MGE UPS Systems 3.5 to 21 kVA N+1 Power Supply User Manual
Contents
1. BATTERY eo m oo i INVERTER RECEIVER INVERTER RECEIVER WITH JUNCTION BOX WITH JUNCTION BOX BACK VIEW SIDE VIEW Installation amp Operation Line to Neutral page 2 5 3 5 to 21 kVA 1 Inverter Figure 2 3a BATTERY BATTERY IND GND L OUT L IN N OUT N IN GND page 2 6 Static Switch Section Input and Output Wiring STATIC SWITCH SECTION Y M O MN o ll I d o 2 ol e o lo u o o _ e o 2 o o gt 5 HIE ololo S GS gt o LE I a SSS AC amp DC CONNECTIONS Installation amp Operation Line to Neutral Owner s Manual 2 5 4 Connections All DC input connections are made through the knock outs located in the top or left side panel Refer to Figure 2 1 Make sure that the upstream source DC circuit breaker and AC circuit breaker if applicable supplying the invert er are in the off or open position DC input power cables should be sized such that the maximum voltage drop between inverter busbar terminals and battery terminals is less than 1 0 volt atthe breaker current rating See Table 2 2 for CB breaker rating verses kVA rating2. Glossary page g 1 BYPASS Bypass Bypass AC Input BYPASS mode Carrier cm Comm Conduit Cold start Connection module C S S Current rating dB DC dBA dBrnC DC or dc Digital Meter Double conversion Earth ground Electrician FET Freg Frequency slew rate page g 2 3 5 to 21 kVA 1 Inverter See Static Transfer switch Maintenance bypass wrap around manual maintenance bypass using the optional bypass cir cuit breaker Q3BP in conjunction with circuit breaker Q4S and isolation circuit breaker Q5N Mains 2 See off line mode The company or individual responsible for delivering goods from one location to another Common Circuit breaker Centimeter Communication A flexible or rigid tube enclosing electrical conductors See Start on battery power Unit grouping the receptacles for connection to the AC power source and the equipment Customer Support Service The maximum current that a conductor or equipment can carry reliably without damage Decibels Direct current Decibel Adjusted Decibel above reference noise Direct current or voltage The LCD display on the front panel of inverter system The power supplied to the connected equipment is completely regenerated by continuous double conversion i e the AC power from the AC power source is rectified AC DC then converted back DC AC to AC power A ground circuit that has contact
3. A solid state switching mechanism electronically controlled to pass AC power directly from the utility to an output load Synchronization Refers to an electronic technician qualified to maintain and repair electronic equipment Not necessarily qualified to install electrical wiring DB 9 type connector on the LCD panel allowing MGE UPS SYSTEMS Customer Support Service technician to access programmable and diagnostic features of the system Maintenance bypass circuit breaker is closed and system output circuit breaker is open Uninterruptible power system Volts Volt amperes Volt amps unit for apparent power measurement equal V x I Voltage of AC type Voltage of DC type Glossary Reorder form MGE 1660 Scenic Avenue UPS SYSTEMS mg Costa Mesa CA 92626 Use this form to order additional copies of this document or to report any errors omissions or other problems you have experienced NAME COMPANY STREET ADDRESS CITY STATE ZIP would like to order quantity 50 00 each additional copies of the 3 5 to 21 kVA N 1 Inverter Owners Manual 86 153460 01 would like to report the following problems with this document www mgeups com MGE UPS SYSTEMS 1660 Scenic Avenue Costa Mesa California 92626 714 557 1636 Po
4. C Off line Inverter frequency C 50 hz 60 hz DC fail auto restart Save Cancel After the selections are complete click on the Save button The data will be sent to the appropriate address in the controllers EEROM Remove the applied 48VDC to the system by turning off the main DC feed circuit breaker 2 9 3 Unit kVA Rating ID Label For kVA rating see the inverter ID label Use the label kVA rating regardless of the number of inverter modules installed The processor will detect and display the number of modules installed and the number of modules that are ON and operating without fault MGE is offering the 7 14 and 21 kVA rating 2 9 4 On Line Mode On line mode is the mode in which the load is powered by the inverter system not the utility It will get clean tran sient free electrical power from the inverter system which is producing the AC power from a DC power source In the event of inverter failure the static transfer switch will transfer the load to the utility power if available 2 9 5 Off Line Mode Off line mode is the mode in which the load is powered from the Utility power line external AC input power In the event of a power failure a static transfer switch will connect the system output to the inverter and activate the invert er so as to provide continuous power to the load with no interruptions of power to the load Installation amp Operation Line To Line page 2 15 3 5 to 21 kVA 1
5. There are two separate inverter AC output EMI filters Each filter provides one half of the output power to the sys tem These filters must be connected in parallel for 110 120VAC output or connected in series for 220 240VAC out put There are only two wires connected to these two filters The neutral wire with the white band is connected to the lower EMI filter left hand stud The AC output wire is connected to the upper EMI filter right hand stud In the 110 120VAC configuration the left hand studs of the EMI filters are connected together by a copper busbar strap and the two right hand studs of the EMI filters are connected together by a busbar strap See Figure 2 4 To change to the 220 240VAC connection remove the wires and busbars from the output terminals of the EMI fil ter Install the copper busbar between the lower EMI filter right hand stud to the upper EMI filter left hand stud Re connect the white neutral wire to the lower EMI filter left hand stud and the AC output wire to the upper EMI filter right hand stud Replace the hardware flat washer lock washer and nut and tighten the 10MM nuts to the pre scribed torque 35 4 inch Ibs 4 Nm Refer to the decal on the cover plate of the static switch for strap positions Again verify that P23 plug on the static switch printed circuit board located on the right side panel is in the 240VAC rear most position before applying any voltage to the inverter system The extra copper busbar ma
6. page 3 4 Maintenance Adjustment and Troubleshooting 3 8 Owner s Manual Redundant Microprocessor 72 153588 00 Installation Configuration Follow this procedure to replace or add a microprocessor board to the S4 Inverter Only one microprocessor can be configured at a time To configure a microprocessor install only that microprocessor board in the inverter receiver The redundant microprocessor board is factory calibrated and pre configured Please see the configuration on the label If this is the desired configuration skip steps 6 to 10 Before installing the microprocessor disconnect all power sources that feed the inverter If a Maintenance Bypass Switch is installed transfer the unit to MBP position If no Maintenance Bypass switch is installed Turn the inverter off Attention No power to the load in this case open the DC and AC breakers that feed the inverter 1 Using a Phillips screwdriver remove the four screws securing the display panel to the inverter receiver 2 Remove the two screws securing the bracket in front of the Microprocessor board 3 Use this bracket to pull out the old microprocessor 4 Install the new microprocessor Mount the Display Panel 5 Verify that the unit is in Standby mode and the inverter modules are OFF 6 Apply AC only to the inverter Attention The inverter output is powered Unit with Maintenance Bypass move switch to SBP The display should be ON 7 Connect a PC th
7. C 50hz 60hz Iv DC fail auto restart Save Cancel After the selections are complete click on the Save button The data will be sent to the appropriate address in the controllers EEROM Remove the applied 48VDC to the system by turning off the main DC feed circuit breaker Installation amp Operation Line To Neutral page 2 9 3 5 to 21 kVA 1 Inverter 2 6 3 2 6 4 2 6 5 Unit kVA Rating ID Label For kVA rating see the inverter ID label Use the label kVA rating regardless of the number of inverter modules installed The processor will detect and display the number of modules installed and the number of modules that are ON and operating without fault MGE is offering the 7 14 and 21 kVA rating On Line Mode On line mode is the mode in which the load is powered by the inverter system not the utility It will get clean tran sient free electrical power from the inverter system which is producing the AC power from a DC power source In the event of inverter failure the static transfer switch will transfer the load to the utility power if available Off Line Mode Off line mode is the mode in which the load is powered from the Utility power line external AC input power In the event of a power failure a static transfer switch will connect the system output to the inverter and activate the invert er so as to provide continuous power to the load with no interruptions of power to the load page 2
8. Phillips screw driver remove the two screws holding the microprocessor boards in place The circuit board secur ing bracket is also a circuit board extractor Using this bracket pull the top microprocessor circuit board out slight ly so that it is disengaged from its 70 pin edge plated connector Return the display panel back to its vertical posi tion and install the two screws to hold the panel in position Do not tighten the screws very much since they will be removed again System Personalization Before installing the power modules into the receiver rack apply the 48 VDC input voltage 44 to 56VDC The controller microprocessor within the unit should become activated The status indicators on the display panel should sequence through their self test mode changing from red to yellow to green then momentarily off in approx imately 4 seconds After this ignore all the LED displays Using the laptop PC call up the filed service set up pro gram In the Windows menu select the desired inverter voltage frequency and modes of operation The Windows menu will appear similar to Figure 2 7 page 2 14 Installation amp Operation Line To Line Owner s Manual Figure 2 7 Line To Line Setup Screen Line To Line Inverter Configuration Rack kVA rating r 10 C 14 0 6 21 0 Utility 34 Voltage connected C AC tree Mode On line Inverter voltage C 208 220 C 230 240
9. The inverter can accommodate three positive wires and three nega tive wires up to 4 0 Two 3 8 hole lugs compression type with hole spacing of 1 should be used All ground con nections should be made first then positive DC input cable should be connected then the negative connec tion last The DC input landings are marked and Insert the input DC power cable through the selected top or side panel knock out Connect the positive cable to the lower terminal connection and the negative cable to the upper terminal connection landing The 14 kVA and 21 kVA inverter require the super flexible fine strand wire which is installed with an optional Maintenance Bypass unit and with an optional Junction Box that is mount ed to the back side of the Inverter receiver 14kVA and 21 kVA only See Figure 2 3 Figure 2 4 EMI and Busbar VAC Configurations AC Line Output Stud BUSBARS EMI Filter Neutral Output BUSBAR 220 240VAC Configuration 110 120VAC Configuration STATIC SWITCH PCB TOP FRONT EDGE JUMPER POSITION FOR 128 VAC JUMPER POSITION FOR 240 URC TOP OF PCB VOLTAGE SELEC VOLTAGE SELEC 240URC J23 120URC 240URC J23 120URC OR eO 5 FRONT OF PCB Cle O OO 22 000000000 22
10. 10 Installation amp Operation Line To Neutral Owner s Manual 2 7 Wiring Connections Line to Line Units Note For Line to Neutral units continue to section 2 11 page 2 17 2 7 1 Grounding For safety and proper operation of the unit including maximum attenuation of electrical noise suitable grounding is required A separate grounding electrode conductor should be connected from the safety ground GND terminal to a nearby grounding electrode and should be sized per National Electrical Code Article 250 94 The grounding elec trode should be grounded structural metal a metal water pipe or a suitable ground rod National Electrical Code 250 26 The grounding electrode should be as near as possible to the unit The S4 will accommodate two 1 0 gauge wire Customer provides grounding system Move the receiver cabinet to its intended location using one of the suggested handling methods After it is in its final position remove the blank panels from the front of the receiver cabinet Blank panels are supplied with the unit so as to prevent damage to the unit during shipment Remove these blank panels but do not discard them Remove top cover panel on the receiver s static switch cover of the panel with two fans for access to the wiring area The connections to be made are the DC input connections load connections AC input connections and optional remote alarm connections The connection terminals and busbars are located at the static swi
11. 2 BYP static normal Static bypass on normal operation Line 3 LOAD 120V 100 AC Output Load of nominal Line 4 AC IN 120V 60 Hz AC input voltage frequency Line 5 DC IN 48 0V 073 5A DC voltage DC current Line 6 LOAD 03000 W 025 0A Load Power W Current A Line 7 INV 6 of 6 60 Hz Number of good modules out of installed modules Operation Frequency Installation amp Operation page 2 17 3 5 to 21 kVA 1 Inverter Figure 2 9 S4 Inverter Components Communications Controller Redundant Inverter on Stand by Port Status LEDs Microcontroller Panel Primary Microcontroller LCD Scroll Button LCD Panel Cooling Fan Assembly Inverter Module Status LEDs Static Transfer Switch Cabinet Inverter DC Input Switch Thumb Screw 3 5 kVA Inverter Module SZ POWER MODULE veu ING STATUS TEMPERATURE Receiver Cabinet Chasis NOTE Modules are shipped separately to reveiver cabinet page 2 18 Installation amp Operation Owner s Manual 2 12 Remote Alarm The system provides three alarm signals namely Utility alarm Minor alarm and Major alarm P Utility alarm Utility alarm is ON when utility input voltage is lost out of tolerance Minor alarm The system sends out this signal to indicate something is not functioning properly but invert er can still maintain the load Major alarm Whenever load is lost power and t
12. BI 10 000000000 B Installation amp Operation Line to Neutral page 2 7 3 5 to 21 kVA 1 Inverter The utility input and output cables are connected to a screw type terminal block Connect the ground wires first then the neutral wires then connect the AC input wire if applicable and the AC output wire A separate optional Maintenance Bypass unit and a Power Distribution panel 200A Square QO type of circuit breakers are avail able 2 5 5 AC Input Output Voltage Selection The inverter is preset at the factory for 120VAC input ON LINE 120VAC 60 Hz output If the input voltage for your installation is different 220VAC to 240VAC the following procedure MUST be followed In the static switch area there is a printed circuit board mounted to the right side panel A multi pin connector is located on the printed circuit board close to the static switch front panel identified as J23 This connector has 13 pins Its mating plug has 12 positions with interconnecting wires This allows the jumper plug P13 to be installed in one of two positions When this jumper plug is in it most forward position closest to the front panel the unit is set for 110 120VAC operation Removing the plug and installing it in its rear most position selects 220 240VAC operation Verify that this plug is in the proper position before applying any voltage to the inverter system See Figure 2 4 2 5 6 Filter Wiring
13. IMPORTANT SAFETY INSTRUCTIONS FOR INVERTER SERVICING SHOULD BE PERFORMED OR SUPERVISED BY QUALIFIED PER SONNEL ONLY WARNING DC input power to the inverter is normally from a bank of bat teries with potentially high short circuit current capability Accidental welding and severe burns are highly possible if mistake occurs during connecting or disconnecting these conductors WARNING The green grounding wire at the TB1 4 to E1 ground lug needs to be removed If the inverter is to be attached to AC input power instead of an AC free environment Preventative Maintenance The following preventive maintenance routines should be considered as a minimum requirement Your installation and site may require additional preventive maintenance to assure optimal performance from your installed inverter and associated equipment These routines should be performed twice a year more often if required We strong ly recommend a contract with MGE Customer Support Services for preventive and remedial maintenance The technician or electrician performing preventive maintenance on the equipment must read and understand thor oughly this manual and be familiar with the indicators controls and operation of the equipment a Isolate and de energize the equipment for all maintenance operations b Ensure that the equipment is clean and free of loose dust dirt and debris The exterior of the enclosures can be cleaned with a mild solution of soap and water li
14. Inverter 2 10 Redundant Controller Set Up After making sure the 48VDC power has been removed from the unit remove the two Phillips head screws from the display panel as above Re install the top controller printed board that was previously partially removed Using the circuit board retaining bracket disengage the bottom controller board from its connector Replace the display panel and secure it with the two Phillips head screws previously removed Repeat steps for the second controller When the set up is complete remove the 48VDC applied to the system Again open the front display panel and reseat the bottom controller circuit board Replace the circuit board retaining bracket and secure it in its final position using the two 6 32 Phillips head screws Replace the display panel and secure it to the rack using the two 8 32 x 3 8 Phillips head screws Set up is complete 2 10 1 Inverter Module Installation The power modules are designed to be hot swapped However for initial start up all of the inverter modules should be installed In a system where all of the module positions are not used reinstall the previously removed blank panels in these locations Install the inverter modules and tighten the four thumbscrews on each module Before turning on the main source DC circuit breaker and utility AC circuit breaker if used make sure that all of the inverter module cir cuit breakers upper left hand corner of each module is OFF Also verify
15. Inverter System Characteristics Part Power Nominal Input Maximum Maximum Output Selectable Number rating Input Voltage Input Current Amperes at selectable Output kVA Voltage Range 40VDC output voltage of Frequency VDC VDC Amperes 120 208 240 Hz 64074 H 7 48 40 to 60 176 58 29 50 or 60 64144 H 14 48 40 to 60 353 116 58 50 or 60 64214 H 21 48 40 to 60 529 174 87 50 or 60 page 1 2 Introduction Table 1 2 1 3 1 3 1 1 3 2 Owner s Manual Inverter Module Dimensions Inverter Module 64004 9MSK1 HEIGHT in cm 5 18 13 16 DEPTH in cm 15 12 38 4 WIDTH in cm 15 76 40 03 WEIGHT Ib kg 46 20 86 Note Weight Six mod receiver 135 Ibs 61 2 kg 1 UPS Module 46 lbs 20 09 kg Total System Weight 21 kVA system 411 Ibs 186 4 kg Electrical Specifications Electrical Specifications are subject to revision without notice DC Input Nominal 48Vdc Operating Range 39 5Vdc to 57 NOTE AC Output per module EEE U a U a An external DC circuit breaker or fuse should be used at the DC source Voltage 120Vrms or 240Vrms Current 25Arms or 12 5Arms Frequency 60Hz or 50Hz Table 1 3 S4 AC Output Current Ratings Attention Watts rating 85 of the VA rating at 120 240 VAC MAXIMUM OUTPUT RATINGS 7 KVA unit 14 KVA unit 21 KVA unit Vout lout Output Output lout Output Output lout Output Output Vac A Power V
16. Pres page SCORE equ dubbed E v de tune V E bud 3 2 Safety Instructions for Servicing 3 2 Preventative Maintenance 3 2 Equipment Adjustment and Calibration 3 3 Air Intake Cleaning 3 3 AC Fan Replacement 3 3 DC Fan Replacement 3 3 Replacement Parts 124822 Axt Klare 3 4 Redundant Microprocessor 72 153588 00 Installation Configuration 3 5 Troubleshooting and Servicing 3 6 Installation Check lisse 3 6 AC Output Circuit Breaker 3 6 Cable Connection and Static Switch Module 3 6 Troubleshooting Guide 3 7 Contents page c iii 3 5 to 21 kVA 1 Inverter Figures figure i 2 1 2 2 2 3 2 3a 2 4 2 5 2 6 2 6a 2 7 2 8 2 9 3 1 Tables table 1 1 1 2 1 3 1 4 2 1 2 2 2 4 2 5 3 1 3 2 page c iv description so aroa aa aa a a a nn page System Configurations N 1 added redundancy 1 2 Installation Drawing 7 KVA Inverter System 2 2 Front View 7 kVA System Component Description 2 3 Line To Neutral Inverter Receiver Junction Box 2 5 Static Switch Section Input and Output Wiring 2 6 EMI and Busbar VAC Configuration
17. Utility Alarm x x No Utility Alarm x x X indicates a short circuit between J21 terminal block points Installation amp Operation page 2 19 3 5 to 21 kVA 1 Inverter 2 13 2 13 1 2 13 2 2 13 3 Start Up Sequence Confirm that all power modules ON OFF circuit breakers are set to the OFF position On the LCD Display panel be sure inverter switch SW1 is set at STANDBY position Power Up Procedure Turn the main source DC input circuit breaker ON to apply 48VC to the system The controller boards and LCD Display panels are now energized The following message will be displayed See Figure 2 9 Line 1 INV off module Line 2 BYP static AC LOW If the system is equipped with two controllers one controller will take control of the system the other will be a back up Assuming Controller A takes control of the system the BYPASS Status LED 051 will be red Inverter Status LED DS2 will be out Controller B Bypass and Inverter LED s 053 DS4 will alternately blink On and Off green for Bypass green for Inverter If Controller B takes control its Status LED s will be as for Controller A above If an external AC power source is used turn on the source AC circuit breaker After about 20 seconds the LCD should display the following information Line 1 INV off module Line 2 BYP static normal The Status LED s will be as above except the Bypass will be green if the AC inp
18. as applicable We strongly recommend contracting MGE for system start up Do not allow unqualified personnel to handle install or operate MGE UPS SYSTEMS static inverter systems NOTE The inverter can be mounted close to a rear wall because there is no rear access to the unit All input DC output AC and input AC wiring to the inverter enters through the top or left side of the rack assembly Service to the inverter rack is through the front If a maintenance bypass unit or junction box is installed rear access is required for this unit Installation amp Operation page 2 1 3 5 to 21 kVA 1 Inverter 2 3 Mechanical Mounting The equipment can be floor mounted or rack mounted in a 19 48 3 cm 23 58 4 cm or 25 63 5 cm rack Optional mounting bracket kits can be ordered for rack mounting in a 25 63 5 cm or 26 66 0 cm rack All receivers and inverter power modules are shipped separately from the factory Receivers will be shipped on a pallet These receivers can be secured to a floor or to some other permanent base using one half inch bolts through the four holes in the base supports The inverter modules will be shipped based on customer s discretion on power configuration or the size of the receiver they are using Modules will be shipped separately from exterior chassis Refer to Figure 2 2 on page 2 3 Figure 2 1 Installation Drawing 7 kVA Inverter System FOR 1 2 54
19. at a front panel that has twin cooling fans The top panel can be opened with a 2 Phillips screw driver When making connection always double check to make sure that DC cable goes to DC busbars identified as and The utility cables go to a terminal block for Line to Neutral units 120 240VAC line connects to TB1 2 NEUTRAL to TB1 4 AC output is from TB1 1 120 240VAC NEUTRAL to TB1 3 For Line to Line units 208 240 Line 1 connects to TB1 2 and L2 to TB1 4 AC outputs L1 connects to TB1 1 and L2 to TB1 3 One of the best ways to verify continuity is to use a DMM page 3 6 Maintenance Adjustment and Troubleshooting Owner s Manual 3 11 Troubleshooting Guide After having thoroughly reexamined the installation and setup of the system and still found it un operational user can follow Table 3 2 to identify a problem its cause and recommendations for fixing it Table 3 2 Troubleshooting table Problem Possible Cause Possible Solution Display panel not illuminated No power to system Check AC amp DC power sources No output voltage SW1 not ON Turn SW1 ON System starts then shuts Overload or shorted Remove some of the load and down almost immediately output restart the inverter Power module LED turn red Module faulted Reset by recycling circuit breaker Module temp indicator on Module fan failure Replace module or cooling fan Maintenance Adjustment and Troubleshooting page 3 7 3 5 to 21 kVA 1 Inverter This
20. 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 communica tions Operation of this equipment in a residential area is like ly to cause harmful interference in which case the user will be required to correct the interference at user s own expense To reduce the risk of fire or electric shock install in a temper ature and humidity controlled indoor area free of conductive contaminant s This equipment is intended only for installations in a RESTRICTED ACCESS LOCATION Pour r duire le riske d inccendie ou d lectrocution installer dans une enciente int rieure contr l e en temp rature et humidit et sans contaminant s conducteurs Ce mat riel est destin seulement pour des installations dans un EMPLACEMENT RESTREINT d cAcc s Um die Gefahr von Feuer und elektrischem Schock zu reduzieren muss das Ger t in einem temperatur und feuchtigkeitskontrollierten Raum frei von leitungsfahigen Verunreinigungen installiert werden Dieses Ger t ist nur f r die Installation an einem Ort mit eingeschr nkter Zugangserlaubnis vorgesehen Diese Ausr stung ist nur f r Anlagen in einem EINGESCHR NKTEN ZUGRIF
21. page left blank intentionally page 3 8 Maintenance Adjustment and Troubleshooting Symbols 2nd ABC AC or ac Ambient Temp Ambient noise ANSI AWG Automatic bypass the AC power source Automatic start following return of input power Backup time Bar graph percent load Battery circuit breaker Battery test Breaker BTU or Btu Owner s Manual Glossary Definition Meaning At And or Plus or Minus Equal to or less than Number Degree Celsius Degree Fahrenheit Phase angle Ohm unit of resistance Trade Mark Second Normal sequence of phase clockwise in three phase power Alternating current also implies root mean square rms Temperature of surrounding air Acoustical noise of surrounding environment American National Standard Institute American Wire Gauge Automatic switch controlled by the UPS used to connect the equipment directly to When AC input power returns following shutdown at the end of the battery backup time UPS automatic start can be enabled or disabled Time that the connected equipment can operate on battery power Device on the front panel indicating the percent remaining backup time or the DC power circuit breaker that protects the battery circuit Internal UPS test on battery status Electrical circuit interrupter British thermal unit Defined as the amount of heat required to raise the tempera ture of one pound of water by 1
22. s factory or for preparation work for field repair or replacement Invoicing of MGE UPS SYSTEMS Inc for labor either performed or subcontracted by Purchaser will not be considered as a liability by the MGE UPS SYSTEMS Inc This warranty shall be exclusive of any and all other warranties express or implied and may be modified only by a writing signed by an officer of the MGE UPS SYSTEMS Inc This warranty shall extend to the Purchaser but to no one else Accessories supplied by MGE UPS SYSTEMS Inc but manufactured by others carry any warranty the manufacturers have made to MGE UPS SYSTEMS Inc and which can be passed on to Purchaser MGE UPS SYSTEMS Inc makes no warranty with respect to whether the products sold hereunder infringe any patent U S or foreign and Purchaser represents that any specially ordered products do not infringe any patent Purchaser agrees to indemnify and hold MGE UPS SYSTEMS Inc harmless from any liability by virtue of any patent claims where Purchaser has ordered a product conforming to Purchaser s speci fications or conforming to Purchaser s specific design Purchaser has not relied and shall not rely on any oral representation regarding the Product sold hereunder and any oral representation shall not bind MGE UPS SYSTEMS Inc and shall not be part of any warranty There are no warranties which extend beyond the description on the face hereof In no event shall MGE UPS SYSTEMS Inc be responsible for conseq
23. the ON Stand by switch on the display panel is in the Standby down position The inverter plant usually supplies power to some type of distribution circuit break er panel Confirm that all of these circuit breakers loads are OFF before starting up the inverter After the DC input cable utility line cable and output cable are properly connected and secured the inverter system is ready to be turned ON Figure 2 8 Inverter Module o EN Thumbscrews DC Breaker 2 en ron 4 typical 3 5 kVA Inverter Module Inverter Module Status LEDs Module After turning the inverter module off to allow discharge of the Input capacitors wait 3 minutes before turning the Inverter Module back ON ATTENTION Turn off the Input Breaker before removing the inverter page 2 16 Installation amp Operation Owner s Manual 2 11 Indicators and Controls There are six LED indicators divided into three groups DS1 and DS2 DS3 and DS4 DS5 and DS6 on the dis play front panel DS1 and DS2 are indicators of controller A DS3 and DS4 are indicators for controller DS5 and DS6 are for output capacitors fuse indicators Failure of output capacitors will trip output fuses and will activate DS5 and or DS6 indicators See Figure 2 9 At power up one of the two controller units will be up quicker than the other and will take control the system The stand by controller LED s will be green toggling on off Conseque
24. they are to be returned to the factory for repair or replacement All items returned to MGE UPS SYSTEMS Inc for repair or replacement must be sent freight prepaid to its factory Purchaser must obtain MGE UPS SYSTEMS Inc s Return Materials Authorization prior to returning items The above conditions must be met if warranty is to be valid MGE UPS SYSTEMS Inc will not be liable for any damage done by unauthorized repair work unautho rized replacement parts from any misapplication of the item or for damage due to accident abuse or Act of God In no event shall the MGE UPS SYSTEMS Inc be liable for loss damage or expense directly or indirectly arising from the use of the units or from any other cause except as expressly stated in this warranty MGE UPS SYSTEMS Inc makes no warranties express or implied including any warranty as to merchantability or fitness for a particular purpose or use MGE UPS SYSTEMS Inc is not liable for and Purchaser waives any right of action it has or may have against MGE UPS SYSTEMS Inc for any consequential or special damages arising out of any breach of warranty and for any damages Purchaser may claim for damage to any property or injury or death to any person arising out of its purchase of the use operation or maintenance of the product MGE UPS SYSTEMS Inc will not be liable for any labor subcontracted or performed by Purchaser for preparation of warranted item for return to MGE UPS SYSTEMS Inc
25. A A Power VA A Power VA W VA W VA W VA 110 58 33 6000 116 66 175 18000 19250 115 58 33 6000 116 66 175 18000 20125 120 58 33 6000 116 66 175 18000 21000 208 29 165 6000 58 33 87 5 18000 18200 220 29 165 6000 58 33 87 5 18000 19250 230 29 165 6000 58 33 87 5 18000 20125 240 29 165 6000 58 33 87 5 18000 21000 Units configured to other then 120 240VAC are derated due to current limit The Load reading on the display panel is always with reference to the 120 240 Vac WATT and VA ratings Introduction page 1 3 3 5 to 21 kVA 1 Inverter Efficiency Power Factor Total Harmonic Distortion Line Regulation Load Regulation Output Frequency Short Circuit Current Overload Capability Transient Deviation and Recovery EMI Emission 85 minimum 88 typical on line mode 97 typical off line mode at full KVA Watt load Rated kVA is available over a power factor range of 0 6 lagging to 0 6 leading at nominal volt age Watt rating should not be exceeded Less than 1 for linear load conditions 3 maximum for crest factor loads up to 3 1 System output voltage variation less than 1 over the DC voltage range System output voltage variation less than 1 from zero to full load at nominal DC input User selectable 50Hz or 60Hz Free run frequency stability shall be within 0 02 of the selected frequency SCC 300 minimum of rated load current for four cycles A SCC is defined as a current that
26. C Input remove the green bonding Jumper wire that is connected between the Neutral TB4 to ground The bond ing wire is used for applications without AC Input in Line to Neutral units only page 2 4 Installation amp Operation Line to Neutral Owner s Manual 2 5 2 DC Input Normal 48VDC Operating Range 39 5 VDC to 57VDC This system is designed for battery systems with the positive terminal Earth Ground All DC breakers are in the negative DC lines The system DC terminals are isolated from Earth Ground 2 5 3 DC Input Circuit Breaker Due to tremendous amounts of short circuit current available in excess of 1000A for as long as several minutes from bank s of batteries that supply electrical power to inverter systems it is extremely important to connect a properly sized DC circuit breaker at the DC input cable that feeds the inverter system The following table is pro vided as a guide for selecting the proper circuit breaker Table 2 2 Line To Neutral Units Suggested DC Circuit Breaker Ratings Inverter rating 7kVA 14 kVA 21 kVA CB rating 200A 400A 600A Figure 2 3 Line To Neutral Inverter Receiver Junction Box EB Q GND al JUNCTION E E N IN 3 BOX 9 N OUT p oo TB1 9990 a sore scos L IN
27. C output wires A separate optional Maintenance Bypass unit and a Power Distribution panel 125 200A Square GO type of circuit breakers is available AC Input Output Voltage Selection The inverter is preset at the factory for 240VAC input ON LINE 240VAC 60 Hz output If the input voltage for your installation is different 208VAC to 240VAC the following procedure MUST be followed Software Configuration Set Up The factory default configurations of the inverter plant is 240V 60Hz Utility voltage connected and Mode of oper ation is Online If the factory configuration is different the inverter plant will ship with marking that will describe the inverter plant configuration Use the configuration setup program when a different configuration is required or when a new processor is installed A lap top personal computer PC with the field service set up software for the S4 inverter family needs to be avail able and connected to the DB 9 connector of the display panel via the appropriate cable In systems that do not have the redundant controller printed circuit board there is no need to open the display panel or remove the redun dant controller skip the dual and redundant controller setup Dual Processor Set Up The following procedure should be followed for systems that contain a redundant second microprocessor Using a 2 Phillips screw driver remove the four screws securing the display panel to the receiver rack Using the
28. F STANDORT bestimmti HIGH LEAKAGE CURRENT Earth connection essential before connecting supply COURANT DE FUITE ELEVE Raccordement a la terre indis pensable avant le raccordement au reseau Hoher Ableitstrom Vor Inbetriebnahme Schutzleiterverbindung herstellen page iii 3 5 to 21 kVA 1 Inverter page iv This manual covers these models Product 64074 64144 64214 64074H 64144H 64214H For service call 1 800 523 0142 86 153460 01 Rating 7 0 KVA 14 0 kVA 21 0 kVA 7 0 kVA 14 0 kVA 21 0 kVA 120 240 Line to Neutral only 120 240 Line to Neutral only 120 240 Line to Neutral only 208 240 Line to Line only 208 240 Line to Line only 208 240 Line to Line only 3 5 kVA to 21 KVA Inverter Owner s Manual C00 06 2003 G E Copyright 2003 MGE UPS SYSTEMS Inc All rights reserved Printed in U S A MGE UPS SYSTEMS Inc 1660 Scenic Avenue Costa Mesa CA 92626 714 557 1636 UPS SYSTEMS __ LE Owner s Manual 3 5 to 21 kVA N 1 Inverter Owner s Manual Warranty The liability of UPS SYSTEMS Inc hereunder is limited to replacing or repairing at UPS SYSTEMS Inc s factory or on the job site at MGE UPS SYSTEMS Inc s option any part or parts which are defective including labor for a period of 12 months from the date of purchase The MGE UPS SYSTEMS Inc shall have the sole right to determine if the parts are to be repaired at the job site or whether
29. Manual 86 153460 01 Copyright 2003 MGE UPS SYSTEMS Inc All rights reserved Printed in U S A Revision A00 ECN 002762 07 2002 Boo ECN 002873 09 2002 Coo ECN 003170 06 2003 Warranty Information page v 3 5 to 21 kVA 1 Inverter How To Use This Manual page vi This manual is designed for ease of use and easy location of information To quickly find the meaning of terms used within the text look to the Glossary To quickly find a specific topic look at the Table of Contents This manual uses Note lines and icons to convey important information Note lines and icons come in four varieties WARNING Y CAUTION NOTE IMPORTANT Indicates information provided to protect the User and service personnel against safety hazards and possible equipment damage Indicates information provided to protect the User and serv ice personnel against possible equipment damage Indicates information provided as an operating tip or an equipment feature Indicates information provided as an operating instruction or m m ct p How To Use This Manual Owner s Manual CAUTION RECORD ALL SERIAL NUMBERS FOR THE S4 INVERTER AND COMPONENTS THESE SERIAL NUMBERS WILL BE REQUIRED IF YOUR SYSTEM NEEDS SERVICE KEEP THIS MANUAL IN A PLACE WHERE YOU CAN REFERENCE THE SERIAL NUMBERS IF SERVICE IS REQUIRED S4 INVERTER UNIT SERIAL NUMBER INVERTER MODULE SERIAL NUMBER RECEIVER CABINET SERIAL NUMBER ADDITI
30. ONAL MODULES SERIAL NUMBERS CAUTION Record All Serial Numbers page vii 3 5 to 21 kVA 1 Inverter This page left blank intentionally page viii Section 1 Section 2 Introduction section 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 3 1 1 3 2 Owner s Manual Installation and Operation section 2 0 2 1 2 2 2 3 2 4 2 5 2 1 4 2 1 2 Contents description een ee an UI gd page IMPORTANT SAFETY INSTRUCTIONS Inside Front Cover Warranty IG FF hh rrr Revision History nieee aae a ee nn How To Use This Manual vi CAUTION Record all Serial Numbers vii description tee SCONE D 1 1 General Description 1 2 Standard Products 1 2 Electrical Specifications 1 3 DG Inp t xxu decetero cee ew a RD EUR 1 3 AC Output per module 1 3 Mechanical Specification 1 4 Environmental Specifications 1 5 Thermal Dissipation llli 1 5 Safety Approvals 1 5 COSCIPUON ea andes eb ead ee oom page SCOD ces asu iu eee borate aul Fae dob ae 2 1 atem 2 1 Handling e TCR 2 1 Storag ME oue cv edu eee Oed dtu ded aded 2 1 Prere
31. cm 1 1 2 3 81 CONDUITS o 8 870 22 53 cm 2 825 17 18 cm SS 16 060 FOR 1 2 54 40 80 2 5 08 3 7 62 cm CONDUITS TOP VIEW 12 210 31 00 cm 3 250 1 650 4 19 cm 8 26 i E LI 0 ILL P FOR 1 2 1 27 cm 3 4 1 90 cm m p PEE s es CONDUITS 2 PLACES ZN I AN AAN I Q D p FOR 1 2 54 cm a Et ta 2 5 08 3 7 62 e CONDUITS TEE Ir ILI Pa mm FOR 1 2 54 cm 1 1 2 3 81cm 8 925 CONDUITS 22 67 cm 11 675 29 65 cm 15 775 40 07 cm LEFT SIDE VIEW page 2 2 Installation amp Operation Owner s Manual Figure 2 2 Front View 7 kVA System Component Description Communications Controller Redundant Inverter on Stand by Port Status LEDs Microcontroller Panel O WARNING Disconnect AC Maine and DC supply betore mwng oe Primary Alarm Microcontroller Panel RUE LCD Scroll Ed e LCD Panel Cooling Fan Assembly 3 5 kVA Inverter _ Inverter Module Module Status LEDs Static Transfer Switch Cabinet Inverter DC Thumb Screw Input Switch 3 5 kVA Inverter _ Module Receiver Cabinet Chas
32. e knock outs located in the top or left side panel Refer to Figure 2 1 Make sure that the upstream source DC circuit breaker and AC circuit breaker if applicable supplying the invert er are in the off or open position DC input power cables should be sized such that the maximum voltage drop between inverter busbar terminals and battery terminals is less than 1 0 volt atthe breaker current rating See Table 2 4 for CB breaker rating verses kVA rating The inverter can accommodate three positive wires and three nega tive wires up to 4 0 Two 3 8 hole lugs compression type with hole spacing of 1 should be used All ground con nections should be made first then positive DC input cable should be connected then the negative connec tion last The DC input landings are marked and Insert the input DC power cable through the selected top or side panel knock out Connect the positive cable to the lower terminal connection and the negative cable to the upper terminal connection landing The 14 kVA and 21 kVA inverter require the super flexible fine strand wire which is installed with an optional Maintenance Bypass unit and with an optional Junction Box that is mount ed to the back side of the Inverter receiver 14kVA and 21 kVA only See Figure 2 6 The utility input and output cables are connected to a screw type terminal block Connect the ground wires first then connect the AC input wires if applicable and the A
33. ed location using one of the suggested handling methods After it is in its final position remove the blank panels from the front of the receiver cabinet Blank panels are supplied with the unit so as to prevent damage to the unit during shipment Remove these blank panels but do not discard them Remove top cover panel on the receiver s static switch cover of the panel with two fans for access to the wiring area The connections to be made are the DC input connections load connections input connections and optional remote alarm connections The connection terminals and busbars are located at the static switch area which is in the center of the receiver cabinet For safety the DC safety ground connection should be connected first then DC positive connection made next then the DC negative last Input and Output Cable Connections AC Input Circuit Breaker CAUTION For Line to Neutral units 64074 64144 and 64214 only WARNING If utility line voltage is connected to the system an appropri ately rated AC circuit breaker MUST be installed between the supplying AC source and the inverter plant Installation must comply with local national electrical installation requirements Table 2 1 Line To Neutral Units Suggested Circuit Breaker Ratings Inverter rating 7 KVA 14 kVA 21 kVA AC breaker rating 120VAC 80A 150A 225A 240VAC 40A 80A 125A CAUTION In applications with AC Input to the inverter before connect ing the A
34. elow to 13 300 feet 4054 Meters above sea level Less than 59 dBA per Type 2 IEC and ANSI SI 4 when measured in a 40 dBA environment at a distance of 4 feet from any surface Cooling is by forced air Air intake is through the front of the unit exhaust out the sides Heat rejection 602 28 BTU Hr for each rated KW of the inverter system This is based on an inverter efficiency of 85 at full load and does not include load dissipation kVA rating Watts BTU Hr Est A C TONS Safety Approvals 7 14 21 1059 2118 3177 3614 7227 10841 0 301 0 602 0 903 Meets UL CSA 60950 listed and European Standard EN60950 Introduction page 1 5 3 5 to 21 kVA 1 Inverter This page left blank intentionally page 1 6 Introduction 2 0 2 1 2 1 1 2 1 2 2 2 Owner s Manual Installation and Operation IMPORTANT Equipment is factory set to operate at 120VAC for Line to Neutral and 240VAC for Line to Line units Please read installation procedure to configure for Line to Neutral and 240VAC for Line to Line units other configurations Scope This section describes installation of the inverters including receiving handling and storage procedures prerequi sites to the installation installation procedures and start up procedures Receiving Before accepting the shipment from the freight carrier inspect the exterior surfaces of all shipping containers or packaging used and the equipment for damage t
35. exceeds 150 of rated current Continuous overload up to 108 of rated VA watts at 50 C maximum Within 20 of average value for any change in output current or step change in input voltage within specified limits Recovery within 1 millisecond from zero to full load Battery Bus less than 30dBrnc FCC 47 CFR part 15 class A EN 55022 class A CISPR 22 class A 1 4 Mechanical Specifications Table 1 4 S4 Receiver Cabinet Mechanical Dimensions and Weights HEIGHT in cm DEPTH in cm WIDTH in cm RECEIVER WEIGHT Ib kg RECEIVER MODULES WEIGHT Ib kg RECEIVER SHIPPING WEIGHT Ib kg page 1 4 MODEL 7 KVA 14 kVA 21 kVA 21 54 31 5 81 42 107 9 18 5 47 5 18 5 47 5 18 5 47 5 17 43 7 17 43 7 17 43 7 88 39 9 111 50 3 136 61 7 182 82 6 299 135 6 418 189 6 100 45 4 123 55 8 148 67 1 Introduction 1 5 1 5 1 1 6 Owner s Manual Environmental Specifications Operating Temperature Shipping Temperature Storage Temperature Operating Humidity Operating Altitude Audible Noise Cooling Thermal Dissipation All models operate to specifications from 5 C to 50 C 23 F to 122 F for alti tude up to 3 300 feet 1006 Meters and 5 C to 35 C 23 to 95 F for up to 13 300 feet 4054 Meters 40 C to 75 C 40 F to 192 F for shipping Not recommended for storage 40 C to 60 C 40 to 166 F 0 to 90 relative without condensation 200 feet b
36. gevorschriften in Kapitel 2 dieses Dokumentes erfolgen Externe Sicherungsautomaten sind f r den Schutz der Quelle und f r sicheres Anschlie en und Trennen der Eingangsnetzes wesentlich Die internen Gleichspannungssicerungsautomaten sind zum Schutz der internen Stromkreise der Systeme Externe Sicherungsautomaten zwischen der Wechselspannungs oder Gleichspannungsquelle und dem System sind f r den Schutz der Quelle und f r sicheres Anschlie en und Trennen der Eingangsnetzstecker wesentlich FG M NOTE 1 DC input power is normally from a battery system with a very high short circuit capacity Accidental weld ing and severe burns can be caused by errors while connecting or disconnecting these conductors NOTE 2 Many operation problems are due to incorrect installation or setup Before turning the unit on review the installation and setup instructions which are associated with your system configuration Maintenance Adjustment and Troubleshooting page 3 1 3 5 to 21 kVA 1 Inverter 3 0 3 1 3 2 Scope This section describes the maintenance and service of the S4 Inverter including safety instructions preventive maintenance descriptions of replacement kits and a troubleshooting table Safety Instructions for Servicing IMPORTANT SAFETY INSTRUCTIONS FOR INVERTER SERVICING SHOULD BE PERFORMED OR SUPER VISED BY QUALIFIED PERSONNEL ONLY WARNING
37. ghtly applied with a lint free cloth c Inspect the air intake and exhaust areas in the inverter module Verify that air flows freely through the equip ment Clean the air intake and exhaust areas and the enclosure interior with a vacuum cleaner as required d Initiate the start up procedure e Test the main operating sequences as applicable to your equipment configuration and installation page 3 2 Maintenance Adjustment and Troubleshooting 3 3 3 4 3 5 3 6 Owner s Manual Equipment Adjustment and Calibration The equipment is factory adjusted and normally no further adjustments and calibration are required However in the course of repair components may have to be changed that will require configuration of the equipment These configurations should only be made by a qualified technician Air Intake Cleaning Inspect the air intake and exhaust openings for blockage Verify that air flows freely through the equipment Clean the air intake and exhaust openings with a vacuum and a soft brush AC Fan Replacement Every five years replace the Static Switch front panel including fans MGE part number 64004 0SSK1 This is accomplish by removing all the DC and AC power to the unit by turning the Maintenance Bypass Switch to the MBP position Perform the following steps 1 Remove the front panel from the static switch panel with two fans using a 2 Phillips screw driver take out the four screws securing the
38. hat may have occurred during transit If the shipping containers or equipment shows evidence of damage note the damage on the receiving document bill of lading prior to sign ing for receipt of equipment ALL CLAIMS FOR SHIPPING DAMAGE MUST BE FILED DIRECTLY WITH THE CARRIER Replacements for damaged components should be ordered through MGE UPS SYSTEMS Handling IMPORTANT A spread bar must be used to avoid bending the bolts or side panels if the S4 Inverter is to be lifted from the top using the eye bolts The equipment can be lifted from the top using the eye bolts however a spreader bar must be used to avoid bend ing the bolts or the side panels The equipment may also be handled using a forklift or pallet mover 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 from 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 Prerequisites to Installation An efficient installation depends on careful planning and site preparation Installation of the equipment must be han dled by skilled technicians and electricians familiar with the special requirements of high voltage electrical equip ment The installation must comply with the requirements of the National Electrical Code ANSI NFPA 70 latest issue and local codes
39. he four screws holding the fan panel and fan guard together 4 Install the new fan in the reverse order of disassembly When installing the front panel onto the chassis care must be taken to ensure the three LED s project through the front panel Install all ten flat head screws 5 Make sure the circuit breaker on the front panel is in its OFF position 6 Install the inverter module back into the receiver rack Maintenance Adjustment and Troubleshooting page 3 3 3 5 to 21 kVA 1 Inverter 3 7 Replacement Parts MGE offers a complete spare parts kit for each model number Spare parts kits include the inverter modules Parts those included in the spare parts kit can be ordered individually or as a complete parts kit To order on individual part give the full description along with the complete model number and serial number of the inverter Table 3 1 Spare Parts and Kits MGE Parts 64004 L1SK1 64004 L2SK1 64004 L3SK1 64004 L3SK2 64004 03SK1 64004 0SSK1 64004 0FSK1 64004 01SK1 64004 9MSK1 Description Level 1 Spares Kit 64004 OFSK1 6 x 038 003002 0000 15A Fuse for PCB 72 153594 OX Level 2 Spares Kit Level 1 64004 9MSK1 Level 3 Spares Kit Level 2 Static Switch PCB 72 153595 00 64004 03SK1 Level 3 Spares Kit for L L receiver Level 2 Static Switch PCB 72 153842 00 64004 03SK1 LCD Display Static Switch Fan Assembly Inverter Module Fan System Controller Inverter Module
40. he system is energized For alarm connection see Table 2 5 2 12 1 Alarm Relays There are three alarm relays All relays are form C type that is the relay has a normally open and a normally closed contact set The Major Alarm relay will be energized when the system is operating properly that is power is being supplied to the load either from the Inverter or from the Utility There are two sets of form C contact sets on the Major Alarm relay The Minor Alarm relay will be de energized and will be energized for the alarm condition A minor alarm will be issued if the system is not operating properly Such an alarm will be issued during overload battery voltage not within specified limits power modules over temperature and module fault The Utility Alarm relay will be de energized during normal operation and will be energized for the alarm condition This alarm will be issued if the utility voltage is not within specified limits or the input frequency is not within proper limits The table below shows the alarm and the non alarm terminal block connections This terminal block is located in the top left side of the receiver cabinet The small front panel must be removed to gain access to the terminal block Table 2 5 Alarm Connections J21 terminal block screw position 1 2 3 4 5 6 4 8 9 10 11 12 MAJOR ALARM X X MAJOR ALARM x x No Major Alarm X x No Major Alarm x x Minor Alarm X X No Minor Alarm X X
41. is NOTE Modules are shipped separately to receiver cabinet 2 3 1 Location The equipment is designed for installation in a protected environment Factors to be considered in selecting a loca tion include ventilation temperature humidity and accessibility Install the unit in a clean dry location with an unre stricted air flow The equipment is cooled by forced air Allow at least 6 inches of air space to the sides of equip ment for proper cooling To comply with NEBS requirement allow 12 30 48 cm to the sides when installed next to other heat generating equipment Installation amp Operation page 2 3 3 5 to 21 kVA 1 Inverter 2 4 2 4 1 2 5 2 5 1 Wiring Connections Line to Neutral Units Note For Line to Line units please skip to section 2 7 page 2 10 Grounding For safety and proper operation of the unit including maximum attenuation of electrical noise suitable grounding is required A separate grounding electrode conductor should be connected from the safety ground GND terminal to a nearby grounding electrode and should be sized per National Electrical Code Article 250 94 The grounding elec trode should be grounded structural metal a metal water pipe or a suitable ground rod National Electrical Code 250 26 The grounding electrode should be as near as possible to the unit The S4 will accommodate two 1 0 gauge wire Customer provides grounding system Move the receiver cabinet to its intend
42. it des la mise sous ten sion de l entr e WARNUNG Eine Ausgangsspannung liegt an den Ausgangsklemmen sobald der Netzeingang angeschlossen wird Fe MI bs a Scope This manual provides technical information for installation operation and maintenance of MGE inverter systems series ranging from 3 5 kVA to 21 kVA Please read this manual thoroughly before installing and operating the sys tem Please retain this manual for future reference The manual is divided into three sections Section 1 Introduction This section introduces the 3 5 to 21 kVA static inverters including a general description of the invert er its components and specifications Section 2 Installation amp Operation This section describes installation of the inverters including receiving handling and storage proce dures prerequisites to the installation installation procedures and start up procedures Section 3 Maintenance This section describes the maintenance and service of the S4 Inverter including safety instructions preventive maintenance descriptions of replacement kits and a troubleshooting table Introduction page 1 1 3 5 to 21 kVA 1 Inverter 1 1 General Description This static modular inverter system series provide stable distortion free AC power from a DC input source at a selectable output voltage and frequency prior to shipment for sensitive equipment With a built in static transfer switch the inverte
43. ne more easily If you cannot wait you may want to consider the following troubleshooting tips 3 9 1 Installation Check Often operation problems are caused by incorrect installation or setup Before turning the system on review Chapter 2 for instructions pertaining to your particular system Use the checklist below If the system fails to oper ate properly after being turned on all items in this list need to be rechecked and verified to make sure things are connected correctly Installation Checklist Installed item to be verified P Inverter System included static transfer switch DB DC input terminals have correct voltage polarity P Utility input terminals have correct voltage connections P AC output terminals voltage connections DB Input conductor size correct ampacity P Output conductor size correct ampacity P Correct output voltage selected in personalization P Correct frequency selected P On Off Line Inverter is on line P Automatic or manual start is selected 3 10 Output Circuit Breaker A Power Distribution Panel is available from MGE UPS SYSTEMS at a nominal cost Order part number 6421P 9 for 14 or 21 kVA units or 6210 0AD for the 7 kVA which will accommodate up to 20 24 single pole circuit breakers Square D QO type 3 10 1 Cable Connection and Static Switch Module All input and output connection terminals are mounted inside the built in Static Switch It is very easy to identify this module by looking
44. nnecting and disconnecting the input power connectors The internal DC circuit breakers in the system are for protection of the systems internal circuits only External circuit breakers between the AC or DC source and the system are essential for the protection of the source and for safely connecting and disconnecting the input power connectors CAUTION Troubleshooting the static inverter should be done only by ATTENTION Le d pannage de l inverseur statique devrait tre fait seulement par les techniciens lectroniques qualifi s Relier et d brancher les conducteurs de puissance d entr e et de sortie au cours du d pannage devraient tre faits selon les instructions d installation dans la section 2 de ce document Les disjoncteurs externes sont essentiels pour la protection de la source et pour sans risque se relier et d brancher et les connecteurs de puissance d entr e Les disjoncteurs internes de C C dans le syst me sont pour la protection des circuits internes de syst mes seulement Les disjoncteurs externes entre la source ou de et le systeme sont essentiels pour la protection de la source et pour sans risque brancher et d brancher les connecteurs de puissance d entr e VORSICHT Fehlersuche am statischen Umformer sollte nur von qualifiziertem Elektronik Technikern ausgef hrt werden Das AnschlieBen und das Trennen der Eingangs und Ausgangsanschlu leitungen sollten in bereinstim mung mit den Monta
45. ntly DS1 or DS3 will be on blinking green sig naling that AC Input is available and the system output is ready to be turned on through the Power Distribution breakers The inverter output voltage is turned ON or to Stand by via switch SW1 located on the left side of the LCD display panel Pushing it up is to turn the inverter ON and pushing it down is to turn the inverter OFF WARNING In the stand by position if AC power is applied to the AC input terminal block AC power will be on the output of the unit When the Inverter voltage is on DS2 or DS4 indicator will be on green steadily signaling that every thing is nor mal The system measurement information is displayed on the LCD display panel Switch SW3 scroll button on the right side of the display panel is pushed down or up to scroll the LCD s screens for more information Individual invert er module has only one control an ON OFF circuit breaker located at the upper left corner of the front panel This breaker is used to energize or de energize the inverter module Note For initial start up the module circuit breakers must be turned on prior to turning the system Inverter ON 2 11 1 LCD Readout The LCD unit displays two lines out of a total of seven lines of information at a time Each line can be scrolled up or down independently by toggling the scroll switch SW3 Typical seven lines of information are shown below Line 1 INV off normal Inverter off on Line
46. nya day hee eere O GU YOU 2 11 Input and Output Cable Connections 2 11 AC Input Circuit Breaker 2 11 DC Input ym d ER 2 11 DC Input Circuit Breaker 2 12 Connections nn 2 14 AC Input Output Voltage Selection 2 14 Software Configuration 2 14 Dual Processor Set Up 2 14 System Personalization 2 14 Rack kVA Rating ID Label 2 15 On Line Mode su sss eei s aaora ani nn 2 15 Off Line Mode se YG GOD on DU Lu ER 2 15 Redundant Controller Set Up 2 16 Inverter Module Installation 2 16 Indicators and Controls 2 17 LCD Readout e Ree ade 2 17 Remote Alarm 00000 cee eee 2 19 Alarm 2 19 Start Up Sequence FFF 949444 2 20 Power up Procedure 2 20 Powering Up the Inverters 2 20 De Energizing the System 2 20 Contents Section 3 Glossary Owner s Manual Maintenance Adjustment and Troubleshooting section 3 0 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 9 1 3 10 3 10 1 3 11 g 1 description sen ea RSEN x
47. panel to the receiver rack 2 Unplug the two fan wires at the static switch printed circuit board 3 Install the fan assembly onto the static switch making sure to plug fan s back into the static switch printed cir cuit board connectors 4 Secure the front panel in place by using the four Phillips head screws previously removed 5 Power up the system by switching the Maintenance Bypass Switch to SBP and to Normal 6 Close DC Breaker and verify that the inverter is in normal mode display panel inverter indicator should be green 7 Verify that the Inverter output indicator on the Maintenance Bypass Switch display is ON DC Fan Replacement Every five years replace the DC fan in each power modules MGE fan part number 64004 0FSK1 This is accom plished by removing the power module from the receiver Perform the following steps 1 Remove the front panel from the power module by removing the six Phillips head screws securing the front panel to the chassis the two screws securing the top cover to the front panel 6 32 Phillips head screws and the two screws hold the DC circuit breaker to the front panel It should not be necessary to remove the top cover 2 Remove the front panel being careful to unplug the fan from the printed circuit board 3 Observe the orientation of the fan wires and the fan guard so that it will appear like all other power module front panels Remove the fan from the front panel by removing t
48. quisites to Installation 2 1 Mechanical Mounting llle 2 2 Location less GE GR LYFR DROIR Uo cra ed os 2 3 Wiring Connections Line To Neutral Units 2 4 Grounding ues RR ERR aa 2 4 Input and Output Cable Connections 2 4 AC Input Circuit Breaker 2 4 Contents page c i 3 5 to 21 kVA 1 Inverter Section 2 page c ii Installation and Operation continued section 2 6 2 7 2 8 2 9 2 5 2 2 5 3 2 5 4 2 5 5 2 5 6 2 6 1 2 6 2 2 6 3 2 6 4 2 6 5 2 7 1 2 8 1 2 8 2 2 8 3 2 8 4 2 8 5 2 9 1 2 9 2 2 9 3 2 9 4 2 9 5 2 10 1 2 11 1 2 12 1 2 13 1 2 13 2 2 13 3 description serasi oen me RR EH page DO Inp t s 23 22x OOS RA RR RYG 2 5 DC Input Circuit Breaker 2 5 Connections s 2 7 AC Input Output Voltage Selection 2 8 EMI Filter Wiring ss ee aan ae 2 8 Software Configuration 2 9 Dual Processor Set Up 2 9 System Personalization 2 9 Rack kVA Rating ID Label 2 10 On Line Mode 2 10 Off Line suse dx edt x eem 2 10 Wiring Connections Line To Line Units 2 11 Grounding a
49. r also forms a reliable and economical part of uninterruptible power supply systems in either on line or off line mode This series employed modular design to provide N 1 redundancy and twin controller cards to double reliability There are three distinctive parts in these tower inverter systems The top part is a built in mod ule that houses the twin controller alarm cards LCD unit and LED indicators The center part is a built in module that houses a static transfer switch and where input and output connectors are located It is easily recognized by a twin fan front panel Above and below this static switch module are individual inverter modules rated 3 5 KVA 3KW each those with single fan front panel S4 inverters are available in three receiver cabinet configurations housing 1 to 6 inverters a static transfer switch console and redundant microcontroller modules Figure 1 1 System Configurations N 1 added redundancy 1 2 ee eo oe Re 28 256 m ee oo ee m eooo ee gt 5 5 8 5 1 8 5 J 7 kVA 8 5 N 1 14 10 5 1 21 kVA 17 5 1 Standard Products Consult table 1 1 below for the system s you are working on Table 1 1
50. ro vided as a guide for selecting the proper circuit breaker Table 2 4 Line To Line Units Suggested DC Circuit Breaker Ratings Inverter rating 7kVA 14 kVA 21 kVA CB rating 200A 400A 600A Figure 2 6 Inverter Receiver Junction Box Input and Output Wiring 5 eo oo JUNCTION Dd E BOX eo oe c c 1 u nt Lol ooo E oon BATTERY Oo 0 oF Ss o o o e BATTERY s G o o o o iim O INVERTER RECEIVER INVERTER RECEIVER WITH JUNCTION BOX WITH JUNCTION BOX BACK VIEW SIDE VIEW page 2 12 Installation amp Operation Line To Line Owner s Manual Figure 2 6a Static Switch Section Input and Output Wiring STATIC SWITCH SECTION BATTERY BATTERY GND AC amp DC CONNECTIONS Installation amp Operation Line To Line page 2 13 3 5 to 21 kVA 1 Inverter 2 8 4 Connections 2 8 5 2 9 2 9 1 2 9 2 All DC input connections are made through th
51. rough RS232 cable to the communication port on the Display Panel 8 Run the configuration setup program on the PC 9 On the configuration screen select the correct configuration for your unit KVA rating inverter voltage inverter frequency Utility Mode and Auto restart Click on SAVE to send the configuration to the Microprocessor mem ory Disconnect the AC power Unit with Maintenance Bypass move switch to MBP 10 To configure a second Microprocessor repeat steps 1 and 3 to 9 Repeat step 1 Reinstall the first Microprocessor board 11 Mount the bracket and the Display panel 12 Restart the unit follow start up instruction in the unit installation and user manual Figure 3 1 Redundant Microprocessor Component Location Redundant Controller Card inserted into Slot 1 PCB Slot 2 Primary Microcontroller Display Maintenance Adjustment and Troubleshooting page 3 5 3 5 to 21 kVA 1 Inverter 3 9 Troubleshooting and Servicing Should you encounter a problem in the operation of the inverter and need MGE Systems to service your equipment it is recommended to leave the unit in its current state Record message if any and color signals on the LCD dis play and LED indicators on the display panel then call MGE Customer Support Services at 1 800 523 0142 for assistance Leaving the unit in its current state will facilitate the field engineers to troubleshoot and bring your equip ment back on li
52. rther discharge Main AC input source Bypass AC input source Milliampere Maximum Thousand circular mil standard wire sizes for multiple stranded conductors over 4 0 AWG in diameter M is from Roman numerical system indicating 1000 Multi Module Refers to individual power inverter module Neutral Normally close National Electrical Code National Fire Protection Association Glossary 9 3 NO Online mode Offline mode OSHA PCA PCB P E PWM Rectifier Charger SCR Shipping damage S M SPDT SSC Static Transfer Switch Sync or synch Technician Test connector Test Maintenance Mode UPS V VA VA VAC or Vac VDC or Vdc page g 4 3 5 to 21 kVA N 1 Inverter Part number Normally open Inverter output power is the primary energy source to load Inverter output is off and the load connected at the inverter output receives power from utility line via a static transfer switch or maintenance bypass relay Occupational Safety and Health Agency Printed circuit assembly Printed circuit board Power Factor Pulse Width Modulation Converts the AC input voltage from the utility source into DC voltage supplying the inverter and regulating the charge of the battery system Silicon controlled rectifier Any damage done to an article while it is in transit Single Module Single Pole Double Throw Static Switch Cabinet in shared systems
53. s 2 7 Line To Neutral Setup Screen 2 9 Line To Line Inverter Receiver Junction 2 12 Static Switch Section Input and Output Wiring 2 13 Line To Line Setup 5 2 15 Inverter Module I FY FF FFF FF nn 2 16 S4 Inverter Components 2 18 Redundant Microprocessor Component Location 3 5 descriptlOn ee deed eu DD de OD DDU dd page Inverter System Characteristics 1 2 Inverter Module Dimensions 1 3 S4 AC Output Current Ratings with resistive load 1 3 S4 Receiver Cabinet Mechanical Dimensions and Weights 1 4 Line To Neutral Units Suggested Circuit Breaker Ratings 2 4 Line To Neutral Units Suggested DC Circuit Breaker Ratings 2 5 Line To Line Units Suggested Circuit Breaker Ratings 2 11 Line To Line Units Suggested DC Circuit Breaker Ratings 2 12 Alarm Connections 2 17 Spare Parts and Kits scis reve p pere aed xk RE 3 4 Troubleshooting table eee 3 7 Contents 1 0 Owner s Manual Introduction WARNING An AC output will be present at the output terminals immedi ately when AC input is energized ATTENTION La tension alternative de sortie appara
54. tch area which is in the center of the receiver cabinet For safety the DC safety ground connection should be connected first then DC positive connection made next then the DC negative last 2 8 Input and Output Cable Connections 2 8 1 AC Input Circuit Breaker CAUTION For Line to Line units 64074H 64144H and 64214H only WARNING If utility line voltage is connected to the system an appropri ately rated AC circuit breaker MUST be installed between the supplying AC source and the inverter plant Installation must comply with local national electrical installation requirements Table 2 3 Line To Line Units Suggested Circuit Breaker Ratings Inverter rating 7 KVA 14 kVA 21 kVA AC breaker rating 240VAC 40A 80A 125A 2 8 2 DC Input Normal 48VDC Operating Range 39 5 VDC to 57VDC This system is designed for battery systems with the positive terminal Earth Ground All DC breakers are in the negative DC lines The system DC terminals are isolated from Earth Ground Installation amp Operation Line To Line page 2 11 3 5 to 21 kVA 1 Inverter 2 8 3 DC Input Circuit Breaker Due to tremendous amounts of short circuit current available in excess of 1000A for as long as several minutes from bank s of batteries that supply electrical power to inverter systems it is extremely important to connect a properly sized DC circuit breaker at the DC input cable that feeds the inverter system The following table is p
55. uential damages or for any damages except as expressly stated herein Service and Factory Repair Call 1 800 523 0142 Direct questions about the operation repair or servicing of this equipment to MGE UPS SYSTEMS Inc Technical Support Services Include the part number and serial number of the unit in any correspondence Should you require factory service for your equipment contact MGE UPS SYSTEMS Inc Technical Support Services and obtain a Return Materials Authorization RMA prior to shipping your unit Never ship equipment to MGE UPS SYSTEMS Inc without first obtaining an RMA Proprietary Rights Statement The information in this manual is the property of MGE UPS SYSTEMS Inc and represents a proprietary article in which MGE UPS SYSTEMS Inc retains any and all patent rights including exclusive rights of use and or manufacture and or sale Possession of this information does not convey any permission to reproduce print or manufacture the article or articles shown herein Such permission may be granted only by specific written authorization signed by an officer of MGE UPS SYSTEMS Inc IBM PC AT ES 9000 and AS 400 are trademarks of International Business Machines Corporation and MGE UPS SYSTEMS are trademarks of MGE UPS SYSTEMS Inc Other trademarks that may be used herein are owned by their respective companies and are referred to in an editorial fashion only Revision History 3 5 to 21 kVA N 1 Inverter Owner s
56. uring the display panel to the receiver rack Using the Phillips screw driver remove the two screws holding the microprocessor boards in place The circuit board secur ing bracket is also a circuit board extractor Using this bracket pull the top microprocessor circuit board out slight ly so that it is disengaged from its 70 pin edge plated connector Return the display panel back to its vertical posi tion and install the two screws to hold the panel in position Do not tighten the screws very much since they will be removed again 2 6 2 System Personalization Before installing the power modules into the receiver rack apply the 48 DC input voltage 44 to 56VDC The con troller microprocessor within the unit should become activated The status indicators on the display panel should sequence through their self test mode changing from red to yellow to green then momentarily off in approximate ly 4 seconds After this ignore all the LED displays Using the laptop PC call up the filed service set up program In the Windows menu select the desired AC output voltage frequency and modes of operation The Windows menu will appear similar to Figure 2 5 Figure 2 5 Line To Neutral Setup Screen Line To Neutral Inverter Configuration Rack kVA rating C 7 0 C 140 21 0 Utility Voltage connected C AC Free Mode On line Inverter voltage C 110 220 C 115 C 230 C Off line Inverter frequency
57. ut voltage is within proper lim its voltage and frequency Powering Up the Inverters DO NOT turn on the inverter switch SW1 yet Turn the circuit breaker on each power module to the ON position The LCD Display panel is still displaying the above two lines but module will change to normal Now every thing is ready and the inverter switch SW1 can be turned ON push up The Status LED s will be as above except that the Inverter indicator that was out will now be green if the system is functioning properly The invert er is now supplying the power to the system Using a voltmeter verify that the proper voltage 110 115 120 208 220 230 240VAC exist at the output terminals Load circuit breaker may be turned ON De Energizing the System If the system is equipped with an AC input turn off the main feed circuit breaker Then turn switch SW1 to the stand by position push down Next turn all the power modules front panel circuit breakers OFF Lastly turn the DC input supply circuit breaker OFF page 2 20 Installation amp Operation Owner s Manual Maintenance Adjustment and Troubleshooting qualified electronic technicians Connecting and disconnect ing the input and output power conductors in the course of troubleshooting should be done in accordance with the installation instructions in Section 2 of this document External circuit breakers are essential for the protection of the source and for safely co
58. with the earth Refers to an installation electrician qualified to install heavy duty electrical components in accordance with local codes and regulations Not necessarily qualified to maintain or repair electrical or electronic equipment Field effect transistor Frequency The change in frequency per unit of time Given in term of Hz per second Hz sec Glossary GND Hz Inverter mode IEC IEEE Input branch circuit Inverter IGBT kVA kVAR kW LCD LED Load Low battery shutdown Mains or Mains 1 Mains 2 mA MAX MCM M M Module N Owner s Manual Ground safety Hertz frequency measurement unit 1Hz is one cycle per second See on line mode Current International Electrotechnical Commission Institute of Electrical and Electronic Engineers The input circuit from the building power panel to the equipment An electrical circuit that generates an AC voltage source from a DC voltage source Insulated gate bipolar transistors KiloVolt Ampere is equal to 1000 Volt Ampere KiloVolt Amperes reactive KiloWatt a measure of real power equal to 1000 watts Line Liquid Crystal Display unit Light Emitting Diode Connected to the UPS output such as computer systems or critical devices The battery has reached the lowest permitted operating voltage and the inverter has shutdown disconnecting the load to protect the battery from damage due to fu
59. www mgeups com 3 5 to 21 kVA N 1 Inverter Owner s Manual MGE UPS SYSTEMS 3 5 to 21 kVA 1 Inverter IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for the S4 Inverter Plant that must be followed during operation of the equipment WARNING Opening enclosures expose hazardous voltages Always refer service to qualified personnel only ATTENTION L ouverture des cabinets expose des tensions dangereuses Assurez vous toujours que le service ne soit fait que par des personnes qualifiees WARNUNG Das ffnen der Geh use legen gef hrliche Spannungen bloss Service sollte immer nur von qualifizierten Personal durchge f hrt werden B y aaa change please ask for confirmation of the information given WARNING As standards specifications and designs are subject to in this publication ATTENTION Comme les normes sp cifications et produits peuvent chang er veuillez demander confirmation des informations con tenues dans cette publication WARNUNG Normen Spezifizierungen und Pl ne unterliegen Anderungen Bitte verlangen Sie eine Best tigung ber alle Informationen die in dieser Ausgabe gemacht wurden page ii Important Safety information Z N NOTE WARNING ATTENTION WARNUNG WARNING ATTENTION WARNUNG Owner s Manual This equipment has been tested and found to comply with the limits for a Class A digital
60. y be discarded Replace the top cover of the static switch and secure it with the three previously removed 6 32x1 4 Phillips head screws WARNING Do not perform this procedure under Section 2 5 6 unless the configuration needs to be changed The voltage selection jumper plug position must agree with the software selection See Figure 2 4 EMI filter strapping page 2 8 Installation amp Operation Line To Neutral Owner s Manual 2 6 Software Configuration Set Up The factory default configurations of the inverter plant is 120V 60Hz Utility voltage connected and Mode of oper ation is Online Ifthe factory configuration is different the inverter will ship with marking that will describe the invert er plant configuration Use the configuration setup program when a different configuration is required or when a new processor is installed A lap top personal computer PC with the field service set up software for the S4 inverter family needs to be avail able and connected to the DB 9 connector of the display panel via the appropriate cable In systems that do not have the redundant controller printed circuit board there is no need to open the display panel or remove the redun dant controller skip the dual and redundant controller setup 2 6 1 Dual Processor Set Up The following procedure should be followed for systems that contain a redundant second microprocessor Using a 2 Phillips screw driver remove the four screws sec
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