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MGE UPS SYSTEMS

Galaxy STS
30A - 600A

Static Transfer Switch

Installation and user manual

SWITCH ANSFER STATIC TR

SOURCE 1

2 SOURCE

E LOAD / CHARG

AUTO RETRA FAULT

NSFERT

LAMP TEST

P
W

E R I D O V R

P
E
I

T H E

U N I N T E R

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Introduction
Thank you for selecting an MGE UPS SYSTEMS product to protect your electrical equipment. The Galaxy STS (Static Transfer Switch) has been designed with the upmost care. We recommend that you take the time to read this manual to take full advantage of the many features of your new equipment. MGE UPS SYSTEMS pays great attention to the environmental impact of its products. Measures that have made Galaxy STS a reference in environmental protection include: the eco-design approach used in product development, recycling of Galaxy STS at the end of its service life. To discover the entire range of MGE UPS SYSTEMS products and the options available for the Upsilon STS, we invite you to visit our web site at www.mgeups.com or contact your MGE UPS SYSTEMS representative.

As standards, specifications and design change from time to time, please ask for confirmation of the information given in this publication. Reproduction of this document subject to prior authorization by MGE UPS SYSTEMS and with the mandatory indication: "Galaxy STS installation and user manual n 51027406XT".

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Safety
MGE UPS SYSTEMS Static Transfer Switches (STS) are reliable and safe. Integrated components protect the equipment from damage likely to cause a fault. Operating and maintenance procedures must be carried out exclusively by qualified personnel, trained by MGE UPS SYSTEMS. The personnel involved in equipment operation and maintenance must have received suitable training to ensure a maximum degree of safety and performance. Caution: operating and maintenance procedures or instructions must be respected to avoid the risk of endangering persons or damaging the equipment. Warning: operation outside the limits indicated in Chapter 7 or non-observance of the procedures presented in Chapter 3 may be detrimental to Galaxy STS reliability.

Electrical-safety recommendations
The Galaxy STS must be considered energized unless all power sources have been cut and a check has been run using a separate measurement device to confirm that no circuit is live. Otherwise, the maintenance procedures must be followed to ensure safety (Chapter 6). Warning: the Galaxy STS must be considered energized unless a check has been run to ensure that the source 1, source 2 and output isolation switches are open. The normal or maintenance bypass switches may be closed to supply the load. We recommend that you call on our after-sales support department to carry out these operations. Caution: operation of Galaxy STS requires that there be only one key to lock the two bypasses (Q1BP and Q2BP). Otherwise, the installation may be damaged. MGE UPS SYSTEMS declines any responsibility if the above rule is not observed. Recommendations: Do not install Galaxy STS in or near a very damp environment. Never block the ventilation grates of Galaxy STS cubicles. System earthing: Galaxy STS is suitable for any system earthing arrangement, arrangement except the IT and TT system. Operated by only personnel authorised to enter restricted access locations.

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Foreword
Pictograms used in this manual
Important instructions that must be followed

Information, advice, help

Visual indication

Action

Earth cables

Other cables

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Contents
1. General .......................................................................................................................... 6
1.1 Operation principle .......................................................................................................................... 6 1.2 General diagram ............................................................................................................................... 7 1.3 Description ....................................................................................................................................... 7

2. Installation .................................................................................................................... 8
2.1 Positioning ....................................................................................................................................... 8 2.2 Inspection ......................................................................................................................................... 8 2.3 Connections ..................................................................................................................................... 9 2.4 Cable cross-sections ..................................................................................................................... 13 2.5 Recommended protection ............................................................................................................. 13 2.6 Connection diagram ...................................................................................................................... 14

3. start-up and shut-down ............................................................................................. 15

3.1 Start-up ........................................................................................................................................... 15 3.2 Shut-down ...................................................................................................................................... 15 3.3 Complete shut-down ..................................................................................................................... 15 3.4 Manual transfer .............................................................................................................................. 15 3.5 Bypass ............................................................................................................................................ 16

4. operation ..................................................................................................................... 17
4.1 General ............................................................................................................................................ 17 4.2 Controls and leds ........................................................................................................................... 17

5. Description of the Galaxy STS .................................................................................. 19

5.1 General description ....................................................................................................................... 19 5.2 Troubleshooting ............................................................................................................................. 23

6. Maintenance ............................................................................................................... 25
6.1 General ............................................................................................................................................ 25 6.2 Safety recommendations .............................................................................................................. 25 6.3 Preventive maintenance ................................................................................................................ 25

7. characteristics ............................................................................................................ 26
7.1 Electrical characteristics ............................................................................................................... 26 7.2 General characteristics ................................................................................................................. 26 7.3 Mechanical characteristics ........................................................................................................... 27 7.4 Customization ................................................................................................................................ 27 7.5 Fuse characteristics ...................................................................................................................... 27 7.6 Losses ............................................................................................................................................. 28 7.7 Electromagnetic-compatibility standards ................................................................................... 28

8. Appendix ..................................................................................................................... 29
8.1 List of the figures in the manual ................................................................................................... 29 8.2 List of the tables in the manual .................................................................................................... 29

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1. General
1.1 Operation principle
Galaxy STS principle
Galaxy STS is a product allowing seamless automatic or manual transfer of one or more 3-phase loads from one power source (known as the Preferred source) to another power source (known as the Alternate source). Transfer is automatic if the Preferred source fails.

Operating symmetry between the sources

The architecture and operation of Galaxy STS is completely symmetrical, i.e. it is possible to select Source 1 as either the Preferred source (with Source 2 as the Alternate source) or the Source 2 (with Source 1 as the Alternate source), and modify this order at any time.

Reversibility of transfers
Depending on installation operating conditions and the system configuration, Galaxy STS also allows automatic reverse transfer (return from the Alternate source to the Preferred source).

Control and reliability of transfers

The switching technology used is of the Break Before Make type (no source overlap), ensuring that during a transfer, both supply sources are never parallel-connected at any time. This: enables transfers between sources of different types, impedances, voltage levels, frequencies and phases; prevents propagation of faults, thereby eliminating a possible single-point failure mode.

Operation with all types of sources

The power sources can be of any type (utility, UPS, generator set). However, to ensure proper operation of the power supply system as a whole (sources, Galaxy STS, loads), sources must normally be balanced as regards voltage, synchronized and in phase, either naturally or by means of a specific synchronization device (installed at source level).

Figure 1: Simplified diagram of Galaxy STS

AC input 1

AC input 2

Circuit-breaker 1

Source 1 preferred (or alternate)

Source 2 alternate (or preferred)

Circuit-breaker 2

Galaxy STS
Control unit Q1 Q2

Q1BP

Q2BP

SS path 1 Q3

SS path 2

Load

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1. General
1.2 General diagram
Figure 2: Typical diagram of a Galaxy STS installation

Building or zone 1

Gen STS 3

Building or zone 2

Main LV switchboard 1

Main LV switchboard 2

Source HQ 1

Source HQ 2

Secondary LV switchboard 1

Secondary LV switchboard 2

STS 1 Load 1

STS 2 Load 2

1.3 Description
Fully solid-state technology
Galaxy STS consists of two three-phase static switches, one on the Source 1 path, the other on the Source 2 path. Each static switch (SS) is made up of 3 pairs of back-to-back Silicon Controlled Rectifiers (SCR). The neutral conductor is not switched.

Mounted in a standard cubicle

The static switches, switches and electronic control unit are mounted in a standard MGE UPS SYSTEMS cubicle. The dimensions vary according to the rating.

Easy to operate and maintain

On the front panel, a complete mimic panel groups the control devices and displays the various status conditions of the sources and loads. To allow maintenance and troubleshooting, the Galaxy STS is equipped with 3 switches for isolation of the static switches as well as 2 bypass switches, provided with an interlocking device, for bypassing the static switches. The switches are accessed from the front of the cubicle.

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2. Installation
2.1 Positioning
The Galaxy STS is designed to be installed on the floor.

Figure 3: Space to reserve arround the Galaxy STS cubicles

35 cm

35 cm

35 cm

Side view of 30A, 50A and 100A Galaxy STS cubicles

72 cm

0 cm

Side view of 160A, 550A, 400A and 600A Galaxy STS cubicles

72 cm

Back

Front

Back

Front

Note : for 30 A, 50 A and 100 A Galaxy STS cubicles, a clearance of 35 centimeters is required behind the cubicle for access by maintenance personnel.

2.2 Inspection
Before installing Galaxy STS, carry out a complete visual inspection: Fully inspect the cubicle, ventilation grates and the doors for any damage that may have occurred during transport. Open the cubicle doors and check each component, as well as the system as a whole. Check all the locking devices. Remove the adhesive tape and any remaining packing materials. Make sure that any drawout modules are fully inserted. Check that all markings and text on the cubicle, the device and components are clearly legible. Check that no lights or switches were damaged during transport, and that all connections and locking systems are correctly tightened. Immediately inform MGE UPS SYSTEMS of any damage or apparent defects concerning the cubicle or the equipment.

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2. Installation
2.3 Connections
Once the Galaxy STS has been correctly positioned and inspected, it can be connected to the power sources. All cables enter at the bottom of the Galaxy STS (see figures 5, 6 and 7). Galaxy STS legs are 40 mm in diameter. Their height is adjustable (recommended height = 100 mm). There are two communications ports on the INTY remote indications card of the Galaxy STS: one RS 485 port, and a terminal block with remote-indication input/outputs (isolated dry contacts). A description of port characteristics and functions is provided in section 5.1. See Table 7 and 8 for information on the signals on each terminal of the INTY card.

Figure 4: Terminals on the INTY card

4 3 2 1 XM2 MODU (4 pts)

Type SUB-D (9 pts) XM10

RS485 port

10 9 8 7 6 5 4 3 2 1

Preffered source 1 Common Preffered source 2 Auto return ON Common Auto return OFF Load ON Common Load OFF Common Not used Transfert inhibit Auto return OFF Auto return ON Source 2 Source 1 Remove fault reset

Wiring diagram for the closing dry contacts to signal a general Galaxy STS fault and a source fault. INTY board
XM9 10 XM7 10 XM6 4 XM6 12

XM9

XM9 9

XM7 11

XM6 5 XM6 11

XM1 type HE10 (50 pts)

INTY board

10 9 8 7 6 5 4 3 2 1

This represents a general fault covering all the conditions monitored by Galaxy STS.

XM8

Wiring diagram for the opening dry contactsto signal a general Galaxy STS fault and a source fault.
XM9 XM9 XM7 XM7 9 10 11 12

121110 9 8 7 6 5 4 3 2 1

Source 2 ON Common Source 2 OFF Source 1 ON Common Source 1 OFF Phase fault Common Good phase Status Source 2 (red) Common Status Source 2 (not red) Status Source 2 (orange) Common Status Source 2 (not orange) Status Source 1 (red) Common Status Source 1 (not red) Status Source 1 (orange) Common Status Source 1 (not orange) Not global alarm Common Global alarm

XM7

INTY board

XM6 5 XM6 6 XM6 11 XM6 12

121110 9 8 7 6 5 4 3 2 1

This represents a general fault covering all the conditions monitored by Galaxy STS.

XM6

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2. Installation
Figure 5: Internal view of Galaxy STS 30 A, 50 A and 100 A

LEM6 LEM5 LEM4

LEM12 LEM11 LEM10

LEM3 LEM2 LEM1 Q6 Q7 X4-1 X4-2

LEM9 LEM8 LEM7

R1

C1

F7

F8

C2

R2

F1

F2

F3

Q4 Q5

F4

F5

F6

ALMY

Q1 Q1BP Q3 Q2BP

Q2

N L1 L2 L3

N L1 L2 L3

N L1 L2 L3

Source 1

Height of connections measured from floor: Source 1: 390 mm Load: 390 mm Source 2: 390 mm Remote-indications card: 1080 mm Connection to screw terminals. Maximum cross-section: 50 mm2.

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Source 2

Load

2. Installation
Figure 6: Internal view of Galaxy STS 160A and 250A
Connection via the top possible

LEM5 LEM3 LEM1 LEM6 LEM4 LEM2

X4-1
Q6Q7

X4-2

F1 F1 F1 A B C ALMY

F2 F2 F2 A B C

Q1

Q2

Q1BP

Q3

Q2BP

N L1 L2 L3

N L1 L2 L3

N L1 L2 L3

Source 1

Height of connections measured from floor: Source 1: 340 mm. Load: 340 mm. Source 2: 340 mm. Remote-indications card: 1430 mm. Connection to 25 x 5 mm copper bars, holes 10,5 mm.

Load

Source 2

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2. Installation
Figure 7: Internal view of Galaxy STS 400A and 600A

LEM6

LEM12

LEM5

LEM11

LEM4

LEM10

LEM3

LEM9

LEM2

LEM8 LEM7 X4-2

Q5 F8

LEM1 X4-1

F8 Q7

Q4Q6 F1 F2

ALMY F6 F5

Q1

Q2

F3

F4

Q1BP

Q3

Q2BP

N L1 L2 L3

N L1 L2 L3

N L1 L2 L3

Source 1

Height of connections measured from floor: Source 1: 450 mm Load: 450 mm Source 2: 450 mm Remote-indications card: 1480 mm Connection to copper bars, 3 holes 12,5 mm.

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Load

Source 2

2. Installation
2.4 Cable cross-sections
The cable cross-sections indicated below are calculated for a rated interphase voltage of 400 V and rated load currents. The information is purely indicative in nature and does not engage the responsibility of MGE UPS SYSTEMS.

Table 1: Cable cross-sections

Galaxy STS 30A 50A 100A 160A 250A 400A 600A AC-source current 30 50 100 160 250 400 600 Recommended Cu cable cross-sections in mm2 16 35 50 70 120 2 x 95 2 x 120

The cross-sections for aluminum cables must be increased 30% with respect to the figures for copper cables. Calculations take into account voltage drops in cables 100 meters long.

2.5 Recommended Protection

The protective devices must comply with applicable standards. They should be selected using the information presented below and taking into account discrimination requirements. The information is purely indicative in nature and does not engage the responsibility of MGE UPS SYSTEMS.

Protection for a TNS system

Table 2: Protection for a TNS system
Galaxy STS 30A 50A 50A 100A 160A 160A 250A 400A 400A 600A Imax phase 30 50 50 100 160 160 250 400 400 600 Imax neutral 30 50 75 100 160 240 250 400 600 600 Im setting 10xIn 10xIn 10xIn 10xIn 10xIn 10xIn 10xIn 10xIn 10xIn Type of circuit breaker C60L 32A NS100H 4P 4D NS100H 4P 4D NS100H 4P 4D NS160H 4P 4D NS250N 4P 4D NS250N 4P 4D NS400H 4P 4D NS630N 4P 4D NS630N 4P 4D Trip unit courbe C STR22SE STR22SE STR22SE STR22SE STR22SE STR22SE STR22SE STR22SE STR22SE

Protection for a TNC system

Table 3: Protection for a TNC system
Galaxy STS 50A 100A 250A 400A 600A Imax phase 50 100 250 400 600 Imax neutral 50 100 250 400 600 Im setting 10xIn 10xIn 10xIn 10xIn 10xIn Type of circuit breaker NS100H 3P NS100H 3P NS250H 3P NS400H 3P NS630H 3P Trip unit STR22SE STR22SE STR22SE STR22SE STR22SE

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2. Installation
2.6 Connection diagram
TNS system
Figure 8: Typical connection diagram for a Galaxy STS on TNS systems

Q1

F2

F5

Q2

F3

F4

Q1BP

Q3

Q2BP

N L1 L2 L3

N L1 L2 L3

N L1 L2 L3

Cable ties

Cable ties

Source 1

TNC system
Figure 9: Typical connection diagram for a Galaxy STS on TNC systems

Q1

F2

Load

F5

Source 2

Q2

F3

F4

Q1BP

Q3

Q2BP

N L1 L2 L3

N L1 L2 L3

N L1 L2 L3

Cable ties

Cable ties

Source 1

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Load

Source 2

3. Start-up and shut-down

3.1 Start-up
The following procedure indicates how to energize the load using Source 1. If the load is to be supplied preferably by Source 2, simply replace the indicated commands and indication LEDs with those for Source 2 in the procedure presented below. See Figure 10 to locate the commands and indication LEDs in the procedure presented below. Each number in brackets corresponds to a number in Figure 10. Check that the Source 1 and Source 2 inputs are supplied with power. Check that all loads are de-energized. Check that Q1BP and Q2BP are open. Close switches Q4 and Q6 and check that LEDs on the card go on. Close Source 1 isolation switch Q1 (22) and check that the U 1 (1) and SS 1 ACTIVE (2) LEDs are green. Close Source 2 isolation switch Q2 (25) and check that the U 2 (7) LED is green. Close switch Q3 (23) and check that the SS 1 ACTIVE (2) and LOAD (6) LEDs are green. The load is now supplied by Source 1. If the Source 1 input voltage is unacceptable and Source 2 input power is available and OK (or downgraded), GALAXY STS automatically switches to Source 2.

3.2 Shut-down
The shutdown procedure for normal maintenance consists in transferring the load to the Source 1 or Source 2 bypass (see section 3.5). However, if total de-energizing is required, follow the procedure indicated in section 3.3.

3.3 Complete shut-down

Caution: this procedure will interrupt the supply of power to the load. In an emergency, it is possible to shut down the Galaxy STS by opening all the switches (numbered 21 to 25). Warning: dangerous voltages are still present in the lower part of the cubicle. Proceed as follows to completely deenergize the system. Open the Source 1 and Source 2 upstream circuit breakers (upstream of Galaxy STS). Check that all the indication LEDs are OFF.

3.4 Manual transfer

The load may be transferred from one source to another as indicated below:

Transfer from Source 1 to Source 2:

Check that the U 2 (7) LED is green. If not, re-establish the supply of power at the Source 2 input. Press simultaneously the KEY (11) button and the SOURCE 2 selection button (10). The SS 2 ACTIVE (8) and S2 PREFERRED (9) indications LEDs should go green. The SS 1 ACTIVE (2) and S1 PREFERRED (3) indication LEDs should go off. Remark: if the S1/S2 phase-condition (5) button is red, transfer is disabled. However, Source 2 nonetheless replaces Source 1 as the preferred source. If AUTO RETRANSFER is enabled, Galaxy STS transfers the load (following the programmed time delay) as soon as the S1/S2 phase-condition (5) button goes off.

Transfer from Source 2 to Source 1:

Check that the U 1 (1) LED is green. If not, re-establish the supply of power at the Source 1 input. Press simultaneously the KEY (11) button and the SOURCE 1 selection button (4). The SS 1 ACTIVE (2) and S1 PREFERRED (3) indications LEDs should go green. The SS 2 ACTIVE (8) and S2 PREFERRED (9) indication LEDs should go off. Remark: if the S1/S2 phase-condition (5) button is red, transfer is disabled. However, Source 1 nonetheless replaces Source 2 as the preferred source. If AUTO RETRANSFER is enabled, Galaxy STS transfers the load (following the programmed time delay) as soon as the S1/S2 phase-condition (5) button goes off.

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3. Start-up and shut-down

3.5 By-pass
It is possible to bypass the Galaxy STS for maintenance without interrupting the supply of power to the load which may be supplied via either Source 1 or Source 2.

Bypass of Source 1:
Check that the Galaxy STS supplies Source 1 power to the load. The SS 1 ACTIVE (2) and LOAD (6) indication LEDs should be green. Open the Source 2 isolation switch Q2 (25). The U2 (7) LED should go red. Close the Source 1 bypass switch Q1BP (21). The U2 (7) LED should flash red indicating that the control electronics inhibit a transfer to Source 2. Open the Source 1 isolation switch (22). The U1 (1) LED should go red. Open the load switch Q3 (23). The LOAD (6) LED should remain green. The load is supplied by Source 1 and Galaxy STS is isolated from Source 1, Source 2 and the load. Open the circuit breakers (Q4 and Q6) on the front panel of the Galaxy STS to de-energize the electronic cards.

Warning: dangerous voltages are still present in the cubicle. Observe all safety recommendations.

Bypass of Source 2:
Check that the Galaxy STS supplies Source 1 power to the load. The SS 2 ACTIVE (8) and LOAD (6) indication LEDs should be green. Open the Source 1 isolation switch Q2 (22). The U1 (1) LED should go red. Close the Source 2 bypass switch Q2BP (24). The U1 (1) LED should FLASH red indicating that the control electronics inhibit a transfer to Source 1. Open the Source 2 isolation switch (25). The U2 (7) LED should go red. Open the load switch Q3 (23). The LOAD (6) LED should remain green. The load is supplied by Source 2 and Galaxy STS is isolated from Source 1, Source 2 and the load. Open the circuit breakers (Q4 and Q6) on the front panel of the Galaxy STS to de-energize the electronic cards.

Warning: dangerous voltages are still present in the cubicle. Observe all safety recommendations.

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4. Operation
4.1 General
This chapter describes all Galaxy STS commands and indication LEDs as well as the required operating procedures. The operating instructions contained in this manual concern exclusively the Galaxy STS, viewed as a separate and autonomous device. In that the Galaxy STS is generally a component in an overall system intended to protect the supply of power to the load, the user must consult the operating instructions for the overall system for information on the operating sequences and procedures of the other components and the system as a whole. Warning: any contact with input or output power conductors represents a major risk for the safety of the concerned persons. Observe all standard precautions during work with the system energized. Check that all the ground connections have been made. Operation and maintenance of this equipment require a high level of attention and care. Follow all the general safety recommendations provided in chapter 1 of this manual.

4.2 Controls and LEDs

All controls are located on the front panel. The actual switches are located behind the front door. Figure 10 shows the controls and indication LEDs with identification numbers. Table 4 to 6 provide the name and a definition for each control and indication LED according to the numbers.

Figure 10 : Mimic panel with controls and indication LEDs

STATIC TRANSFER SWITCH

5 SOURCE 1 4 3 22 1 2 21 23 6 14 LOAD / CHARGE 15 18
ON fault OFF LAMP TEST AUTO RETRANSFER

SOURCE 2 10

Q1 U1

U2

Q2

9 25 7 8 24

Q1BP

Q3

Q2BP

11

12

19

13

16

17

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4. Operation
Table 4 : Description of the indication LEDs
No 1 Name of LEDs U1 (SOURCE 1 VOLTAGE PRESENT) SS 1 ACTIVE S1 PREFERRED S1/S2 PHASE DISPLACEMENT LOAD U2 (SOURCE 2 VOLTAGE PRESENT) SS 2 ACTIVE S2 PREFERRED AUTO RETRANSFER ON AUTO RETRANSFER OFF ALARM Description GREEN: indicates that the source 1 is OK, ORANGE: indicates that the source 1 is downgraded, RED: indicates that the source 1 is unacceptable(*). GREEN: the SCRs on the Source 1 side are on. GREEN: Source 1 is selected as the preferred source. RED: the phase displacement between the two sources is greater than the admissible value. GREEN: the load is supplied with power. GREEN: indicates that the source 2 is OK, ORANGE : indicates that the source 2 is downgraded RED: indicates that the source is unacceptable(*). GREEN: the SCRs on the Source 2 side are on. GREEN: Source 2 is selected as the preferred source. Lit if the auto retransfer mode is enabled. Lit if the auto retransfer mode is disabled. Lights if an internal Galaxy STS fault occurs. The following faults result in an alarm: fuse blown, open SCR, shorted SCR, temperature fault, ventilation fault and other internal faults, such as control-logic or power supply failures.

2 3 5 6 7

8 9 14 15 18

(*): A flashing red LED indicates that the Galaxy STS cannot transfer the load to the source in question, due to a controllogic interdiction, for example in the event of an overload or a command inhibiting transfer.

Table 5 : Description of pushbuttons

No 4 Name of pushbuttons SOURCE 1 PREFERRED Description Press this button and the KEY (11) button simultaneously to select Source 1 as the preferred source. This action results in transfer of the load to Source 1 if transfer conditions are satisfied. Press this button and the KEY (11) button simultaneously to select Source 2 as the preferred source. This action results in transfer of the load to Source 2 if transfer conditions are satisfied. Press this button simultaneously with the SOURCE 1 PREFERRED, FAULT RESET, AUTO RETRANSFER ON/OFF and SOURCE 2 PREFERRED buttons (numbered 4, 12, 13, 16 and 10). Press this button and the KEY (11) button simultaneously to clear the lockout caused by an overload associated with Undervoltage 30 detection. Press this button and the KEY (11) button simultaneously to enable automatic transfer back to the preferred source. Press this button and the KEY (11) button simultaneously to disable automatic transfer back to the preferred source. This button causes all the LEDs on the front panel to light. Press this button to deactivate the buzzer.

10

SOURCE 2 PREFERRED

11

KEY

12

FAULT RESET

13 16 17 19

AUTO RETRANSFER ON AUTO RETRANSFER OFF LAMP TEST ALARM RESET

Table 6 : Isolation and bypass switches

No 21 22 23 24 25 Name of switches Switch Q1BP Switch Q1 Switch Q3 Switch Q2BP Switch Q2 Description Connects/disconnects Source 1 to the load, bypassing the static-switch module. Connects/disconnects Source 1 to the static-switch module. Connects/disconnects the load to the static-switch module. Connects/disconnects Source 2 to the load, bypassing the static-switch module. Connects/disconnects Source 2 to the static-switch module.

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5. Description of the STS

5.1 General description
The Static Transfer Switch Galaxy STS is a dual path, three-phase static source-changeover system used to connect a three-phase load at the output to one of the two three-phase power sources connected to the input. The two input power sources are called Source 1 and Source 2. The source to which the load is connected during normal operation is called the preferred source.

Transfer conditions and modes

Transfer conditions
The electronic control and monitoring unit permanently carries out the following checks (transfer conditions): source voltages (Preferred and Alternate) are present and levels within the authorized (factory adjustable) tolerances; phase angle between the Preferred source voltages and the Alternate source voltages is within the authorized (factory adjustable) tolerances; absence of overload or downstream short-circuit. A transfer sequence can be initialized automatically on detection of a problem (tolerance overrun) on the Preferred source, or manually (by the operator).

Monitoring power-supply sources

The two upstream sources are permanently monitored, phase by phase, for overvoltage and undervoltage. All the detection thresholds, and the hysteresis values, can be adapted when configuring the unit. There are two levels of undervoltage detection thresholds: a threshold referred to as "Undervoltage 30", factory adjustable, beyond which the source is declared to be unacceptable. an intermediate threshold, referred to as "Undervoltage 10", factory adjustable, below which the source is declared to be downgraded but acceptable. Depending on the status of the two sources, the Galaxy STS chooses the best source to supply the load. This leads to a transfer to the Alternate source under the following conditions: when the Preferred source becomes unacceptable and the Alternate source is either OK or downgraded. when the Preferred source becomes downgraded and the Alternate source is OK. The frequency of the supply sources is also monitored. If the frequency goes outside the tolerance limits, the source is also declared to be downgraded.

Transfer modes
If the transfer conditions are satisfied, the transfer is performed instantly by deactivating the active SS (Preferred path) and activating the SS for the Alternate path. The transfer is performed by a "no overlap" technique (Break before Make) that monitors, phase by phase, extinction of the SCRs of the SS to be disconnected before controlling the SCRs of the SS to be triggered. This principle ensures that the two sources are not connected in parallel at any time during the transfer. It also ensures: proper operation of Galaxy STS regardless of the impedance and nature of the power sources (utility, generator sets, Uninterruptible Power Supplies of different power ratings and technologies, etc.). that a fault on the Preferred source (for example a short-circuit upstream of the STS) is not transferred to the Alternate source, which would bring it down by tripping its protective devices.

Transfer times
The transfer time is defined as the total length of time between the occurrence of the event initializing the transfer and the moment when the three phases of the load are fully switched to the Alternate source. Under normal operating conditions (sources synchronized before the event) and when supplying computer type or slightly inductive loads, the transfer time is less than 2 ms. This value may be exceeded (typically up to 5 ms at most) for certain installations and faults such as a solid short-circuit on the Preferred source line upstream of a GALAXY STS with a highly inductive load.

Transfer with out-of-phase sources

If the phase condition between Preferred source and Alternate source voltages is not respected (phase angle outside authorized tolerances), the transfer can be carried out in either of the following two ways: with a voluntary load supply interruption lasting a few cycles (factory adjustable duration) instantly without taking the phase deviation into account. The choice between these two methods is made by the operator during configuration of the unit depending on whether or not the load can handle the phase deviation.

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5. Description of the STS

Disabled transfers
Transfer disabled in the event of a downstream fault
If an overload or downstream short-circuit is detected, the transfer function is disabled.

Voluntary transfer inhibit

An input intended for connection to a volt-free remote control contact is used to lock out transfers of any kind. This function is used in particular for installations comprising a number of Galaxy STSs with a single Alternate source possessing a lower power rating than the total installed power. As soon as one Galaxy STS transfers its load to the Alternate source, transfer is inhibited on all the other Galaxy STSs to avoid overloading the Alternate source.

Transfer back to the Preferred source

Manual or automatic retransfer After a transfer to the Alternate source, due to a problem on the Preferred source, and on re-establishment of the Preferred source power within the specified tolerances, the return transfer of the load to the Preferred source may take place in one of two ways (selected by the operator during configuration of the unit): manually (automatic retransfer disabled) using the button on the control panel. automatically, after monitoring the correct status of the Preferred source for a pre-set length of time (automatic retransfer enabled).

"Rolling Synch" sequence in manual mode

In manual mode, it is possible to retransfer even if the sources are desynchronized and slipping with respect to one another, using a "Rolling Synch" type sequence (transfer at the moment when the zero crossover of the two voltage waves coincides).

Selection of Preferred and Alternate sources

The connection terminals of the 2 sources are marked "Source 1" and "Source 2". In that the architecture and operation of Galaxy STS is completely symmetrical, it is possible to select Source 1 as either the Preferred source (with Source 2 = Alternate) or the Alternate source (with Source 2 = Preferred), indifferently. Selection takes place: either locally via the control panel; or remotely via the remote control features described in section 3.

Remote I/O port

The Galaxy STS has two different communications ports: an RS 485 port, and a terminal block with remote-indication input/outputs (isolated dry contacts). The remote I/O signals may be accessed via the terminal block (TB1). See figure 4 for a detailed list of the signals.

Input
The signals are activated by the closing of an isolated dry contact. Signals to a number of Galaxy STS devices may be connected in parallel and controlled by an NO (normally open) contact (see figure 4). Max. voltage: 24 V DC Max. current per input: 5 mA

Table 7: Remote input signals

Signal Fault reset Reset the alarm memory. Reset the optional buzzer. Remote reset.

Signification

Source 1 select Source 2 select Auto retransfer ON Auto retransfer OFF Transfer inhibit Common

Select Source 1 and preferred Source 1. Select Source 2 and preferred Source 2. Enable auto retransfer to the Preferred source. Disable auto retransfer to the Preferred source. Prevent transfers. Return path for above signals.

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5. Description of the STS

Output
The signals are emitted by dry relay contacts, rated 24 V DC, 1 A resistive.

Table 8 : Remote output signals

Signal General alarm Source 1 orange Source 1 red Source 2 orange Source 2 red Phase fault Source 1 active Source 2 active Preferred source Auto retransfer ON Load supplied Galaxy STS failure or power off NC contact closed = Fault Source 1 downgraded. Source 1 unacceptable. Source 2 downgraded. Source 2 unacceptable. Phase outside tolerances. Source 1 SCRs ON. Source 2 SCRs ON. XM9 terminal 2 = source 1, XM9 terminal 4 = source 2. Activate auto retransfer to the Preferred source. XM9 terminal 5 = ON, XM9 terminal 7 = OFF. Closed path from source to load. Signification

Note: except where indicated otherwise, the "signal" and "signification" describe device status when the NO contact is closed.

Detection circuits
The Galaxy STS comprises a number of circuits that monitor the voltage and current at various points of the device as well as the status of the switches and the fans. These circuits send fault signals to the control logic and the display logic. Each detection circuit is briefly presented below. Detection of blown fuse The blown-fuse detection circuit monitors fuses F1, F2, F3, F4, F5 and F6. Detection of open SCRs This circuit monitors the voltage upstream and downstream of the SCRs. If the circuit detects a fault, the Open SCR signal (Source 1 or Source 2) is sent to the control logic. Detection of shorted SCR This circuit monitors the current flowing through each SCR (12 total, 2 per phase for Source 1 and Source 2). If the circuit detects a fault, the Shorted SCR signal (Source 1 or Source 2) is sent to the control logic. Internal monitoring circuits The power-monitoring circuit monitors the regulated power supplies in the Galaxy STS. A failure results in a VFLT signal being sent to the control logic and tripping of a general alarm. Detection of overload Overload detection circuits (peak and average) are used in the Galaxy STS. Each phase is monitored independently for the peak and average current. An overload status always inhibits the transfer function and is indicated by a flashing red U LED for the inactive source. After clearing the overload, simultaneously press the KEY and FAULT RESET buttons to clear the lock-out function. However, if the overload caused damage and a general alarm, the Galaxy STS must be set to bypass mode and fully checked before a return to full operation. Phase status The S1/S2 phase-condition LED is generally off. The phase detector compares the phase displacement between the source voltages. If the phase displacement is greater than the pre-set value (0 to 25), a phase-fault signal is sent to the control logic and S1/S2 phase-condition LED turns red. The S1/S2 phase-condition LED also turns red if a source is no longer within the permissible frequency range. The concerned source is identified by its U LED which turns orange. Voltage monitoring The voltage-monitoring circuit, located on the Driver card (A3), monitors fuse voltages with respect to the programmed voltage setpoints. If the setpoints are overrun, the "Undervoltage 10", "Undervoltage 30" or overvoltage status conditions apply. This information is displayed by the U LEDs on the control panel, where green indicates the rated voltage, orange the "Undervoltage 10" condition and red the "Undervoltage 30" or overvoltage condition. The Galaxy STS transfers to a green source from an orange or red source, and to an orange source from a red source. Detection of temperature A thermocontact is attached to each radiator assembly. If the radiator temperature exceeds the set value, the thermocontact closes and the control logic transfers the load to the other source. If the manual transfer is forbidden (impossible). That can be released by the vigitherme. It is necessary to verify if we have not an excessive heating. Protection against internal faults The Galaxy STS has a "No Single Point Failure" design. In the event of failure of an internal component, the Galaxy STS switches to the operating status (transfer initiated or inhibited) which best ensures availability of the power supply to the load, while an alarm is triggered to alert the operator. A certain number of functions are redundant (power supplies, ventilation).
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5. Description of the STS

SCR monitoring A dedicated device continuously monitors operation of each static-switch SCR (detection of SCR short-circuit fault, open circuit fault, or gate control circuit failure). On detection of a fault, Galaxy STS switches to the best operating mode to ensure the safety of the power supply to the load, according to the following sequences: transfer to and locking on the Alternate source if a "Preferred" SCR open circuit is detected, or if an "Alternate" SCR short-circuit is detected. On an "Alternate" SCR short-circuit fault, the Preferred source is isolated by shunt tripping of the isolating circuit-breaker of the Preferred SS. transfer inhibit and locking on the Preferred source if a "Preferred" SCR short-circuit is detected, or if an "Alternate" SCR open circuit is detected. On a "Preferred" SCR short-circuit fault, the Alternate source is isolated by shunt tripping of the isolating circuit-breaker of the Alternate SS.

Control-logic
The main functions of the control-logic circuit consist in controlling the SCRs, circuit checking that a source complies with required characteristics prior to transferring the load to that source, receiving fault signals from the detection circuits and in sending fault signals to the display logic. It can also send a trip signal to the A5 card which in turn controls opening of an input switch. When the control-logic circuit receives a fault signal from one of the detection circuits, it orders or inhibits transfer of the load, depending on the type of source selected (i.e. supplying the load) and sends signals to turn on or off the appropriate LEDs on the front panel.

Display-logic
The main functions of the display-logic circuit consist in acquiring the user circuit commands entered on the front panel, receiving fault signals from the detection and control-logic circuits and in turning on the appropriate LEDs on the front panel.

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5. Description of the STS

5.2 Troubleshooting
Troubleshooting is a methodical operation, involving tests on the Galaxy STS and measurements. It consists, first of all, in detecting the existence of a fault condition and then specifically determining the cause(s) of the failure and locating the failure on one or more components. Success of troubleshooting operations depends on in-depth technical knowledge of the device (except for the most simple faults, such as blown fuses, a faulty fan, etc.). Repair work requires special training on the device, training that is provided to the specialized personnel of MGE UPS SYSTEMS. Warning: It is strongly advised to contact the after-sales support department of MGE UPS SYSTEMS.

Figure 11: Location of LEDs on the logic card

5 4 38 39 40

J4

P7

P8

P9

P3

P6 J5

P12

S1

P10

P5 P15

P14

11 10 8
P13

12 13

22 23

S3

24 25 27 29 26 28 36 34 37 35 33

P11

6 9 7 15 17 14 16 18 19 20 31 32 21 30

J17

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5. Description of the STS

Table 9: LEDs on the logic card
Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Signal name SFLT none VFLT S1DRV S2DRV UFLT NOXFER FLT13 GDRV1BAD GDRV2BAD PHSERR FERR1 FERR2 OV1 UV1-10 UV1-30 OL1AVG OL1OUT BFUSE1A BFUSE1B BFUSE1C SHRT1 SHRT2 OPN1 OPN2 BYP1 BYP2 OFFERR DCD4B7 OV2 UV2-10 UV2-30 OL2AVG OL2OUT BFUSE2A BFUSE2B BFUSE2C System fault Fan/thermal fault Power-voltage fault All Source 1 SCRs are ON All Source 2 SCRs are ON STS fault Transfer inhibit Power fault +13 VR Source 1 management circuit fault +15V Source 2 management circuit fault +15V Phase differential outside tolerances Source 1 frequency error Source 2 frequency error Source 1 overvoltage Source 1 Undervoltage 10 Source 1 Undervoltage 30 Source 1 overload Source 1 peak/average overload Source 1 fuse blown, Phase A Source 1 fuse blown, Phase B Source 1 fuse blown, Phase C Source 1 SCR short-circuit Source 2 SCR short-circuit Source 1 SCR OPEN Source 2 SCR OPEN Source 1 bypass circuit breaker closed Source 2 bypass circuit breaker closed SCR detection-circuit error Not used Source 2 overvoltage Source 2 Undervoltage 10 Source 2 Undervoltage 30 Source 2 overload Source 2 peak/average overload Source 2 fuse blown, Phase A Source 2 fuse blown, Phase B Source 2 fuse blown, Phase C GALAXY STS function D33 D24 D27 D35 D36 D39 D40 D41 D42 D43 D44 D45 D46 D47 D48 D49 D50 D51 D52 D53 D54 D55 D56 D57 D58 D59 D60 D61 D62 D63 D64 D65 D66 D67 D68 D69 D70 Part no.

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6. Maintenance
6.1 General
This chapter supplies the necessary information for routine maintenance and troubleshooting to ensure correct operation of the Galaxy STS. Only personnel having received training specifically on the device are authorized to carry out maintenance or troubleshooting. Operating personnel who have not been specifically trained for maintenance on this device must limit their work to identifying the symptoms of a fault.

6.2 Safety recommendations

Follow the general safety recommendations provided in page 3 of this manual. Particular attention must be paid to the Caution and Warning sections in the following procedures. The meaning of the terms "Caution" and "Warning" is the following:

Caution
Used to indicate an operating or maintenance operation, procedure or instruction that must be respected to avoid the risk of endangering persons or damaging the equipment.

Warning
Used to indicate operations and procedures requiring particular attention to avoid major risks to the safety of persons. Great care is required when carrying out all maintenance, troubleshooting and repair procedures. The parts of the Galaxy STS that require particular care during maintenance or repairs are the following:

All zones inside the cubicle if the load is supplied by the Galaxy STS;

All zones in the lower part of the cubicle if the Galaxy STS is connected to an energized source or if the load is supplied via the normal or maintenance bypass switch.

Caution
Before carrying out any maintenance operations inside the Galaxy STS cubicle, the device must be shut down (see section 3.2) or, if the load must remain supplied, the device must be set to bypass mode (see section 3.5).

6.3 Preventive maintenance

Continuous monitoring of the operating status of all the electronic components considerably enhances the chances of avoiding a hardware failure. For this reason, it is advised to create a register to record any events occurring during preventive maintenance. The Galaxy STS requires periodic preventive maintenance. The following procedures must be carried out by trained personnel.

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7. Characteristics
7.1 Electrical characteristics
Table 10 : Electrical characteristics
Sources 1 and 2 inputs Rated voltage (V rms) Voltage range Fated frequency Number of phases Type of connection Output Ratings (A rms) Overload capacity 400 V -15% to + 15% 50 Hz +/- 5 % 3 phases + neutral, 3 ph switched, 3 ph + neutral interrupted 4-wire + earth Characteristics for linear loads 30 - 50 - 100 - 160 - 250 - 400 - 600 A 110 % - 10 minutes 200 % - 20 s 500 % - 1 s 1000 % - 20 ms 400 s typical and 500 s max. 3 ms typical and 4.5 ms max. 35 kA

Manual transfer time Automatic transfer time Rated conditional short-circuit current Indications and communication Display, indications Controls Remote indications Remote controls Functions Standard

16 LEDs: animated mimic panel 8 pushbuttons on mimic panel 11 isolated changeover contacts 6 isolated controls

Continuous source monitoring Automatic or manual transfer without interruption Dual power supply and redundant fans Adjustable transfer parameters Isolating circuit breakers for maintenance Control and indication mimic panel Auxiliary relay card

7.2 General characteristics

Table 11: General characteristics
Environement Ambient temperature Storage temperature Ventilation 0 C to 40 C - 40 C to 70 C Forced air: Entry from underneath, exit through back for 30 A, 50 A and 100 A STS. exit through top for 160 A, 250 A, 400 A and 600 A STS. 0 to 95%, without condensation 0 to 1 000 meters (derating above 1 000 meters, 10% per additional 1 000 meters) < 45 dBA for 30 A, 50 A and 100 A STS < 60 dBA for 160 A, 250 A, 400 A and 600 A STS RAL 9002

Relative humidity Altitude Noise level (as defined by ISO 3746) Color Reference standards Construction and safety Design Degree of protection Protection

EN 50091-1, CEI 950 CEI 146

IP 20

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7. Characteristics
7.3 Mechanical characteristics
Table 12: Mechanical characteristics
Galaxy STS 30 A 50 A 100 A 160 A 250 A 400 A 600 A Dimensions and weight W D 715 mm 715 mm 715 mm 715 mm 715 mm 1015 mm 1015 mm 825 mm 825 mm 825 mm 825 mm 825 mm 825 mm 825 mm H 1385 mm 1385 mm 1385 mm 1900 mm 1900 mm 1900 mm 1900 mm Weight 180 kg 180 kg 180 kg 250 kg 250 kg 430 kg 430 kg

7.4 Customization
ECustomization is carried out via a PC connected to the parameter-setting port using the Setpoint Control Panel Software.

Table 13: Configurable parameters and setting ranges

Parameters Phase differential Overvoltage detection Overvoltage detection hysteresis Undervoltage 10 detection Undervoltage 10 hysteresis Undervoltage 30 detection Undervoltage 30 hysteresis Slow overload detection Fast overload protection Retransfer time delay Interrupt time Range 0 - 25 105 to 120% of the rated value 0 to 6% of the set value -5% to -25% of the rated value 0 to 6% of the set value -20% to -32% of the rated value 0 to 6% of the set value 100% to 125% of the rated current 150% to 250% of the rated peak current 1 to 255 seconds 0 to 3 seconds Default setting 15 112% 3% -12% 3% -25% 3% 110% 200% 3s Interrupt 0 second 1/2 cycle running average Instantaneous peak detection on all 3 phases Duration of source OK check For automatic out-of-phase transfers Source unacceptable Source downgraded Comments Absolute value of phase displacement between sources Source unacceptable

7.5 Fuse characteristics

Table 14: Fuse ratings for the various STS devices
Galaxy STS 30 A 50 A 100 A 160 A 250 A 400 A 600 A Fuses F1, F2, F3 200A-660V 200A-660V 200A-660V 450A-660V 450A-660V 1000A-660V 1000A-660V F4, F5, F6 200A-660V 200A-660V 200A-660V 450A-660V 450A-660V 1000A-660V 1000A-660V F7 6A-500V 6A-500V 6A-500V 6A-500V 6A-500V 25A-500V 25A-500V F8 6A-500V 6A-500V 6A-500V 6A-500V 6A-500V 25A-500V 25A-500V

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7. Characteristics
7.6 Losses
Table 15: Losses
Galaxy STS 30 A 50 A 100 A 160 A 250 A 400 A 600 A Losses in W for RL loads 1/4 x Pn 1/2 x Pn 60 110 440 320 560 730 50 120 200 490 340 1020 1200 3/4 x Pn 90 130 320 540 1190 1160 1380 1 x Pn 140 160 600 890 1390 2160 2200

7.7 Electromagnetic-compatibility standards

Table 16: Electromagnetic-compatibility standards
Immunity to: Conducted and radiated emissions Electrostatic discharges Radiated fields Low-energy impulse waves High-energy impulse waves Conducted disturbances EMC standards EN 55011 - level B EN 50091-2 CEI 1000-4-2 level 3 CEI 1000-4-3 level 3 CEI 1000-4-4 level 3 CEI 1000-4-5 level 4 CEI 1000-4-6 level 3

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8. Annexes
8.1 List of the figures in the manual
Figure 1: Simplified diagram of Galaxy STS ........................................................................................................................... 6 Figure 2: Typical diagram of a Galaxy STS installation. ......................................................................................................... 7 Figure 3: Space to reserve arround the Galaxy STS cubicles ............................................................................................... 8 Figure 4: Terminals on the INTY card ..................................................................................................................................... 9 Figure 5: Internal view of Galaxy STS 30 A, 50 A and 100 A ............................................................................................... 10 Figure 6: Internal view of Galaxy STS 160A and 250A ........................................................................................................ 11 Figure 7: Internal view of Galaxy STS 400A and 600A ........................................................................................................ 12 Figure 8: Typical connection diagram for a Galaxy STS on TNS systems ........................................................................... 14 Figure 9: Typical connection diagram for a Galaxy STS on TNC systems .......................................................................... 14 Figure 10: Mimic panel with controls and indication LEDs .................................................................................................... 17 Figure 11: Location of LEDs on the logic card ...................................................................................................................... 23

8.2 List of the tables in the manual

Table 1: Cable cross-sections ............................................................................................................................................... Table 2: Protection for a TNS system ................................................................................................................................... Table 3: Protection for a TNC system ................................................................................................................................... Table 4: Description of the indication LEDs .......................................................................................................................... Table 5: Description of pushbuttons ..................................................................................................................................... Table 6: Isolation and bypass switches ................................................................................................................................ Table 7: Remote input signals. ............................................................................................................................................. Table 8: Remote output signals ............................................................................................................................................ Table 9: LEDs on the logic card ............................................................................................................................................ Table 10: Electrical characteristics ....................................................................................................................................... Table 11: General characteristics ......................................................................................................................................... Table 12: Mechanical characteristics .................................................................................................................................... Table 13: Configurable parameters and setting ranges ........................................................................................................ Table 14: Fuse ratings for the various STS devices ............................................................................................................. Table 15: Losses ................................................................................................................................................................... Table 16: Electromagnetic-compatibility standards .............................................................................................................. 13 13 13 18 18 18 20 20 24 26 26 27 27 27 28 28

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