MGE Galaxy 4000
40–75 kVA 208 V
Installation
Table of Contents
Safety .................................................................................................................................... 1
Safety Instructions ......................................................................................................
Certification Standards — Three Phase UPS .............................................................
Safety of Persons ......................................................................................................
Product Safety ...........................................................................................................
Special Precautions ...................................................................................................
Environment ..............................................................................................................
1
1
2
2
2
2
Specifications ................................................................................................................... 3
Environmental Recommendations.......................................................................... 3
Electrical Specifications ............................................................................................ 3
Mechanical Assembly .................................................................................................. 4
Major Components ...................................................................................................... 5
Single Line Diagram .................................................................................................. 5
Standard Cabinets ....................................................................................................... 5
Preparation for Operation.......................................................................................... 6
Cabinet Placement....................................................................................................... 6
Heat Rejection............................................................................................................... 7
Cabinet Clearances ..................................................................................................... 7
Preparation for Storage.............................................................................................. 7
Prepare the Installation ............................................................................................... 8
Conduit Plate Locations for Bottom Entry............................................................ 8
Conduit Plate Locations for Top Entry................................................................... 9
Connect AC Input and Power Cables..................................................................10
Installation Steps .........................................................................................................10
First steps by an on-site qualified Technical Engineer ..............................................10
Electrical Connections ...............................................................................................10
Typical Power Connections .......................................................................................11
UPS Connections.......................................................................................................12
Main AC Input Connections .......................................................................................12
Bypass AC Input Connections (optional) ...................................................................12
Connect Battery Cables ..............................................................................................13
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Battery Connections ...................................................................................................13
Battery Control Connections ....................................................................................13
Connect AC Output .......................................................................................................14
AC Output Connections .............................................................................................14
External Maintenance Bypass Control Connections (optional) ......................14
Accessories Outlets ....................................................................................................14
Connect Remote Emergency Power Off............................................................15
Remote Emergency Power Off Connections........................................................15
Connect Relay Communication Card..................................................................16
Relay Communication Card Contacts ....................................................................16
Relay Communication Card Connections .............................................................18
Characteristics of Output Contacts ........................................................................18
Characteristics of Input Contacts............................................................................18
Appendix Single Line Diagram ...............................................................................19
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MGE Galaxy 4000 40–75 kVA 208 V
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Safety
Safety Instructions
This manual contains important instructions for MGE Galaxy 4000 that must be followed during
operation and maintenance of the equipment.
WARNING: Opening enclosures expose hazardous voltages. Always refer service to
qualified personnel only.
WARNING: As standards, specifications, and designs are subject to change, please
ask for confirmation of the information given in this publication.
Note: This equipment has been tested and found to comply with the limits for a Class
A digital device, pursuant to part 15 of the FCC rules. These limits are designed to
provide reasonable protection against harmful interference when the equipment is
operated in a commercial environment. This equipment generates, uses, and can radiate
radio frequency energy and, if not installed and used in accordance with the instruction
manual, may cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference in which case the
user will be required to correct the interference at user's own expense.
WARNING: To reduce the risk of fire or electric shock, install in a controlled indoor
environment free of conductive contaminants. This equipment is intended only for
installations in a RESTRICTED ACCESS LOCATION.
WARNING: HIGH LEAKAGE CURRENT. Earth connection essential before
connecting supply.
Certification Standards — Three Phase UPS
• IEC1004/ANSI C62.41 Standards for Surge Withstand Ability.
• FCC Part 15, Subpart J, Class A.
• UL/CUL 1778, Standards for Uninterruptible Power Supply Equipment.
• NEMA PE 1 - Uninterruptible Power Systems.
• NFPA 70 – National Electrical Code.
• ISO 9001.
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Safety of Persons
• The UPS has its own internal power source (the battery). Consequently, the power terminals may
be energized even if the UPS is disconnected from the AC power source.
• The UPS must be properly grounded.
• The battery supplied with the UPS contains small amounts of toxic materials. To avoid accidents,
the directives listed below must be observed:
— Never burn the battery (risk of explosion).
— Do not attempt to open the battery (the electrolyte is dangerous for the eyes and skin.
— Comply with all applicable regulations for the disposal of the battery.
— Batteries constitute a danger (electrical shock, burns). The short-circuit current may be very
high.
— Precautions must be taken for all handling: remove watches, rings, bracelets and any other metal
objects, use tools with insulated handles.
— Do not lay tools or metal parts on top of batteries.
Product Safety
• Upstream protection must be installed and be easily accessible.
• The UPS can be disconnected from the AC power source by opening the input protective devices.
• The UPS must be connected to a nearby power source that is easily accessible.
• Never block the ventilation openings of the UPS.
• The UPS must be installed in a controlled environment.
Special Precautions
• The UPS connection instructions and operation described in the manual must be followed in the
indicated order.
• Check that the indications on the rating nameplate correspond to your AC powered system and to
the actual electrical consumption of all the equipment to be connected to the UPS.
• Before and after the installation, if the UPS remains de-energized for a long period, the UPS
must be energized for a period of 24 hours, at least once every 3 months (for a normal storage
temperature less than 25°C). This charges the battery, thus avoiding possible irreversible damage.
Environment
This product has been designed to respect the environment; It does not contain any Chlorofluorocarbon
(CFC) or Hydrochlorofluorocarbon (HCFC).
UPS recycling at the end of service life; APC undertakes to recycle, by certified companies and in
compliance with all applicable regulations, all UPS products recovered at the end of their service life
(contact your APC certified service partner).
Packing; UPS packing materials must be recycled in compliance with all applicable regulations.
WARNING: This product contains lead-acid batteries. Lead is a dangerous
substance for the environment if it is not properly recycled by specialized companies.
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Specifications
Environmental Recommendations
Recommended Environment
20° to 25°C (68° to 77°F.); 50% relative humidity; computer room or other
temperature, and humidity-controlled environment
Operating Temperature
0° to 30°C (32° to 86°F) except battery
Storage
-20° to 40°C (-4° to 113°F) except battery
Humidity
Up to 90% non-condensing (operating)
Altitude
Sea level to 3,000 feet without derating
Acoustic Noise
69 dBA at rated load as measured 3 feet from the front of the UPS cabinet.
Electrical Specifications
Output Power Rating (0.8) PF
40 kVA
50 kVA
65 kVA
75 kVA
UPS Voltage (input/output)
208/208
208/208
208/208
208/208
Input/Output Requirements &
Frequency
Three phase, Three wire + N + G, 60Hz
Input Phase Rotation
A,B,C Clockwise
Input Power Factor
>.98
Input Current
102A
127A
166A
191A
Maximum Input Current (at low line
—15%)
120A
150A
195A
225A
Bypass Current
111A
139A
180A
208A
Output Current
111A
139A
180A
208A
Battery Voltage
198 VDC End Voltage 240VDC Nominal 282VDC
Max. Maintenance Voltage
Max. Battery Current at Nominal
Battery Voltage (240 VDC at 100%
load)
157A
196A
255A
294A
Max. Battery Current at Nominal EndVoltage (198 VDC at 100% load)
190A
238A
309A
357A
Battery Disconnect Circuit Breaker
Rating
250A
400A
Input, Bypass, and Maintenance Bypass
(optional) Switch Rating
150A
250A
Input Fuse Rating
200A
300A
Output Isolation Circuit Breaker Rating
175A
300A
NOTE: Interrupted Transfer to Bypass Source:
If the bypass source is beyond the conditions stated below, the UPS will make an interrupted transfer (not more
than 100 msec. in duration).
1. Bypass voltage greater than +15%, —15% from the UPS rated output voltage.
2. Bypass frequency greater than ±2 Hz from the UPS rated output frequency.
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Mechanical Assembly
General Description
The MGE Galaxy 4000 is the world’s first data center grade Uninterruptible Power Supply system
designed specifically for mid-range enterprise level applications. The MGE Galaxy 4000 family
consists of units available in power ratings from 40 - 75KVA, and are optimized for compatibility with
nonlinear computer-type loads.
By incorporating the Ultra High Availability Topology (UHAT), the MGE Galaxy 4000 family of UPS
systems are designed to provide the optimal level of reliability and to react to any power disturbance
in an inherently safe way to protect the critical load. The MGE Galaxy 4000 all-in-one design
incorporates every feature into one compact cabinet, including a graphical user interface, power factor
corrected input, and communication cards that support network based power management.
The MGE Galaxy 4000 UPS and its auxiliary equipment are designed for installation in a room where
humidity and temperature can be controlled.
The MGE Galaxy 4000 UPS and auxiliary equipment is listed for safety by Underwriters Laboratories,
Inc. (UL) under UL Standard 1778 – Uninterruptible Power Systems; and also listed by Underwriters
Laboratories (CUL) under Canadian Standards Association (CSA) standard C22.107.
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MGE Galaxy 4000 40–75 kVA 208 V
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Major Components
Rectifier
Converts AC input voltage to DC voltage. The rectifier uses IGBT (Insulated
Gate Bipolar Transistor) power transistors and a Pulse Width Modulated (PWM)
technique to provide input power factor correction and to minimize any harmonic
reflected onto the input power lines.
Inverter
Converts DC voltage from the rectifier or from the batteries into AC output voltage
to maintain the attached load. This module uses the IGBT technology to provide
digital power quality.
Static Switch
Automatically supplies the attached load from the bypass source when the inverter
is off.
Battery System
Stores energy for utilization by the inverter and attached load in the event that utility
AC power is lost or is of unacceptable quality.
Single Line Diagram
During normal operation, the utility power (Main input) is supplied to the UPS rectifier. The rectifier
converts the AC power to DC that is supplied to the inverter. The inverter converts the DC voltage to
three-phase regulated AC voltage, which is supplied to the attached load.
During power failure conditions, the inverter is supplied by the stored energy in the battery system, and
the load is powered continuously with no interruption.
The MGE Galaxy 4000 UPS is designed for internal operation of 208VAC input and output. External
batteries, and an output distribution panel may be contained in auxiliary cabinets similar in design to
the MGE Galaxy 4000 cabinet. Batteries or external maintenance bypass circuit breakers may also be
contained in third party cabinets or wall mounted units.
Refer to Appendix “Single Line Diagram”.
Standard Cabinets
The MGE Galaxy 4000 individual cabinet dimensions are:
• UPS cabinet: 72.1in (1831mm) H x 33.5in (851mm) W x 35.6in (904mm) D.
• External battery cabinet: 72.1in (1831mm) H x 26.5in (673mm) W x 33.5in (851mm) D OR –
• External battery cabinet: 72.1in (1831mm) H x 33.5in (851mm) W x 33.5in (851mm) D.
• Distribution cabinet: 72.1in (1831mm) H x 19.5in (495mm) W x 33.5in (851mm) D.
The UPS cabinet is designed to provide for top and bottom entry of the utility power feed. An output
voltage of 208VAC is standard with the MGE Galaxy 4000 and does not require any additional
cabinetry. The complete list of additional cabinets that could be included with your MGE Galaxy 4000
system are: external maintenance bypass wall cabinet, external battery cabinet, and distribution cabinet.
The external battery cabinets are provided in two different cabinet sizes depending upon the battery type
selected. Up to four battery cabinets may be provided. The cabinets may be installed adjacent to the
UPS or remotely and are designed for top and bottom entry. The distribution cabinet provides a 42 pole
panelboard, with an optional submain circuit breaker. The cabinet is designed for top and bottom entry.
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Preparation for Operation
Several items must be considered when preparing the MGE Galaxy 4000 UPS system for operation.
1. The UPS cabinet and its auxiliary cabinets must be arranged in the required configuration to
insure that the interconnection cables are located in the correct adjacent cabinets.
2. The cabinets must be in a location that provides for proper air flow and heat rejection.
3. The room in which the MGE Galaxy 4000 UPS system is located must maintain environmental
conditions within recommended tolerances.
4. All electrical connections must utilize the top or bottom conduit entries provided.
The following sections discuss these items in more detail.
Cabinet Placement
The complete UPS system may consist of one to three cabinets depending on the options selected. The
UPS cabinet allows system options to be selected based on the application. When facing the MGE
Galaxy 4000 UPS from the front, the standard arrangement provides for any external batteries to be
located on the right hand side, and the distribution cabinet to be located on the left hand side of the UPS.
A
Air exhaust
F
External battery cabinet (optional)
B
Display panel
G
UPS cabinet
MGE Galaxy 4000
C
Allow 36” top clearance for fan exhaust and
service maintenance
H
Front view
D
Leveling jacks
I
Distribution cabinet (optional)
E
Casters
J
Air intake
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Heat Rejection
The MGE Galaxy 4000 UPS cabinets generate heat and exhaust air through the top portion of its
enclosures. Air intake is through the bottom and front of the cabinet. All other cabinets are convection
cooled. To assist you in planning for your HVAC needs, heat rejection data is provided in table below.
The cabinet airflow and recommended top clearance are provided in “Cabinet Placement“ section.
The MGE Galaxy 4000 is intended for use in an environment where control of temperature and
humidity is provided.
Heat Rejection Data @ 208/208 VAC
UPS Cabinet
40 kVA
50 kVA
65 kVA
75 kVA
BTU/Hr
14,900
18,700
24,200
28,000
Note: To provide for adequate ventilation, a minimum of 36 inches clearance should be
maintained above the top of the MGE Galaxy 4000 cabinet.
Cabinet Clearances
The MGE Galaxy 4000 UPS cabinet top clearance of 36 inches for fan exhaust is recommended.
Additionally, adequate space must be included in the front and top of each cabinet (approx. 36 inches)
to allow the doors/panels of the cabinet to be opened for service and maintenance procedures.
For an installation where seismic requirements must be met, additional clearance at the side of the
cabinet must be included to accommodate the seismic anchors. Contact the Customer Support Center
to order.
Preparation for Storage
If the equipment is to be stored prior to installation, it should be stored in a cool, dry, well-ventilated
location that is protected against rain, splashing water, chemical agents, etc. The equipment should
be covered with a tarpaulin or plastic wrapper to protect it against dust, dirt, paint, or other foreign
materials. See the section of this manual titled "Environmental Recommendations" for recommended
storage environmental conditions.
Note: Batteries should be stored no longer than three (3) months at 25°C (77°F) or lower
prior to recharging. Exceeding the recommended ambient storage temperature will
reduce battery back-up time and may adversely affect battery life.
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Prepare the Installation
Conduit Plate Locations for Bottom Entry
Cable entry through the bottom is the standard preferred design for the MGE Galaxy 4000 UPS
cabinet. The bottom entry conduit plate provides space for up to five (5) separate conduit entries. The
plate is secured with screws which should be retained for the conduit plate after the power connections
are made. See illustration below for the location of the bottom entry conduit plates.
A
Cable entry plate
B
Air intake
Do not block
C
Seismic bracket (optional) (4 PLCS)
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Conduit Plate Locations for Top Entry
The UPS cabinet for the MGE Galaxy 4000 is capable of accepting power input and output cables
through a top entry. The conduit plate on the top of the cabinet provides provisions for knockouts for
conduit and is secured to the cabinet with screws.
A
10 x 20.5 conduit
E
UPS
B
Air exhaust
Do not block
F
Distribution
C
26W battery
(33W battery)
G
(16) x 1.125 K.O.
(34) .857 K.O
D
9 x 20.5 conduit
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Connect AC Input and Power Cables
Installation Steps
APC recommends correct installation verification and unit startup to be performed by an APC
certified Service partner.
Caution: Scheduling of the APC certified Service partner typically should be done
7 to 10 days before they are required on-site. If the startup of the UPS is critical to
maintaining your schedule, please contact the Customer Support Center for assistance.
To insure a successful installation, each of these (5) steps should be followed in their correct
sequence. Note that any unauthorized installation may cause damage to the UPS(s).
First steps by an on-site qualified Technical Engineer
1. Unpack and position the unit.
2. Connect the main (utility) power.
3. Connect the output to the load.
Final steps by an APC certified Service partner
4. Call APC and wait for the APC certified Service partner to approve the installation.
5. The APC certified Service partner finalizes the installation and the startup process.
Electrical Connections
Caution: Only an authorized electrical professional should access electrical connections.
A severe shock hazard exists.
The ONLY user serviceable items in the MGE Galaxy 4000 unit are:
A
The main and bypass power connections.
B
The load connection.
C
Any cable connection to external or auxiliary modules.
D
The communication card options.
The access method for connections made to the communication cards is clearly seen when the front
right door to the MGE Galaxy 4000 unit is opened. However, access to the main, bypass and load
connections is made through the removal of the safety panel located in the lower right of the MGE
Galaxy 4000 (with the right door open). This safety panel is removed by first removing the screws
securing the panel. It can then be removed by lifting the safety panel away from the unit.
Caution: Before making any electrical connections, verify that all battery disconnect
circuit breakers (QF1) are in the "off" position. Customer-supplied upstream protective
devices and distribution circuits should be OFF.
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MGE Galaxy 4000 40–75 kVA 208 V
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Typical Power Connections
A
Front view
N
B
B
Rear area
O
C
C
Front
P
Output TB2
D
TB4
Q
A
E
TB1
R
B
F
TB2
S
C
G
Ground
T
TB3 Bypass input
H
Neutral
Negative
Positive
Busbars
U
TB1 Main input
I
TB4 Control
V
Ground
J
A
W
Neutral
K
B
X
Battery Positive
L
C
Y
Battery Negative
M
A
Z
Busbars
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UPS Connections
Electrical connections and cabinet interconnection will vary depending upon the configuration and
options selected with your MGE Galaxy 4000 UPS system. Refer to the installation drawings supplied
with your equipment.
Connecting Power Cable Connections:
To access the connection terminal blocks, open the right door to the MGE Galaxy 4000 UPS. Remove
the safety panel located in the lower right hand section of the unit. See “Typical Power Connections“.
1. The ground and neutral conductors must be connected to the ground and neutral busbars,
respectively. The input and output neutral are connected at the neutral busbar.
2. Connect the three conductors of the main AC source to terminal block TB1.
3. If bypass source is present, connect the conductors of the bypass AC source to terminal block
TB3. If bypass source is not present, verify jumpers in place between TB1 and TB3.
4. Connect the three conductors supplying the load to terminal block TB2.
5. Connect the battery conductors to the positive and negative busbars.
6. Secure all cables with cable ties.
7. Put all panels and covers back in place.
Main AC Input Connections
The connections to be made are the three phases, neutral, and ground cables from the utility AC power
source to the UPS. The main AC input cables are terminated at the main input terminal block (TB1).
See “Typical Power Connections“.
Note: For single input (optional configuration), jumper cables are provided from
terminal blocks TB1 to TB3.
Bypass AC Input Connections (optional)
The bypass AC input cables are terminated at the bypass input terminal block (TB3). This option
provides a separate AC input source for bypass operation. See “Typical Power Connections“.
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MGE Galaxy 4000 40–75 kVA 208 V
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Connect Battery Cables
Battery Connections
The connections to be made are the positive, negative, and ground cables from the battery cabinet to
the UPS. The battery cables are terminated at the positive, negative, and ground busbars. See “Typical
Power Connections“.
Battery Control Connections
The battery control connections are made with the battery control cables from the external battery
cabinet to the UPS terminal block TB4-1 to TB4-4. See “Typical Power Connections“.
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Connect AC Output
AC Output Connections
The connections to be made are the three phases, neutral, and ground cables from the load to the
UPS. The output cables are terminated at the output terminal block (TB2). See “Typical Power
Connections“.
External Maintenance Bypass Control Connections
(optional)
The external maintenance bypass (MBP) control connections are made with the MBP control
cable from the external MBP to the UPS terminal block TB4-9 to TB4-10. See “Typical Power
Connections“.
WARNING: These wires carry HIGH VOLTAGE 120VAC.
Accessories Outlets
The 120VAC outlets to be used on APC authorized accessories only. The outlets total current not to
exceed 2 amps.
Caution: Improper use of outlets may cause failure or damage to UPS.
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MGE Galaxy 4000 40–75 kVA 208 V
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Connect Remote Emergency Power Off
Remote Emergency Power Off Connections
The control connections are available for Remote Emergency Power Off (REPO) through a
customer-supplied (normally closed) pushbutton. With REPO connected, the jumper on the REPO
terminal blocks must be removed. See “Typical Power Connections“.
A.
Remove the jumper from terminal block TB4 located across terminals 7 and 8.
B. Connect the remote emergency power off NC contact to terminals 7 and 8.
Caution: The UPS is also equipped with a local Emergency Power Off (EPO) button on
the front of the UPS cabinet. This switches all UPS critical power off. EPO or REPO
should be used for emergency only!
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Connect Relay Communication Card
Relay Communication Card Contacts
The relay communication card contains six programmable dry contact outputs and two programmable
dry inputs and is standard on the MGE Galaxy 4000. The inputs and outputs are factory programmed
according to functions listed in table below.
Inputs
Factory Settings
Options (available on both contacts)
1.A
UPS ON
• Room temperature fault
1.B
UPS OFF
• Transfer to bypass disabled
• Transfer to bypass disabled if bypass AC source out of
tolerance
• Desynchronize UPS from bypass AC source
Outputs
Factory Settings
Options (available on all contacts)
1.1
General alarm
• Overload
1.2
Battery fault
• PFC Fault
1.3
Load on UPS
• Inverter fault
1.4
Load on automatic
bypass
• Charger fault
1.5
Load on battery power
1.6
Low battery warning
• Automatic bypass fault
• Bypass AC source out of tolerance
• Battery-temperature fault
• Emergency power off activated
• Battery circuit breaker(s) open
• Phase-sequence fault on normal or bypass
• AC source
• Blown fuse(s)
• Transfer to bypass AC source disabled
• Operation in ECO mode
• UPS on bypass AC source
The output contacts numbers for a second relay board installed will be 2.1 to 2.6. Contacts are of
the NO (normally open) type. For dry contacts setting see “MGE Galaxy 4000 40–75 kVA 208 V
Operation Manual — User Configuration — Settings Screen“.
Caution: Isolate and lock-out all power sources for this card before making connections.
Never connect ELSV (extra low safety voltage) and non-ELSV circuits to the different
outputs of the same card.
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1
2
3
2
4
1
BA
2
5
6
5
4
3
6
7
1
BA
2
3
4
5
6
5
4
6
3
1
2
2
7
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MGE Galaxy 4000 40–75 kVA 208 V
17
Relay Communication Card Connections
Refer to “Relay Communication Card Contacts“ for relay communication card, cover and hardware
details. See “MGE Galaxy 4000 40–75 kVA 208 V Operation Manual — Operation — Preparing for
Startup“ for communication card port location in the unit.
1. Remove the cover “3” secured by the screws “1”.
2. Run the communication cables through the cable entry holes “4”.
3. Connect the conductors to the input “6” and output “5” terminal blocks (refer to “Relay
Communication Card Contacts“ for a connection example.)
4. Put the cover back in place and secure it with the screws “1”.
5. Tighten the screws “7” to clamp the cables.
6. Indicate the locations of the power sources on the labels.
7. Insert the card in its slot.
8. Secure the card with two screws “2”.
Characteristics of Output Contacts
Relay Type
Normally Open
Max. voltage
250VAC, 30VDC
Max. current
2A
Cable
4 x 0.93 mm, 6.6 ±0.3 mm
Characteristics of Input Contacts
Switched voltage
5VDC
Consumption
10 mA
Cable
4 x 0.34 mm, 5 ±0.5 mm
Output alarms are always activated on the conditions stated unless requested by customer to operate on
other conditions.
Input contacts are designed for remote UPS operation. Use extreme caution when using these contacts
so as not to endanger persons or compromise the UPS load.
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Appendix Single Line Diagram
A
UPS
M
Main Input TB1
B
Battery
N
Optional Bypass Input 208YVAC
C
Distribution
O
Main Input 280YVAC
D
Supplied by MGE & Connected
by customer
P
Input Fuses
E
To critical load
Q
Input Static Switch
F
42 Pole Panel board
R
PFC Boost Rectifier
G
Output (optional)
S
Inverter
H
Output
T
Output Static Switch
I
(optional)
U
Battery Static Switch
J
(optional)
V
Battery Charger
K
Bypass Static Switch
W
Supplied by MGE & Connected by customer (adjacent
version)
Supplied & connected by customer (stand alone version)
L
Bypass Input TB3
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19
Worldwide Customer Support
Customer support for this or any other product is available at no charge:
• Contact the Customer Support Center by telephone or e-mail. For local, country-specific centers:
go to www.apc.com/support/contact for contact information.
© APC by Schneider Electric. APC and the APC logo are owned by Schneider Electric Industries
S.A.S., American Power Conversion Corporation, or their affiliated companies. All other trademarks
are property of their respective owners.
990–3964–001
December
2010