MGE UPS Systems POWER-SURE 700 Installation And User Manual
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MGE UPS Systems POWER-SURE 700 Installation And User Manual

MGE UPS Systems POWER-SURE 700 Installation And User Manual

Three phase power conditioners
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Power-Sure
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Three Phase
Power Conditioners
Installation and User Manual

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  • Page 1 w w w . m g e u p s . c o m Power-Sure ™ Three Phase Power Conditioners Installation and User Manual...

  • Page 2: Important Safety Instructions

    Power-Sure™ 700 — Three Phase Power Conditioners IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS – This manual contains important instructions for Power-Sure™ 700 that must be followed during operation of the equipment. WARNING Opening enclosures expose hazardous voltages. Always refer service to qualified personnel only.

  • Page 3: How To Use This Manual And Symbol Usage

    WARNING ATTENTION WARNUNG! WARNING ATTENTION WARNUNG! How to use this manual and Symbol Usage This manual is designed for ease of use and easy location of information. Locate specific topics in the Table of Contents. Typographical conventions use single quote marks in procedures to denote a prompt for user action: For example: 1.

  • Page 4: Caution: Record All Serial Numbers

    Power-Sure™ 700 — Three Phase Power Conditioners CAUTION: Record All Serial Numbers! RECORD ALL SERIAL NUMBERS FOR THE POWER-SURE™ 700 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! POWER-SURE™...

  • Page 5: Revision History

    Revision History Power-Sure™ 700 Three Phase Power Conditioners Installation and User Manual Revision: For service call 1-800-523-0142 Copyright © 2006 MGE UPS SYSTEMS, INC. All rights reserved. Printed in U.S.A. MGE UPS SYSTEMS, INC. 1660 Scenic Avenue Costa Mesa, CA 92626...
  • Page 6 Power-Sure™ 700 — Three Phase Power Conditioners (This page left blank intentionally) 86-108814-00 B01...

  • Page 7: Table Of Contents

    Installation Notes ........2 — 1 MGE UPS Systems Power-Sure™ 700 ....2 — 1 Power-Sure™...
  • Page 8 Power-Sure™ 700 — Three Phase Power Conditioners Section 3 Maintenance section description ......... . .page Scope .
  • Page 9 Figures figure description ..........page 2-1: Power-Sure™...
  • Page 10 Power-Sure™ 700 — Three Phase Power Conditioners (This page left blank intentionally) c iv 86-108814-00 B01...

  • Page 11: Introduction

    Scope This section is a general description of the Power-Sure™ 700 Three Phase Power Conditioners. Includes receiving, location and storage, electrical, mechanical specifications, monitoring, and internal protection for components. Reference Manuals Section Descriptions This manual is divided into three sections: Section 1: Introduction This section is a general description of the Power-Sure™...

  • Page 12: Receiving And Inspection Notes

    Remove top and side panels (Not applicable on 225kVA and larger). Check the nameplate to be sure that the voltage and frequency match the available power supply. Under no circum- stance should the unit be connected to a power source which does not conform to the nameplate rating.

  • Page 13: Electrical And Performance Specifications

    1.4.1 Electrical and Performance Specifications *Output *Input *Frequency Efficiency Line Regulation Load Regulation Response Time Correction Time Harmonic Distortion Transverse-Mode Noise Attenuation Common-Mode Noise Attenuation Audible Noise Turn On Characteristics Overload Rating Ambient Rating *Optional extended input regulation range provided on some units. If provided, reference description next to the units specification tag.

  • Page 14: Input Breaker

    Power-Sure™ 700 — Three Phase Power Conditioners 1.4.3 Input Breaker Main input molded case circuit breaker, rated at 125% of full load input current. Monitoring the Power-Sure™ 700 Monitoring of the Power-Sure™ 700 is simple, clean, and effective. Three green light indicators are utilized to display “POWER ON”...

  • Page 15: Installation And Operation

    For installation of conduit, reference NEC Article 348 and 350 and any applicable local electrical codes. Refer to the following installation diagrams for electrical hookup. MGE UPS Systems Power-Sure™ 700 An efficient installation depends on careful planning and site preparation. Installation of the equipment must be handled by skilled technicians and electricians familiar with the special requirements of high-voltage electrical equipment.

  • Page 16: Power-Sure™ 700 Installation Drawings And Cabinet Dimensions

    Power-Sure™ 700 — Three Phase Power Conditioners Power-Sure™ 700 Installation Drawings and Cabinet Dimensions When sizing the Power-Sure™ 700, be sure to take into consideration all loads and circuits the Power-Sure™ 700 is to supply. Figure 2-1: Power-Sure™ 700 — 10-15kVA Mechanical Cabinet Measurements. FOR INSTALLATION 24"...

  • Page 17: Power-Sure™ 700 - 25-30Kva Mechanical Cabinet Measurements

    Figure 2-2: Power-Sure™ 700 — 25-30kVA Mechanical Cabinet Measurements. 24" (609.6m) CLEARANCE FOR SERVICEABILITY 21.5" (546.1m) POWER ON ALERT 44" (1117.6m) FRONT VIEW 86-108814-00 B01 TO REMOVE TOP: REMOVE RETAINING SCREW IN REAR OF TOP, 12" LIFT REAR AND SLIDE FORWARD (304.8m) FOR INSTALLATION PURPOSES ONLY...

  • Page 18: Power-Sure™ 700 - 45-150Kva Mechanical Cabinet Measurements

    Power-Sure™ 700 — Three Phase Power Conditioners Figure 2-3: Power-Sure™ 700 — 45-150kVA Mechanical Cabinet Measurements. 24.000 CLEARANCE SERVICEABILITY ENVIRONMENTAL CLEARNESS FRONT 45.000 44.000 FRONT VIEW INPUT CIRCUIT BREAKER 1.000 .500 ÿ 0.312 1.000 .25" COPPER BAR INPUT TERMINATION 3.500 RECOMMENDED 9.000 INPUT...

  • Page 19: Power-Sure™ 700 — 225-300Kva Mechanical Cabinet Measurements

    Figure 2-4: Power-Sure™ 700 — 225-300kVA Mechanical Cabinet Measurements. LIFT-OFF ACCESS PANEL EDGE FRAMING FOR SCREENING (18 GAGE .047 THICK STEEL) 36" CLEARANCE REQUIRED (THIS SIDE) METAL – LAYER 1 (1.47D X 1.47W , 120 THICK) METAL (GALVANIZED STEEL – LAYER 2 (1.25D X 1.25W , 120 THICK) LIFT-OFF...

  • Page 20: Power-Sure™ 700 Cable Connections

    Power-Sure™ 700 — Three Phase Power Conditioners As the input voltage (building power) varies, the voltage available at each tap of the transformer will also change. The amount of variation is dependent upon the input sag or surge, turns ratio and transformer losses. By selecting a particular tap voltage, the output can be kept within a tight range.

  • Page 21: Vac Input And 208 Vac Output Wire Size Chart

    Table 2-1: 480 VAC Input and 208 VAC Output Wire Size Chart. Unit Size in kVA Table based on 480 VAC input and 208 VAC output. Table 2-2: 208 VAC Input and 208 VAC Output Wire Size Chart. Unit Size in kVA 1200 Amp Table based on 208 VAC input and 208 VAC output.

  • Page 22: Start-Up Sequence

    Start-Up Sequence WARNING: THERE ARE DANGEROUSLY HIGH VOLTAGES PRESENT WITHIN THE ENCLOSURE OF THE POWER SUPPLY SYSTEM. CAUTION MUST BE TAKEN WHEN WORKING WITH THE ENCLOSURE. IT IS RECOMMENDED THAT ALL WORK BE PERFORMED BY QUALIFIED ELECTRICAL PERSONNEL ONLY. NOTE: INITIAL START-UP SHOULD BE PERFORMED WITH NO-LOAD ON THE SYSTEM.

  • Page 23: Maintenance

    Scope This section contains preventive maintenance for the Power-Sure™ 700, electrical connection troubleshooting, checking power modules (SCR), voltage adjustments, and PCB card troubleshooting to assist the user with commu- nication and configuration connections. WARNING: Preventive Maintenance To ensure longer component life and trouble free operation, minor preventive maintenance procedures should be performed at regular intervals, recommended once every year.

  • Page 24: Power-Sure™ 700 Performance Checklist

    Power-Sure™ 700 — Three Phase Power Conditioners Power-Sure™ 700 Performance Checklist Company: ____________________________________________________________________________________ Model #:_________________________________________Serial #: ______________________________________ Customer Comments or Problems: ______________________________________________________________________________________________ Power Conditioner Environment (clean and dust free): Phase Rotation Correct (ABC): Yes__________ No__________ Electrically wired properly (ie., conductor sizing, breakers, grounding): ____________________________ Verify Input Voltage (see spec.
  • Page 25 Power-Sure™ 700 Performance Checklist Input/Output Voltage Checks (Adjust as needed): No Load Input A-B____________VAC B-C____________VAC A-C____________VAC Available Load Input A-B____________VAC B-C____________VAC A-C____________VAC Input/Output Current Checks (Balance as needed): Input A____________Amps B____________Amps C____________Amps Fans Operational: _________________________________________________________________________________________ Testing Shutdown Circuitry ie...REPO, Over/Under Voltage: _________________________________________________________________________________________ Comments: _________________________________________________________________________________________...

  • Page 26: Troubleshooting Guide

    5. No Output Voltage. WARNING: THERE ARE DANGEROUSLY HIGH VOLTAGES PRESENT WITHIN THE ENCLOSURE OF THE POWER SUPPLY SYSTEM. UNDER NO CIRCUMSTANCES SHOULD ANY PERSON REACH WITHIN THE ENCLOSURE OF THIS EQUIPMENT. ALL SERVICE TO THIS PIECE OF EQUIPMENT SHOULD BE PERFORMED BY QUALIFIED PERSONNEL ONLY.

  • Page 27: Step 1. Disassembling The Power Conditioners

    3.3.1 Step 1. Disassembling the Power Conditioners 1. Turn off the power to the conditioner at its source. 2. Turn off the input circuit breaker on the unit and the output circuit breakers to all loads. (Remove all loads from unit). 3.

  • Page 28: Test Wire Diagram

    Power-Sure™ 700 — Three Phase Power Conditioners NOTE: When checking the power module assembly, if more than one defective power module is present it will appear as if all the power modules are defective. The individual power module must be isolated from the power transformer: ◗...

  • Page 29: Check Control Card And Filter Card

    RE-CONNECT SEMI-CONDUCTOR FUSE, AND ALL WIRES AND FANS. DOUBLE CHECK THAT ALL CONNEC- TIONS ARE SECURE. NOTE: DO NOT CONNECT TB1, TB2, and TB3 CONNECTORS FROM THE CONTROL CARDS #49120/407415 YET! 3.5.1 Check Control Card and Filter Card 1. Verify input to the conditioner matches the units specification. Also verify correct control board #49120 / 407415 jumper setup.

  • Page 30: Final Testing And Adjustments

    Power-Sure™ 700 — Three Phase Power Conditioners FORMULA AC Input x 2.47 = Volts DC at TP2 480 (Nominal) Example: 475 Volts AC Input x 2.47 = 2.44 Volts DC at TP2 480 (Nominal) 8. After calculations are complete, place DC voltmeter on the 20 volt scale and check between TP2 and TP GND on control card.

  • Page 31: Unit Component Location Diagrams

    5. Turn the input circuit breaker off. 6. Connect customers equipment. 7. Energize system. 8. Repeat Step #4 and adjust as needed. 9. Be sure over/under detect is connected and if input breaker trips or there is no output voltage, re-calibrate the detect board or replace board if defective.

  • Page 32: Power-Sure™ 700 - 45-150Kva Major Components (Rear View)

    Power-Sure™ 700 — Three Phase Power Conditioners Figure 3-5: Power-Sure™ 700 — 45-150kVA Major Components (Rear View). MULTI-SHIELDED ISOLATION TRANSFORMER OUTPUT FILTERING INPUT TERMINAL PADS OUTPUT TERMINAL PADS REGULATOR ASSEMBLY 3 —10 COOLING FAN Maintenance SENSE CARD CONTROL CARD HEATSINK SNUBBER CARD SCR POWER MODULE SEMI-CONDUCTOR FUSES...

  • Page 33: Input Output Locations

    Figure 3-6: Power-Sure™ 700 — 225-300kVA Cable Connections, Input Output Locations. LIFT-OFF ACCESS PANEL EDGE FRAMING FOR SCREENING (18 GAGE .047 THICK STEEL) 36" CLEARANCE REQUIRED (THIS SIDE) METAL – LAYER 1 (1.47D X 1.47W , 120 THICK METAL (GALVANIZED STEEL – LAYER 2 (1.25D X 1.25W , 120 THICK LIFT-OFF...

  • Page 34: Scr Heat Sink Assemblies

    Power-Sure™ 700 — Three Phase Power Conditioners SCR Heat Sink Assemblies Figure 3-7: Power-Sure™ 700 — 10-30kVA SCR Heatsink Assembly. SEMI-CONDUCTOR FUSE SHUNT GATE CONNECTIONS G1 - 1 THROUGH G1 - 7, G2 - 1 THROUGH G2 - 7 (TYPICAL) FUSIBLE LINK 3 —12...

  • Page 35: Power-Sure™ 700 - 45-50Kva Scr Heatsink Assembly

    Installation and User Manual Figure 3-8: Power-Sure™ 700 — 45-50kVA SCR Heatsink Assembly. SEMI-CONDUCTOR FUSE CABLE TO TRANSFORMER SHUNT TAP WIRES FROM POWER TRANSFORMER GATE CONNECTIONS (K2-1 THROUGH K2-7 G1 - 1 THROUGH G1 - 7, CONNECTIONS, TYPICAL) G2 - 1 THROUGH G2 - 7 (TYPICAL) THERMAL SENSOR...

  • Page 36: Power-Sure™ 700 — 75-150Kva Scr Heatsink Assembly

    Power-Sure™ 700 — Three Phase Power Conditioners Figure 3-9: Power-Sure™ 700 — 75-150kVA SCR Heatsink Assembly. GATE CONNECTIONS G1 - 1 THROUGH G1 - 7, G2 - 1 THROUGH G2 - 7 (TYPICAL) FUSIBLE LINK (CONTINUOUS THROUGH EACH POWER MODULE) DIODE 3 —14 POWER MODULE...

  • Page 37: Power-Sure™ 700 — 225-300Kva Scr Heatsink Assembly

    Figure 3-10: Power-Sure™ 700 — 225-300kVA SCR Heatsink Assembly. GATE LEADS (TYPICAL) FUSIBLE LINK (CONTINUOUS THROUGH EACH POWER MODULE) THERMAL SENSOR DIODE Field Adjustments of Circuit Cards 3.9.1 Power-Sure™ 700 Control Card #49120/407415 WARNING: 86-108814-00 B01 ALL SERVICE TO THIS PIECE OF EQUIPMENT MUST BY PERFORMED BY QUALIFIED PERSONNEL.

  • Page 38: Power-Sure™ 700 Controller Card (Top View)

    Power-Sure™ 700 — Three Phase Power Conditioners CAUTION: THE CONTROL BOARD (#49120/407415) IS ELECTRICALLY REFERENCED TO HIGH VOLTAGE, NOT EARTH OR CHASSIS GROUND. EXTREME CARE MUST BE USED WHEN TAKING MEASUREMENTS ON THE CONTROL BOARD. ANY AC POWERED INSTRUMENTS MUST BE GROUND ISOLATED PRIOR TO TAKING MEASUREMENTS.

  • Page 39: Over/Under Voltage Detection Board #35867

    Example: NOTE: 7. After calculations are complete, place DC voltmeter on 20 volt scale and check between TP2 and TP GND on control card. Adjust pot P1 so meter reads DC level calculated in Step 6 for all 3 phases. NOTE: 8.

  • Page 40: 3.9.3.3 Delay Adjustment

    Power-Sure™ 700 — Three Phase Power Conditioners P1 will adjust the overvoltage set point. One turn on P1 will change the voltage level approximately 1 volt. Clockwise = Decrease Sensitivity. Counter-clockwise = Increase Sensitivity. 3.9.3.3 Delay Adjustment The delay adjustment can be adjusted for a minimum of 5 cycles to a maximum of 15 seconds. The standard set point is 6 seconds.

  • Page 41: Replacement Parts

    3.11 Replacement Parts Individual components are available upon request. Please contact MGE for specific part numbers and prices. See Section 3.7 in this manual for component location and description. When contacting MGE Service at 1-800-523-0142, please have the unit’s full model number and serial number for identification. 3.12 Part Numbers Table 3-1: Power-Sure™...
  • Page 42 Power-Sure™ 700 — Three Phase Power Conditioners Table 3-1: Power-Sure™ 700 Power Conditioners Part Numbers (Continued). Part Number TDL-010K-6 TDL-015K-6 TDL-025K-6 TDL-030K-6 TDL-045K-6 TDL-050K-6 TDL-075K-6 TDL-100K-6 TDL-125K-6 TDL-150K-6 TDL-225K-6 TDL-300K-6 TDN-010K-6 TDN-015K-6 TDN-025K-6 TDN-030K-6 TDN-045K-6 TDN-050K-6 TDN-075K-6 TDN-100K-6 TDN-125K-6 TDN-150K-6 TDN-225K-6 TDN-300K-6 TEL-010K-6...

  • Page 43: Appendices

    86-108814-00 B01 Appendices K1-7 G1-7 G2-7 K2-7 K1-6 G1-6 49(A) G2-6 48(A) K2-6 K1-5 47(A) G1-5 46(A) G2-5 K2-5 K1-4 G1-4 G2-4 K2-4 K1-3 G1-3 G2-3 K2-3 K1-2 G1-2 G2-2 K2-2 K1-1 58(A) G1-1 G2-1 57(A) K2-1 56(A) K1-7 G1-7 G2-7 K2-7 K1-6...
  • Page 44 K1-7 G1-7 G2-7 K2-7 K1-6 G1-6 G2-6 K2-6 K1-5 G1-5 G2-5 K2-5 K1-4 G1-4 G2-4 K2-4 K1-3 G1-3 G2-3 K2-3 K1-2 G1-2 G2-2 K2-2 K1-1 G1-1 G2-1 K2-1 K1-7 G1-7 G2-7 K2-7 K1-6 G1-6 G2-6 K2-6 K1-5 G1-5 G2-5 K2-5 K1-4 G1-4 G2-4...
  • Page 45 86-108814-00 B01 K1-7 G1-7 G2-7 K2-7 K1-6 G1-6 G2-6 K2-6 K1-5 G1-5 G2-5 K2-5 K1-4 G1-4 G2-4 K2-4 K1-3 G1-3 G2-3 K2-3 K1-2 G1-2 G2-2 K2-2 K1-1 G1-1 G2-1 K2-1 K1-7 G1-7 G2-7 K2-7 K1-6 G1-6 G2-6 K2-6 K1-5 G1-5 G2-5 K2-5 K1-4...
  • Page 46 Power-Sure™ 700 — Three Phase Power Conditioners (This page left blank intentionally) A —4 86-108814-00 B01...
  • Page 47 MGE and shall not be part of this or any other 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 conse- quential damages or for any other damages except as expressly stated herein.
  • Page 48 Technical questions? If you encounter a problem while following the instructions in this manual, or have question the operation, repair, or servicing of your equipment, please direct calls to MGE UPS SYSTEMS, INC. Customer Care Center or visit our web site www.mgeups.com for complete service information.
  • Page 52 . m g e u p s . c o m Contact MGE United States MGE UPS SYSTEMS 1660 Scenic Ave. Costa Mesa, CA 92626 Tel: (714) 557-1636 CCC: (800) 438-7373 Fax: (714) 557-9788 email: info@mgeups.com www: mgeups.com...

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