9001
F. The UPS shall be designed in accordance with the applicable sections of the documents

published by:

 National Fire Protection Association (NFPA)/National Electric Code (NEC)
 National Electrical Manufacturer’s Association (NEMA) & (NEMA PE 1)
 Occupational Safety & Health Administration (OSHA)

1.3 SUBMITTALS

Submittals shall contain the following documentation:
A. Installation Package: Complete electrical characteristics and connection requirements.

Provide detailed equipment outlines with cabinet dimensions and spacing requirements;
location of conduit entry/exit paths; location of floor/seismic mounting; available battery
types/sizes; all cabinet weights; heat rejection and air flow requirements; single-line diagram;
control and external wiring.

B. Product Data: Provide catalog sheets and technical data sheets to indicate physical data and

electrical performance, electrical characteristics, and connection requirements.

C. Manufacturer’s Installation Instructions: Indicate application conditions and limitations of

use stipulated by Product testing agency. Include instructions for storage, handling, protection,
examination, preparation, installation, and starting of Product. Include equipment installation

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outline, connection diagram for external cabling, internal wiring diagram, and written instruction
for installation.

1.4 FINAL SUBMITTALS

Upon delivery of the UPS system the following submittals shall be included:
A. A complete set of installation drawings showing all the information stated in section 1.3.
B. An installation and users manual showing safe and correct operation of all UPS functions.

1.5 QUALIFICATIONS & QUALITY ASSURANCE

A. Manufacturer’s Certification: The manufacturer shall specialize in manufacturing of on-line,

double conversion three phase UPS modules specified in this document with a minimum of
twenty years documented experience, and with a nationwide first party service organization.
The manufacturer shall be ISO 9001 certified and shall design to internationally accepted
standards.

B. Factory Testing: Prior to shipment the manufacturer shall complete a documented test

procedure to test all functions of the UPS module and batteries (via a discharge test), when
supplied by the UPS manufacturer, and guarantee compliance with the specification. The
factory test shall be performed in the presence of the customer providing the manufacturer
receives adequate prior notice. The manufacturer shall provide a copy of the test report upon
request.

C. Materials and Assemblies: All materials and parts comprising the UPS shall be new, of

current manufacture, and shall not have been in prior service, except as required during factory
testing. All active electronic devices shall be solid state and not exceed the manufacturer’s
recommended tolerances for temperature or current to ensure maximum reliability. All
semiconductor devices shall be sealed. All relays shall be provided with dust covers. The
manufacturer shall conduct inspections on incoming parts, modular assemblies, and final
products.

1.6 DELIVERY, STORAGE, AND HANDLING

A. All products shall be packaged in a manner to prevent penetration by debris and to allow safe

delivery by all modes of ground transportation and air transportation where specified.
B. Prior to shipping all products shall be inspected at the factory for damage.
C. Equipment shall be protected against extreme temperature and humidity and shall be stored in

a conditioned or protected environment.
D. Equipment containing batteries shall not be stored for a period exceeding three months without

powering up the equipment for a period of eight hours to recharge the batteries.

1.7 ENVIRONMENTAL REQUIREMENTS

The UPS shall operate under the following environmental conditions:
A. Temperature:

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UPS Module Operating: 0° to 40°C (32°F to 104°F)
Non-Operating: -20° to +45°C (-4°F to 113°F)

B. Relative humidity (operating and storage): 0 to 95% non-condensing
C. Barometric Pressure: Up to 1000 meters above sea level (up to 2000 meters with

ambient temperature less than 28°C) / (up to 12,000 meters above sea level non operating)
D. Audible Noise: 69 dBA at 3 feet

1.8 WARRANTY

A. UPS Module: The UPS shall be covered by a full parts and labor warranty from the

manufacturer for a period of twelve (12) months from date of installation or acceptance by

customer or eighteen (18) months from date of shipment from the manufacturer, whichever

occurs first.
B. Battery: The battery manufacturer’s warranty shall be passed through to the final customer and

shall have a minimum period of one year.

1.9 SERVICE AND SPARE PARTS

The manufacturer shall, upon request, provide spare parts kits for the UPS module in a timely
manner as well as provide access to qualified factory trained first party service personnel to provide
preventative maintenance and service on the UPS module when required.

1.10 MAINTENANCE, ACCESSIBILITY AND SELF DIAGNOSTICS

All UPS subassemblies, as well as the battery, shall be accessible from the front. UPS design
shall provide maximum reliability and minimum MTTR (mean time to repair). To that end, the
UPS shall be equipped with a self-test function to verify correct system operation. The self-test
function shall identify the subassembly requiring repair in the event of a fault. The electronic UPS
control and monitoring assembly shall therefore be fully microprocessor based, thus doing away
with all potentiometer settings. This shall allow:

 Auto-compensation of component drift;
 Self-adjustment of replaced subassemblies;
 Extensive acquisition of information vital for computer-aided diagnostics (local or remote);
 Socket connection to interface with computer-aided diagnostics system.

The UPS shall be repairable by replacing standard subassemblies requiring no adjustments.
Communication via a modem with a remote maintenance system shall be possible.

2.0 PRODUCT DESCRIPTION

2.1 APPROVED MANUFACTURERS & PRODUCT DESCRIPTION

A. Approved Manufacturer(s): The specified equipment will be manufactured by APC by

Schneider Electric or approved manufacturer in compliance with specifications.
B. Product Description: This specification describes a three-phase, double conversion, on-line,

solid state Uninterruptible Power System, hereafter referred to as the UPS. The UPS shall

operate in conjunction with the existing building electrical system to provide power conditioning,

back-up power protection and distribution for electronic equipment loads. The system shall

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consist of a solid state IGBT PWM inverter, IGBT rectifier with a power factor corrected input,

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static switch, battery plant, graphical status/control panel, dry contact and communications

ports, and synchronizing circuitry as described herein.

2.2 SYSTEM DESCRIPTION

A. UPS Design Requirements

1. Output Power Continuous Rating: The continuous output power rating of the UPS shall
be [ ] kVA at a 0.9 lagging power factor.

Galaxy 5000 available: Choose 40, 50, 60, 80, 100, 130kVA

2. Input Voltage: 480 VAC – 15% / +10%, 3 phase, 3 wire “grounded wye” configuration
plus ground.

3. Output voltage: 480 VAC 3 phase, 3 plus ground

4. Battery Autonomy: The UPS shall be capable of operating at full load for [ ] minutes at

0.9 PF output at a temperature of 25°C on battery power.

5. Battery Type: Valve regulated sealed lead acid (VRLA)

B. AC Input Characteristics

1. Voltage: 480VAC, – 15% / +10%, 3 phase, 3 wire “grounded wye” configuration plus
ground.

2. Frequency: 60 Hz ±5%

3. Power Factor: > .98 lagging

4. Total Harmonic Distortion: less than 5% at full load

5. Inrush Current: less than nominal input current for less than one cycle

6. Input Surge Protection: The UPS is equipped to withstand surges per IEC 1004/ANSI
C62.41

C. AC Output Characteristics

1. Voltage: 480VAC , – /+ 1% steady-state variation phase to phase voltage VAC , 3 phase,
3 wire plus ground

2. Frequency: 60 Hz

3. Voltage Regulation:

4. Voltage Distortion: Maximum 2% total (THD) and 1% any single harmonic on 100% linear
loads.

5. Voltage Transient (Step Load) Response:

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+1% (or selectable up to 4%); 60 Hz + 0.1% when free running

+ 1.0% for balanced load
+ 1.75 for 50% unbalanced load
+ 2.5% for 100% unbalanced load

+ 3% for 50% step load change
+ 5% for 100% step load change

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+ 1% for loss or return of AC input power or
manual transfer at full load

6. Voltage Recovery Time: Return to within 1% of nominal value within 16.67 milliseconds
(one cycle)

7. Phase Angle Displacement: 120°
load

8. Non-Linear Load Capability: Output voltage total harmonic distortion shall be less than
3% when connected to a 100% non-linear load with a crest factor not to exceed 3%.

9. Slew Rate: 1 Hz/second maximum (or selectable up to 2.0 Hz/sec)

10. Power Factor: 0.9 at the rated volt-amperes (VA)

11. Inverter Overload Capability: 125% of rated load for 10 minutes
150% of rated load for 1 minute

12. Bypass Overload Capability: > 212% for one cycle; > 150% for 1 minute

D. Battery

1. Battery Voltage: 356 VDC minimum before cutoff; 432 VDC nominal; 490 VDC
equalization voltage

2. Maximum DC Current: Maximum DC current at cutoff voltage will be [ ] A.

2.3 MODES OF OPERATION

The UPS module shall be designed to operate as a double conversion, on-line reverse transfer
system in the following modes.

A. Normal: The inverter shall continuously supply power to the critical load. The PFC rectifier shall

derive power from the utility AC source and supply DC power to the inverter while
simultaneously float charging the battery.

B. Emergency: Upon failure of the utility AC power source, the critical load shall be supplied by

the inverter, which, without any interruption, shall obtain its power from the battery.

C. Recharge: Upon restoration of the utility AC power source (prior to complete battery discharge),

the PFC rectifier shall power the inverter and simultaneously recharge the battery.

D. Bypass Mode: The static bypass transfer switch shall be used to transfer the load to the

bypass without interruption to the critical power load. This shall be accomplished by turning the
inverter off. Automatic re-transfer or forward transfer of the load shall be accomplished by
turning the inverter on.

2.4 COMPONENT DESCRIPTION

A. PFC Rectifier and Battery Charger

+ 1° for balanced load; 120° + 3° for 100% unbalanced

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Incoming AC power shall be converted to a regulated DC output voltage by an IGBT
(insulated gate bipolar transistor) power factor correction (PFC) rectifier. The PFC rectifier
shall provide high quality DC power to charge the batteries and power the inverter and shall
have the following characteristics:

1. Input Power Factor Correction (PFC): The PFC rectifier shall be power factor
corrected so as to maintain an input power factor of 0.98 lagging to unity at 75% or above
load levels to ensure generator compatibility and avoid reflected harmonics from
disturbing loads sharing the utility power.

2. Input Harmonic Current Suppression: The PFC rectifier shall produce a sinusoidal
input AC current on each phase with low harmonic content, limiting THD on the UPS
input to below 5%.

3. Battery Charger Current Limiting: The UPS shall be equipped with a system designed
to limit the battery recharge current (from 0.05 C10 to 0.1 C10).

4. Charging Levels: The battery charging circuitry shall be capable of being set for
automatic battery recharge operation, float service, manual battery charge service, and
equalizing or commissioning operation.

5. Intermittent Charging: The battery charge level shall be maintained by an intermittent
charging technique between two values Vfmin and Vfmax very close to the floating
voltage. This technique shall be based on a cycle made up of a short charge period (a
few seconds) from Vfmin to Vfmax followed automatically by a slow discharge period (a
few minutes) from Vfmax to Vfmin. This cycle shall be repeated continuously to maintain
the battery charge level. In this way the battery shall actually be charging only for a small
part of the time, which considerably increases its service life.

6. Temperature Compensated Charging: The battery charger shall be equipped with a
temperature probe to enable temperature compensated charging and adjust the battery
float voltage to compensate for the ambient temperature using a negative temperature
coefficient of 3 mV per cell per degree Celsius at a nominal temperature of 25°C.

7. Battery Capacity : The battery charger shall have sufficient capacity to support a fully
loaded inverter and fully recharge the battery to 95% of its full capacity within 6-8 hours
up to 4 battery cabinets..

B. Inverter

The UPS output shall be derived from a Variable Frequency Pulse Width Modulated (PWM)
IGBT inverter design. The inverter shall be capable of providing the specified precise output
power characteristics while operating over the battery voltage range.

C. Static Bypass – 100% Rated, Continuous Duty

The static bypass transfer switch shall be solid-state, rated for 100% continuous duty without
mechanical contactor device in parallel for higher reliability and consistent response time and
shall operate under the following conditions:

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