Instruction/ maintenance manual of the product EX-5, EX-7, EX-11RT MGE UPS Systems
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EX 5/7/11R T Systems Installation and User Manual www .mgeups.com.
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Installation and User Manual iii 86-86000-00 B00 EX 5/7/1 1RT Systems Installation and User Manual Revision History EX 5/7/1 1R T Systems Installation and User Manual , 86-86000-00 Revision: A01 ECN#:003984 07/2004 A02 ECN#:004086 1 1/2004 A03 ECN#:004284 05/2005 B00 ECN#:004379 01/2006 Copyright © 2006 MGE UPS SYSTEMS, INC.
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Contents Contents c i 86-86000-00 B00 section description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii IMPORT ANT SAFETY INSTRUCTIONS .
EX 5/7/1 1RT Systems Contents c ii 86-86000-00 B00 section description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page Section 2 Setup and Installation 2.0 Scope . . . . . . . . . . . . . . . . . . . . . . . .
Installation and User Manual section description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page Section 4 Maintenance 4.0 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figures figure description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-1: T ower Configuration with Power Module, Battery Module, and optional T ransformer Module. . . . . . . . . . . . . . .
Installation and User Manual Figures (continued) figure description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3-1: Initial Startup Display . . . . . . . . . . . . . . . . . . . . . . . . . . .
EX 5/7/1 1RT Systems c vi 86-86000-00 B00 IMPORT ANT SAFETY INSTRUCTIONS SA VE THESE INSTRUCTIONS. This manual contains important instructions that should be followed during installation and maintenance of the UPS and batteries.
Installation and User Manual c vii 86-86000-00 B00 Safety of Persons CAUTION: Safety of persons ◗ The system has its own power source (the battery). Consequently , the power outlets may be energized even if the systems is disconnected from the AC power source.
EX 5/7/1 1RT Systems c viii 86-86000-00 B00 CAUTION: Record all serial numbers! CAUTION: Record All Serial Numbers! RECORD ALL SERIAL NUMBERS FOR EX 5/7/1 1RT AND ACCESSORIES.
Installation and User Manual Symbol Usage c ix 86-86000-00 B00 Symbol Usage This manual uses the following icon symbols with text to convey important information and tips. W ARNING Indicates information provided to protect the user and service personnel against safety hazards and/or possible equipment damage.
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Introduction 1.0 Scope Introduction is a general description of system configurations of the EX 5/7/1 1R T , and its mechanical electrical characteristics. Additionally there is an optional accessories section with important information on MGE products that will enhance the performance of the EX 5/7/1 1R T .
T able 1-2: Optional Accessories (See section 1.5 for description) EX 5/7/1 1RT Systems Introduction 1 — 2 86-86000-00 B00 Part Number Description 86001 Rail Kit for Power Module EX 5/7/1 1R T 86002.
Installation and User Manual 1.1 System Electrical Characteristics T able 1-3: UPS Characteristics System Ratings. T able 1-4: T ransformer Module Characteristics Ratings. CAUTION Power Module is factory configured at 208V ac, 60 Hz input and output. Without transformer , Input and Output of the UPS must always be the same.
T able 1-5: Battery Module Ratings. 1.2 Standard Configuration The EX 5/7/1 1R T systems can be set up in tower or rack configurations. 1.2.1 T ower Configuration Figure 1-1: T ower Configuration with Power Module, Battery Module, and optional T ransformer Module.
Installation and User Manual 1.2.2 Rack Configuration Figure 1-2: Rack Configuration with Power Module, Battery Module, and optional T ransformer Module. T able 1-6: System Dimensions and Weights. (*) For depth constraint applications, a shorter version of I/O Box for Power Module is available.
1.3 Rear Panel Components 1.3.1 Power Module EX 5/7/1 1 RT Figure 1-3: Rear panel of the Power Module. 1.3.2 Battery Module EXB 5/7/1 1RT With Remote Emergency Power Off (REPO) Function Figure 1-4: Rear Panel of the Battery Module.
Installation and User Manual 1.3.3 EX RT T ransformer Module Figure 1-5: Rear Panel of the optional T ransformer Module. (PN 8621 1) 1.4 Power Module Display and Control Panel Figure 1-6: View of typical control panel interface.
1 . 5 Optional Accessories Optional Accessories describes the options available for upgrades and enhancement of the EX 5/7/1 1RT systems. Detailed installation of the unit is described in following sections. T o ensure a successful installation, all procedures should be followed in their correct sequence.
Installation and User Manual 1 — 9 86-86000-00 B00 EX 5/7/1 1RT Systems 1.5.3 Multiple Battery Module Backup Time at Full Load Standard EX 5/7/1 1RT systems (one Power Module, and one Battery Module), of fers a standard backup time of 5 to 12 minutes at full load.
EX 5/7/1 1RT Systems 1 — 10 86-86000-00 B00 1.5.5 Battery Integration Kit with Casters (Part number 86005) Battery Integration Kit is a cart, designed to hold up to 8 modules. It has swivel wheels with brakes, leveling feet, seismic floor mount panels, plates to lock modules and hardware included.
Installation and User Manual 1 — 11 86-86000-00 B00 EX 5/7/1 1RT Systems 1.5.7 T ransformer Module - For use with EX 5/7/1 1RT Power Module This module provides isolated 120/208/240V ac outputs. Figure 1-1 1: T ypical T ransformer Module contents and connections.
EX 5/7/1 1RT Systems 1 — 12 86-86000-00 B00 1.5.8 CLA Charger Module Extended back-up time (up to 8 hours at full load) requires a high power battery cabinet connected to the EX 5/7/1 1RT via the CLA Module. IMPORT ANT The CLA can not be used to charge the Battery Module (EXB).
Setup and Installation 2.0 Scope Setup and Installation guides the user through tools and equipment required for connecting the EX 5/7/1 1RT and battery installation or replacement. Included are assembly instructions, power cable connections with wire diagrams for configuring the product to hardware specifications.
EX 5/7/1 1RT Systems 2 — 2 86-86000-00 B00 2.2 Contents of Standard EX 5/7/1 1RT Systems IMPORT ANT Packaging must be destroyed according to waste management standards. Recycling icons are displayed for easy selection. Figure 2-1: Contents of EX 5/7/1 1RT Power Module.
Installation and User Manual Figure 2-2: Contents of EXB 5/7/1 1RT Battery Module. Installation 2 — 3 86-86000-00 B00 Contents of EXB 5/7/1 1RT Battery Module : (PN 86207 /86209) Stabilizer Bracket and hardware. EXB 5/7/1 1RT . T ower stand expanders.
2.3 Installation in T ower Configuration Follow the numerical sequence to assemble tower stands and tower stand expanders, shown in Figure 2-3. Figure 2-3: T ower Configuration of Standard System and Optional T ransformer Module. EX 5/7/1 1RT Systems Installation 2 — 4 86-86000-00 B00 w w w .
Installation and User Manual 2.4 Installation in Rack Mounting Configuration 2.4.1 Adjustment of front panel logo and control panel for rack orientation.
2.4.2 Prepare Battery Module for Rack Mounting IMPORT ANT This step requires two people. The Battery Module is very heavy (151 lbs.). T o ease its rack mounting, you can remove the battery pack from the Battery Module, as explained below . Proceed as follows: 1.
Installation and User Manual 2.4.3 Power , Battery , T ransformer , and CLA Charger Module Rack Mounting The following steps apply to all modules. For simplicity , only Power Module is shown. Proceed as follows: 1. Attach both front mounting ear brackets to module with supplied screws.
NOTE: This step is unique to the Power Module. It involves the installation of the I/O Box Bracket System. The I/O Box bracket system keeps the I/O Box stationary while hot swapping the Power Module. It will then be easier to slide the replacement module into the connectors of the I/O Box.
Installation and User Manual 2.5 Communication Ports EX 5/7/1 1RT Power Module provides 3 communication method's that can be used simultaneously: ◗ A female DB9 provides RS232 communications using MGE Serial HID UPS T ransfer (SHUT) protocol. This COM Port is compatible with Solution Pac 2 to perform graceful shutdown.
2.5.2 Connecting the Dry (Relay) Contact Communication Port The system status is indicated by the connection of common pin (Pin 5) to the appropriate pins. Refer to the pin explanations below for details. Figure 2-9: Relay Pin Connections for Communication Port.
Installation and User Manual A wide range of optional cards will allow your UPS to talk to nearly all equipment management systems, making integration faster and easier . All these cards can plug directly into the UPS, saving time and money on your next UPS project.
2.6 Remote Emergency Power Off (REPO) Communication Port The end user is responsible for the installation of a Remote Emergency Power Off function. Installation must be carried out in compliance with local code regulations.
Installation and User Manual 2.7 System Connections W ARNING This type of connections must be carried out by qualified electrical personnel. Before carrying out any connections, check that battery circuit breaker is OFF and that the upstream protection devices (Normal and Bypass AC sources) are open (OFF/OPEN).
Proceed as follows: 1. For normal AC input, make connections to L1, L2 and terminals only . No connections are required for Bypass AC input. Make connections to , L5, L6 terminals for output. CAUTION: Always connect the earth ground wire first. Jumper must be between L1 and L3.
2.7.2 Connecting EX RT T ransformer Module (Part number 8621 1) This module is to provide isolated 120/208/240 V AC outputs to the protected loads. Figure 2-13: View of EX R T T ransformer Module connected downstream for 120/208/240 V ac outputs (shown with one EXB).
2.7.3 Connections with Separate Normal and Bypass AC sources (2 Mains) CAUTION: This connection requires isolation T ransformer Module. Call MGE T echnical Support for details. Figure 2-14: Normal AC and Bypass AC inputs, Output Cables Installation, and Simplified Connection Diagram.
Installation and User Manual 2.7.4 System Connections as Frequency Converter (without Bypass AC source) Figure 2-15: Accessing T erminal Blocks for Input and Output power cables.
2.8 Connection of Battery Module EXB 1. Check that the battery circuit breaker (5) is OFF (“0”) position. 2. Connect the battery power cable to the connectors and of the Power and Battery Modules. 3. Connect the battery detection cable between connectors and of the Power and Battery Modules.
Installation and User Manual 2.9 Connection of Optional CLA Module 1. Connect the battery power cable and battery detection cable (provided with the CLA Module) between the Power Module and the CLA Module. 2. Connect the DC Input of the CLA Module to high power battery cabinet.
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Operation 3.0 Scope Operation describes EX 5/7/1 1RT systems characteristics of indicators and controls, modes and specifications and theory of operating the EX 5/7/1 1RT . The user procedures include performing software programming that will maintain smooth performance.
3.2 UPS Personalization W ARNING Before changing items from T ables, 3-1, 3-2, 3-3, and 3-4, the UPS system must be turned OFF . IMPORT ANT If specific settings are required, it is recommended to enter the UPS personalization mode at this stage.
Installation and User Manual T able 3-1: Local Settings. Display Factory setting Options Language English French, Spanish, German, Italian Date/time format International US Date/time change (DD-MM-YYYY/HH:MM) MM-DD-YYYY/HH:MM adjustable Audible alarm Quick beeps Slow beeps T able 3-2: Output Features.
T able 3-3: ON/OFF Features. Display Factory setting Options Comments Cold start Disabled Enabled Start on battery . Forced reboot Enabled Disabled UPS restarts automatically when normal AC source is restored. Automatic restart Enabled Disabled UPS restarts automatically when normal AC source is restored.
Installation and User Manual 3.3 Information T echnology IT Network and Industrial Operating Modes T able 3-5: System Operation in IT Netowrk and Industrial Modes. Symptoms IT Network mode Industrial mode Overload, and Bypass Load is transferred to Bypass AC source.
3.3.1 UPS personalization through external software Insert the Solution-Pac 2 CD ROM in your CD drive. ◗ At the first Navigator Screen, select " Installation " and follow the instructions to install Solution-Pac 2 for Windows. ◗ If nothing appears, launch startup.
Installation and User Manual 3.4 Operating Modes 3.4.1 Normal (double conversion) Mode Figure 3-4: Normal (double conversion) mode. Operation 3 — 7 86-86000-00 B00 OFF ON OFF ON 15 15 16 L OAD LEVEL 4kW / 5 kV A REMAINING TIME 10 minutes 21 22 This is the standard operating mode, set by the factory .
3.4.2 ECO Mode Figure 3-5: ECO mode display . EX 5/7/1 1RT Systems Operation 3 — 8 86-86000-00 B00 The main advantage of the ECO mode is that it reduces the consumption of electrical power by not running in the online mode.
Installation and User Manual 3.5 Operation on Battery Power Figure 3-6: T ransfer , Threshold and End of backup time. Operation 3 — 9 86-86000-00 B00 3.5.1 T ransfer to Battery Power The load continues to be protected by the UPS when the Normal AC source is not available.
3.6 Return of Normal AC source After an outage, the UPS restarts automatically when AC power is restored (unless this function has been disabled via UPS personalization). 3.7 Shutdown Figure 3-7: Shutdown display , circuit breaker , and AC source switch.
Maintenance 4.0 Scope Maintenance includes a troubleshooting guide of symptoms and possible solutions, hot swapping the Power Module and Battery Module, and testing scenarios. 4.1 T roubleshooting ◗ If any of LEDs or is on, there is an operating anomaly or an alarm.
T able 4-2: T roubleshooting requiring MGE after-sales support. Symptoms Indication Correction LED and are on, Internal fault Call Customer Care (800) 438-7373. Bypass AC Source is present and transfer of load (Hours: 24/7) or (800) 523-0142 (During business on Bypass AC source business hours) and audible alarm is on.
Installation and User Manual 4.2 Hot Swapping the Power Module This operation can be performed without interrupting the load. Figure 4-1: Disconnecting the Power Module. Maintenance 4 — 3 86-86000-00 B00 1. Stop the system with the OFF button (press more than 3 seconds).
4.3 Re-connecting the Power Module This operation can be performed without interrupting the load. Figure 4-2: Reconnect the Power Module. EX 5/7/1 1RT Systems Maintenance 4 — 4 86-86000-00 B00 1. Secure the Input/Output box using the three screws. 2.
Installation and User Manual 4.4 Hot Swapping the Battery Module During the replacement of the Battery Module, it is imperative to use the same type and number of element as the original Battery Module provided with the UPS to maintain an identical level of performance and safety .
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Appendix 5.0 Electrical Specifications Electrical and Mechanical specifications for the EX 5/7/1 1RT . 5.1 System Input/Output Power Ratings T able 5-1: EX 5/7/1 1 RT V oltages and Frequency Characteristics.
EX 5/7/1 1RT Systems 5 — 2 86-86000-00 B00 5.3 System Backup Characteristics T able 5-2: Backup T ime (in minutes). 1 1 kV A with 9Ah battery modules: 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Standa.
Installation and User Manual T able 5-3: Battery Recharge time to recover 90% of the rated backup time after discharge at full load. Configuration for Configuration for Configuration for 2 hours backu.
T able 5-7: Efficiency on ECO mode (all kinds of load) and batteries fully charged. 5.6 Heat Rejection T able 5-8: Full load heat rejection in BTU’s/hr .
MGE W arranty & Proprietary Rights for Single Phase Products Standard W arranty Form (Applicable within the United States, Canada and Mexico) MGE Standard Single Phrase W arranty MGE UPS SYSTEMS, INC.
W arranty and Product Registration Thank you for choosing MGE UPS SYSTEMS, INC. for your power protection, distribution, and quality requirements. We are pleased to have you join our increasing family of users.
MGE Customer Care Center - Single Phase Products T echnical Support and Product Services T echnical questions? If you encounter a problem while following the instructions in this manual, or have questions about the operation, repair , or servicing of your equipment, please direct calls to MGE UPS SYSTEMS, INC.
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Glossary T erm used Definition/Meaning @ At. / And/or . +/- Plus or Minus. ≤ Equal to or less than. # Number . °C Degree Celsius. °F Degree Fahrenheit. Ø Phase angle. Ω Ohm; unit of resistance. ® T rade Mark. 2nd Second. AC or ac Alternating current, also implies root-mean-square (rms).
dBrnC Decibel above reference noise. DC or dc Direct current, or voltage. Earth ground A ground circuit that has contact with the earth. Electrician Refers to an installation electrician qualified to install heavy-duty electrical components in accordance with local codes and regulations.
Glossary G — 3 86-86000-00 B00 OSHA Occupational Safety and Health Agency . P C A Printed circuit assembly . P C B Printed circuit board. PN Part number . PWM Pulse Width Modulation. RCD Load Load consists of resistor , capacitor and diode. A computer with switched mode power supply is considered a RCD load.
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Reorder Form 1660 Scenic A venue Costa Mesa, CA 92626 Use this form to report any errors, omissions, or other problems you have experienced, or to order additional hardcopies of this document. A free copy of this document may be downloaded from the proprietary MGE Rep Web site.
www .mgeups.com Contact MGE United States MGE UPS SYSTEMS 1660 Scenic Ave. Costa Mesa, CA 92626 T el: (714) 557-1636 (800) 523-0142 Fax: (714) 557-9788 email: info@mgeups.com www: mgeups.com Canada MGE UPS SYSTEMS #9, 2789 Thamesgate Drive Mississauga, ON L4T 4E8 T el: (905) 672-0990 (877) 672-0990 Fax: (905) 672-7667 email: info@mgeups.
An important point after buying a device MGE UPS Systems EX-5, EX-7, EX-11RT (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought MGE UPS Systems EX-5, EX-7, EX-11RT yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data MGE UPS Systems EX-5, EX-7, EX-11RT - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, MGE UPS Systems EX-5, EX-7, EX-11RT you will learn all the available features of the product, as well as information on its operation. The information that you get MGE UPS Systems EX-5, EX-7, EX-11RT will certainly help you make a decision on the purchase.
If you already are a holder of MGE UPS Systems EX-5, EX-7, EX-11RT, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime MGE UPS Systems EX-5, EX-7, EX-11RT.
However, one of the most important roles played by the user manual is to help in solving problems with MGE UPS Systems EX-5, EX-7, EX-11RT. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device MGE UPS Systems EX-5, EX-7, EX-11RT along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
