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MGE UPS Systems 3.5 to 21 kVA N+1 Owner's Manual

3.5 kva to 21 kva inverter
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Owner's Manual

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  Summary of Contents for MGE UPS Systems 3.5 to 21 kVA N+1

  • Page 1 . m g e u p s . c o m 3.5 to 21 kVA N+1 Inverter Owner’s Manual...
  • Page 2: Important Safety Instructions

    3.5 to 21 kVA N+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: ATTENTION: WARNUNG! WARNING: ATTENTION: WARNUNG! page ii Opening enclosures expose hazardous voltages.
  • Page 3 NOTE: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment.
  • Page 4 3.5 to 21 kVA N+1 Inverter This manual covers these models: Product: 64074 64144 64214 64074H 64144H 64214H For service call 1-800-523-0142 86-153460-01 Copyright © 2003 MGE UPS SYSTEMS, Inc. All rights reserved. Printed in U.S.A. MGE UPS SYSTEMS, Inc.
  • Page 5: Warranty

    The liability of MGE UPS SYSTEMS, Inc. hereunder is limited to replacing or repairing at MGE 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.
  • Page 6: How To Use This Manual

    3.5 to 21 kVA N+1 Inverter How To Use This Manual: 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.
  • Page 7: Caution: Record All Serial Numbers

    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: ________________________________________...
  • Page 8 3.5 to 21 kVA N+1 Inverter (This page left blank intentionally) page viii...
  • Page 9: Table Of Contents

    Section 1 Introduction section 1.3.1 1.3.2 1.5.1 Section 2 Installation and Operation section 2.1.1 2.1.2 2.3.1 2.4.1 2.5.1 description ........page IMPORTANT SAFETY INSTRUCTIONS .
  • Page 10 3.5 to 21 kVA N+1 Inverter Section 2 Installation and Operation (continued) section 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 2.10.1 2.11 2.11.1 2.12 2.12.1 2.13...
  • Page 11 Section 3 Maintenance Adjustment and Troubleshooting section 3.9.1 3.10 3.10.1 3.11 Glossary g—1 description ........page Scope .
  • Page 12 3.5 to 21 kVA N+1 Inverter Figures figure description ........page System Configurations.
  • Page 13: Introduction

    WARNING: ATTENTION: WARNUNG! 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...
  • Page 14: General Description

    With a built-in static transfer switch, the inverter 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.
  • Page 15: Electrical Specifications

    Table 1-2: Inverter Module Dimensions. Inverter Module HEIGHT (in/cm) 64004-9MSK1 Note: Weight: Six-mod receiver = 135 lbs. (61.2 kg) 1 UPS Module = 46 lbs. (20.09 kg) Total System Weight, 21 kVA system = 411 lbs. (186.4 kg) Electrical Specifications Electrical Specifications are subject to revision without notice.
  • Page 16: Mechanical Specification

    3.5 to 21 kVA N+1 Inverter Efficiency 85% minimum, 88% typical (on-line mode); 97% typical (off-line mode) at full kVA/Watt load. Power Factor Rated kVA is available over a power factor range of 0.6 lagging to 0.6 leading at nominal volt- age.
  • Page 17: Environmental Specifications

    Environmental Specifications Operating Temperature Shipping Temperature Storage Temperature Operating Humidity Operating Altitude Audible Noise Cooling 1.5.1 Thermal Dissipation 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...
  • Page 18 3.5 to 21 kVA N+1 Inverter (This page left blank intentionally.) page 1 — 6 Introduction...
  • Page 19: Installation And Operation

    (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. 2.1.1 Handling IMPORTANT: The equipment can be lifted from the top, using the eye-bolts;...
  • Page 20: Mechanical Mounting

    3.5 to 21 kVA N+1 Inverter 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.
  • Page 21: Location

    Figure 2-2: Front View, 7 kVA, System Component Description. WARNING: Disconnect AC (Mains) and DC supply before removing this cover. Alarm Panel DC INPUT WARNING! OPEN BREAKER BEFORE REMOVING MODULE Cooling Fan Assembly 3.5 kVA Inverter Module WARNING: Disconnect AC (Mains) and DC supply before removing this cover.
  • Page 22: Wiring Connections Line To Neutral Units

    3.5 to 21 kVA N+1 Inverter Wiring Connections Line to Neutral Units Note: For Line to Line units please skip to section 2.7, page 2—10. 2.4.1 Grounding For safety and proper operation of the unit, including maximum attenuation of electrical noise, suitable grounding is required.
  • Page 23: Dc Input

    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!)
  • Page 24: A Static Switch Section - Input And Output Wiring

    3.5 to 21 kVA N+1 Inverter Figure 2-3a: Static Switch Section - Input and Output Wiring. BATTERY (+) BATTERY (-) L-OUT L-IN N-OUT N-IN page 2 — 6 STATIC SWITCH SECTION AC & DC CONNECTIONS Installation & Operation - Line to Neutral...
  • Page 25: Connections

    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.
  • Page 26: Ac Input/Output Voltage Selection

    3.5 to 21 kVA N+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 D “QO”...
  • Page 27: Software Configuration Set-Up

    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. If the factory configuration is different, the inverter will ship with marking that will describe the invert- er plant configuration.
  • Page 28: On-Line Mode

    3.5 to 21 kVA N+1 Inverter 2.6.3 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”...
  • Page 29: Wiring Connections Line To Line Units

    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.
  • Page 30: Dc Input Circuit Breaker

    3.5 to 21 kVA N+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.
  • Page 31: A Static Switch Section - Input And Output Wiring

    Figure 2-6a: Static Switch Section - Input and Output Wiring. BATTERY (+) BATTERY (-) L1-OUT L1-IN L2-OUT L2-IN STATIC SWITCH SECTION AC & DC CONNECTIONS Installation & Operation - Line To Line Owner’s Manual page 2 — 13...
  • Page 32: Connections

    3.5 to 21 kVA N+1 Inverter 2.8.4 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.
  • Page 33: Rack Kva Rating Id Label

    Figure 2-7: Line To Line Setup Screen. Line To Line Inverter Configuration Rack kVA rating 14.0 Inverter voltage Inverter frequency 50 hz 60 hz Save After the selections are complete, click on the Save button. The data will be sent to the appropriate address in the controllers “EEROM”.
  • Page 34: Redundant Controller Set-Up

    3.5 to 21 kVA N+1 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.
  • Page 35: Indicators And Controls

    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 B; DS5 and DS6 are for output capacitors fuse indicators.
  • Page 36: S4 Inverter Components

    3.5 to 21 kVA N+1 Inverter Figure 2-9: S4 Inverter Components. WARNING: Alarm Panel DC INPUT WARNING! OPEN BREAKER BEFORE Cooling Fan REMOVING MODULE Assembly 3.5 kVA Inverter Module WARNING: Disconnect AC (Mains) and DC supply before removing this cover.
  • Page 37: Remote Alarm

    2.12 Remote Alarm The system provides three alarm signals, namely, Utility alarm, Minor alarm, and Major alarm. 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.
  • Page 38: Start-Up Sequence

    3.5 to 21 kVA N+1 Inverter 2.13 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. 2.13.1 Power-Up Procedure Turn the main source DC input circuit breaker ON to apply 48VC to the system.
  • Page 39 M a i n t e n a n c e A d j u s t m e n t a n d Tr o u b l e s h o o t i n g CAUTION: Troubleshooting the static inverter should be done only by qualified electronic technicians.
  • Page 40: Scope

    3.5 to 21 kVA N+1 Inverter 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.
  • Page 41: Equipment Adjustment And Calibration

    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.
  • Page 42: Replacement Parts

    3.5 to 21 kVA N+1 Inverter 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.
  • Page 43: Redundant Microprocessor (72-153588-00) Installation/Configuration

    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.
  • Page 44: Troubleshooting And Servicing

    AC 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”...
  • Page 45: Troubleshooting Guide

    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 Display panel not illuminated No output voltage System starts, then shuts...
  • Page 46 3.5 to 21 kVA N+1 Inverter (This page left blank intentionally) page 3 — 8 Maintenance Adjustment and Troubleshooting...
  • Page 47: Glossary

    Symbols Definition/Meaning 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. ® Trade Mark. Second. Normal sequence of phase (clockwise) in three-phase power. AC or ac Alternating current, also implies root-mean-square (rms).
  • Page 48 3.5 to 21 kVA N+1 Inverter BYPASS See “Static Transfer switch”. Bypass 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. Bypass AC Input Mains 2.
  • Page 49 Ground (safety). Hertz, frequency measurement unit, 1Hz is one cycle per second. Inverter mode See “on-line” mode. Current. International Electrotechnical Commission. IEEE Institute of Electrical and Electronic Engineers. Input branch circuit The input circuit from the building power panel to the equipment. Inverter An electrical circuit that generates an AC voltage source from a DC voltage source.
  • Page 50 Refers to an electronic technician qualified to maintain and repair electronic equipment. Not necessarily qualified to install electrical wiring. Test connector 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. Test/Maintenance Mode Maintenance bypass circuit breaker is closed and system output circuit breaker is open.
  • Page 51: Reorder Form

    STREET ADDRESS ___________________________________________________________ CITY ___________________________________ STATE ___________ ZIP ______________ I would like to order ________ (quantity @ $50.00 each) additional copies of the: 3.5 to 21 kVA N+1 Inverter I would like to report the following problems with this document: Reorder form...
  • Page 54 w w w . m g e u p s . c o m 1 6 6 0 S c e n i c Av e n u e , C o s t a M e s a , C a l i f o r n i a 9 2 6 2 6 • ( 7 1 4 ) 5 5 7 - 1 6 3 6...

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