MGE UPS Systems EX 5 Installation And User Manual
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MGE UPS Systems EX 5 Installation And User Manual

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EX 5/7/11 RT Systems
Installation and User Manual

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  • Page 1 . m g e o p s . c o m EX 5/7/11 RT Systems Installation and User Manual...

  • Page 3: Revision History

    B 0 1 E C N # : 0 0 5 0 2 0 1 0 / 2 0 0 6 Copyright © 2007 MGE Office Protection Systems All rights reserved. Printed in U.S.A. MGE Office Protection Systems 13 Whatney, Suite #101...
  • Page 4 EX 5/7/11 RT Systems (This page left blank intentionally) 86-86000-00 B01...

  • Page 5: Table Of Contents

    Rear Panel Components .......1 — 6 1.3.1 Power Module EX 5/7/11 RT ......1 — 6 1.3.2 Battery Module EXB 5/7/11RT With Remote Emergency Power Off (REPO) Function .
  • Page 6 Unpacking and Parts Check ......2 — 1 Contents of Standard EX 5/7/11 RT Systems ....2 — 2 Installation in Tower Configuration .
  • Page 7 Installation and User Manual section description ......... . .page Section 4 Maintenance Scope .
  • Page 8 1-12: CLA Module Contents and Connections......1 — 12 2-1: Contents of EX 5/7/11 RT Power Module......2 — 2 2-2: Contents of EXB 5/7/11RT Battery Module.
  • Page 9 After-Sales Support .........4 — 2 5-1: EX 5/7/11 RT Voltages and Frequency Characteristics ....5 — 1 5-2: Back-up Time (in minutes) .

  • Page 10: Important Safety Instructions

    EX 5/7/11 RT Systems IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS. This manual contains important instructions that should be followed during installation and maintenance of the UPS and batteries. EX 5/7/11 RT models that are covered in this manual are intended for installation in an environment within 0 to 40°C, free of conductive contaminant.

  • Page 11: Caution: Safety Of Persons

    UPS recycling at the end of service life: MGE Office Protection Systems undertakes to recycle, by certified companies and in compliance with all appli- cable regulations, all UPS products recovered at the end of their service life (contact your MGE Office Protection Systems branch office).

  • Page 12: Caution: Record All Serial Numbers

    EX 5/7/11 RT Systems CAUTION: Record All Serial Numbers! RECORD ALL SERIAL NUMBERS FOR EX 5/7/11 RT AND ACCESSORIES. THESE SERIAL NUMBERS WILL BE REQUIRED IF YOUR SYSTEM NEEDS SERVICE. KEEP THIS MANUAL IN A PLACE WHERE YOU CAN REFERENCE THE SERIAL...

  • Page 13: Symbol Usage

    Office Protection Systems representative for detailed information on these options. Setup and Installation Setup and Installation guides the user through tools and equipment required for connecting the EX 5/7/11 RT and battery installation or replacement. Included are assembly instructions, power cable connections with wire diagrams for configuring the product to hardware specifications.
  • Page 14 EX 5/7/11 RT Systems (This page left blank intentionally) 86-86000-00 B01...

  • Page 15: Introduction

    MGE Office Protection Systems products, we invite you to visit our website at www.mgeops.com. Scope Introduction is a general description of system configurations of the EX 5/7/11 RT, and its mechanical electrical characteristics. Additionally there is an optional accessories section with important information on MGE Office Protection Systems products that will enhance the performance of the EX 5/7/11 RT.

  • Page 16: Optional Accessories (See Section 1.5 For Description)

    EX 5/7/11 RT Systems Table 1-2: Optional Accessories (See Section 1.5 for description) Part Number Description 86001 Rail Kit for Power Module EX 5/7/11 RT 86002 Rail Kit for Battery/Transformer/CLA Module 86005 Battery Integration Kit with Casters 86006 Battery Extension Cable Kit...

  • Page 17: System Electrical Characteristics

    Installation and User Manual System Electrical Characteristics Table 1-3: UPS Characteristics System Ratings. UPS Characteristics MAIN 1 (Normal AC Source) default Input Current (A) Input Input Output Output Power Inrush Voltage Breaker Voltage Current Rating Current Online Bypass (VAC) (VAC) 5 kVA 21.6 19.25...

  • Page 18: Standard Configuration

    Battery Output Voltage 240VDC 240VDC Standard Configuration The EX 5/7/11 RT systems can be set up in tower or rack configurations. 1.2.1 Tower Configuration Figure 1-1: Tower Configuration with Power Module, Battery Module, and optional Transformer Module. E X B R...

  • Page 19: Rack Configuration

    Table 1-6: System Dimensions and Weights. Model Dimensions (HxWxD) Weights (3U) 5.16” x 17.49” x 26.25” EX 5/7RT Power Module 49.6 lbs (22.5 kg) (131 x 444 x 667mm) (3U) 5.16” x 17.49” x 26.25” EX 11RT Power Module 60.6 lbs (27.6 kg) (131 x 444 x 667mm) (3U) 5.16”...

  • Page 20: Rear Panel Components

    EX 5/7/11 RT Systems Rear Panel Components 1.3.1 Power Module EX 5/7/11 RT Figure 1-3: Rear panel of the Power Module. Slot for optional communication cards. Dry (relay) contacts Communication Port. Remote Emergency Power Off (REPO) function. (See Section 2.6.) Connector for automatic detection of Battery Module(s).

  • Page 21: Ex Rt Transformer Module

    Installation and User Manual 1.3.3 EX RT Transformer Module Figure 1-5: Rear Panel of the optional Transformer Module. (PN 86211/86311) Load 3: 1 NEMA L6-30R, 208Vac Load 2: 4 NEMA 5-15/20R, 120Vac Load 4: 4 NEMA 5-15/20R, 120Vac Load 3 Circuit Breaker Load 4 Circuit Breaker Load 2 Circuit Breaker Main Output Circuit Breaker...

  • Page 22: Optional Accessories

    EX 5/7/11 RT Systems Optional Accessories Optional Accessories describes the options available for upgrades and enhancement of the EX 5/7/11 RT systems. Detailed installation of the unit is described in following sections. To ensure a successful installation, all procedures should be followed in their correct sequence. Note that any unauthorized installation may cause damage to the UPS(s) and void the MGE Office Protection Systems warranty.

  • Page 23: Multiple Battery Module Back-Up Time At Full Load

    1.5.3 Multiple Battery Module Back-up Time at Full Load Standard EX 5/7/11 RT systems (one Power Module and one Battery Module), offers a standard back-up time of 5 to 12 minutes at full load. To increase back-up time, it is possible to connect up to 5 additional Battery Modules to the standard system. See Section 2.8 for connections between standard system and Battery Module (EXB 5/7/11RT)

  • Page 24: Battery Integration Kit With Casters

    EX 5/7/11 RT Systems 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. Modules not included.

  • Page 25: Transformer Module - For Use With Ex 5/7/11 Rt Power Module

    EX 5/7/11 RT Systems Installation and User Manual 1.5.7 Transformer Module - For use with EX 5/7/11 RT Power Module This module provides isolated 120/208/240VAC outputs. Figure 1-11: Typical Transformer Module Contents and Connections. EX RT Transformer Module Box Contents...

  • Page 26: Cla Charger Module

    EX 5/7/11 RT Systems 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 5/7/11 RT via the CLA Module. IMPORTANT The CLA can not be used to charge the Battery Module (EXB). It is designed to charge the customer provided high power battery cabinet.

  • Page 27: Setup And Installation

    Unpacking and Parts Check Once the EX 5/7/11 RT systems has been inspected and received from the shipping courier, the unit should be moved to a position as close to the final installation location as possible. See Figures 2-1, on Page 2 — 2.

  • Page 28: Contents Of Standard Ex 5/7/11 Rt Systems

    EX 5/7/11 RT Systems Contents of Standard EX 5/7/11 RT Systems Contents of EX 5/7/11 RT Power Module: (PN 86215 / 86216 / 86217) EX 5/7/11 RT Power Module. Two sets of tower stands. RS232 communication cable. Product documentation. Input/Output Box. (PN 86009 for EX 5/7RT; 86010 for EX 11RT) Solution-Pac 2 CD.

  • Page 29: Contents Of Exb 5/7/11Rt Battery Module

    Installation and User Manual Contents of EXB 5/7/11RT Battery Module: (PN 86207 /86209) Stabilizer Bracket and hardware. EXB 5/7/11RT. Tower stand expanders. Battery Power cable. Battery/EX RT Transformer/CLA Module rail kit, PN 86002. Battery detection cable. EXB Documentation. Bezel hex drive. Figure 2-2: Contents of EXB 5/7/11RT Battery Module.

  • Page 30: Installation In Tower Configuration

    EX 5/7/11 RT Systems Installation in Tower Configuration Follow the numerical sequence to assemble tower stands and tower stand expanders, shown in Figure 2-3. Figure 2-3: Tower Configuration of Standard System and Optional Transformer Module. Tower Configuration with Standard System...

  • Page 31: Installation In Rack Mounting Configuration

    Installation and User Manual Installation in Rack Mounting Configuration 2.4.1 Adjustment of Front Panel Logo and Control Panel for Rack Orientation. NOTE If system includes the Transformer Module, we recommend to mount the Battery Module on the bottom, then mount the Power Module above the Battery Module and mount the Transformer Module on top for optimum stability.

  • Page 32: Prepare Battery Module For Rack Mounting

    EX 5/7/11 RT Systems 2.4.2 Prepare Battery Module for Rack Mounting IMPORTANT This step requires two people. The Battery Module is very heavy (151 lbs.). To ease its rack mounting, you can remove the battery pack from the Battery Module, as explained below.

  • Page 33: Power, Battery, Transformer, And Cla Charger Module Rack Mounting

    Installation and User Manual 2.4.3 Power, Battery, Transformer, 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. (For this step, it is possible to adjust the position of both front mounting brackets.) 2.

  • Page 34: Input/Output Box Bracket System

    EX 5/7/11 RT Systems 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.

  • Page 35: Communication Ports

    EX 5/7/11 RT. The EX 5/7/11 RT systems can now communicate with Solution Pac 2 for power management. UPS configuration settings are done by Personal Solution Pac for Windows or through the LCD screen on the front panel (See Section 3.2).

  • Page 36: Connecting The Dry (Relay) Contact Communication Port

    EX 5/7/11 RT Systems 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.
  • Page 37 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.

  • Page 38: Remote Emergency Power Off (Repo) Communication Port

    EX 5/7/11 RT Systems 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. To shutdown the entire system completely in case of emergency: ◗...

  • Page 39: System Connections

    Bypass AC source 200/208/220/230/240Vac 200/208/220/230/240Vac Normal AC source 200/208/220/230/240Vac Terminal tightening torque: – 18 lb-in. for EX 5/7RT Power Module – 35 lb-in. for EX 11RT Power Module Terminal block capacity: - Max. 4AWG (EX 11RT) Jumper - Max. 6AWG (EX 5/7RT) (see note) ◗...

  • Page 40: Normal Ac Input And Output Cables Installation

    EX 5/7/11 RT Systems 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.

  • Page 41: Connecting Ex Rt Transformer Module

    Figure 2-13: View of EX RT Transformer Module connected downstream for 120/208/240 Vac outputs (shown with one EXB). BATTERY MODULE EXB 5/7/11 RT POWER MODULE EX 5/7/11 RT Transformer Module I/O Box TRANSFORMER MODULE EX RT AC Input from AC Output to Load...

  • Page 42: Connections With Separate Normal And Bypass Ac Sources (2 Mains)

    EX 5/7/11 RT Systems 2.7.3 Connections with Separate Normal and Bypass AC Sources (2 Mains) CAUTION: This connection requires isolation Transformer Module. Please visit our web site www.mgeops.com or call (800) 279-7776. Figure 2-14: Normal AC and Bypass AC inputs, Output Cables Installation, and Simplified Connection Diagram.

  • Page 43: System Connections As Frequency Converter (Without Bypass Ac Source)

    Installation and User Manual 2.7.4 System Connections as Frequency Converter (without Bypass AC source) Figure 2-15: Accessing Terminal Blocks for Input and Output Power Cables. CAUTION: Always connect the earth ground wire first. 1. Remove the cover plate under the I/O Box. OF F Remove the jumper connecting L3 and L1.

  • Page 44: Connection Of Battery Module Exb

    EX 5/7/11 RT Systems 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 of the Power and Battery Modules. 3. Connect the battery detection cable...

  • Page 45: Connection Of Optional Cla Module

    Installation and User Manual 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. ◗...
  • Page 46 EX 5/7/11 RT Systems (This page left blank intentionally) 86-86000-00 B01 2 — 20...

  • Page 47: Operation

    Operation describes EX 5/7/11 RT systems characteristics of indicators and controls, modes and specifications and theory of operating the EX 5/7/11 RT. The user procedures include performing software programming that will maintain smooth performance. Refer to Figure 1.6 for descriptions of circled numbers.

  • Page 48: Ups Personalization

    If specific settings are required, it is recommended to enter the UPS personalization mode at this stage. It is possible to enter this mode through the front panel buttons or the Solution-Pac 2 software for Windows included in the MGE Office Protection Systems Solution-Pac 2 CD-ROM. 3.2.1 Accessing personalization with front panel buttons ◗...

  • Page 49: Configuration Used To Provide Cascade Redundancy To Critical Loads

    Installation and User Manual Table 3-1: Local Settings. Display Factory setting Options Language English French, Spanish, German, Italian Date/time format International Date/time change (DD-MM-YYYY/HH:MM) MM-DD-YYYY/HH:MM adjustable Audible alarm Quick beeps Slow beeps Table 3-2: Output Features. Display Factory setting Options Comments Output voltage 208 Volts AC (***)

  • Page 50: On/Off Features

    EX 5/7/11 RT Systems Table 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.

  • Page 51: Information Technology It Network And Industrial Operating Modes

    Installation and User Manual Information Technology IT Network and Industrial Operating Modes Table 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. Same as IT Network mode, but AC source in tolerance.

  • Page 52: Ups Personalization Through External Software

    EX 5/7/11 RT Systems 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.exe ◗...

  • Page 53: Operating Modes

    Installation and User Manual Operating Modes 3.4.1 Normal (Double Conversion) Mode Figure 3-4: Normal (Double Conversion) Mode. This is the standard operating mode, set by the factory. Two possible cases. 1. If Normal AC source available: LOAD LEVEL 4kW / 5 kVA LED is ON.

  • Page 54: Eco Mode

    EX 5/7/11 RT Systems 3.4.2 ECO Mode Figure 3-5: ECO Mode Display. The main advantage of the ECO mode is that it reduces the consumption of electrical power by not running in the online mode. When this mode is selected, the system works as an offline UPS system, powered by Bypass source if Bypass source is inside user’s defined range.

  • Page 55: Operation On Battery Power

    Installation and User Manual Operation on Battery Power Figure 3-6: Transfer, Threshold and End of back-up time. 3.5.1 Transfer to Battery Power The load continues to be protected by the UPS when the Normal AC source is not available. Power is supplied by the battery.

  • Page 56: Return Of Normal Ac Source

    EX 5/7/11 RT Systems 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). Shutdown Figure 3-7: Shutdown Display, Circuit Breaker, and AC Source Switch.

  • Page 57: Maintenance

    If any of LEDs is on, there is an operating anomaly or an alarm. ◗ Use "scroll up" or "scroll down" function button to reset the audible alarm. Table 4-1: Troubleshooting Not Requiring MGE Office Protection Systems After-Sales Support. Symptoms Indication Correction...

  • Page 58: After-Sales Support

    EX 5/7/11 RT Systems Table 4-2: Troubleshooting Requiring MGE Office Protection Systems After-Sales Support. Symptoms Indication Correction are on, Internal fault Please visit www.mgeops.com Bypass AC Source is present and transfer of load or call (800) 279-7776 for technical and audible alarm is on.

  • Page 59: Hot Swapping The Power Module

    Installation and User Manual Hot Swapping the Power Module This operation can be performed without interrupting the load. Figure 4-1: Disconnecting the Power Module. 1. Stop the system with the OFF button (press more than 3 seconds). System is now powered by Bypass AC source.

  • Page 60: Re-Connecting The Power Module

    EX 5/7/11 RT Systems Re-Connecting the Power Module This operation can be performed without interrupting the load. Figure 4-2: Reconnect the Power Module. 1. Secure the Input/Output box using the three screws. 2. Reconnect the cables to the Power Module.

  • Page 61: Hot Swapping The Battery Module

    Installation and User Manual 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. In case of doubt, please refer to our web site at www.mgeops.com or call (800) 279-7776.
  • Page 62 EX 5/7/11 RT Systems (This page left blank intentionally) 86-86000-00 B01 4 — 6...

  • Page 63: Appendix

    Appendix Electrical Specifications Electrical and Mechanical specifications for the EX 5/7/11 RT. System Input/Output Power Ratings Table 5-1: EX 5/7/11 RT Voltages and Frequency Characteristics. Source Voltage Frequency Normal AC Source 156 to 280 VAC 40 to 70 Hz Bypass AC Source...

  • Page 64: System Back-Up Characteristics

    Std + 3 EXB Std + 4 EXB Std + 5 EXB 1220 System Short Circuit Protection Short circuit current provided by EX 5/7/11 RT in normal or battery mode: EX 5/7RT 110A for 80ms EX 11RT 150A for 80ms...
  • Page 65 Installation and User Manual Table 5-3: Battery Recharge Time to Recover 90% of the Rated Back-Up Time After Discharge at Full Load. Configuration for Configuration for Configuration for 2 hours back-up time 4 hours back-up time 8 hours back-up time EX 5RT 7 hours 15 hours...

  • Page 66: Heat Rejection

    EX 5/7/11 RT Systems Table 5-7: Efficiency on ECO Mode (All Kinds of Load) and Batteries Fully Charged. kVA / kW 100% Output load percentage Output: 220 / 230 / 240 Volts 5kVA / 4kWatts Output: 200 / 208 / 250 Volts...

  • Page 67: Technical Support And Product Services

    Scheduling Field Service Engineer Support Scheduling of the MGE Office Protection Systems Field Service Engineers typically should be done 7 to 10 days before they are required on-site. If the startup of the UPS is critical to maintaining your schedule, please contact MGE Office Protection Systems, to insure a safe installation and start-up that will maintain the MGE Office Protection Systems warranty and insure smooth performance.
  • Page 69 Glossary Term used 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. AC or ac Alternating current, also implies root-mean-square (rms). Ambient Temp.
  • Page 70 EX 5/7/11 RT Systems 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.
  • Page 71 Installation and User Manual OSHA Occupational Safety and Health Agency. Printed circuit assembly. Printed circuit board. Part number. Pulse Width Modulation. RCD Load Load consists of resistor, capacitor and diode. A computer with switched mode power supply is considered a RCD load. RL Load Load consists of resistor, and inductor.
  • Page 72 EX 5/7/11 RT Systems (This page left blank intentionally) 86-86000-00 B01 G — 4...

  • Page 73: Whatney, Suite #101 Irvine, Ca

    A free copy of this document may be downloaded from the proprietary MGE Office Protection Systems Rep Web site. Please contact your MGE Office Protection Systems Representative for assistance.
  • Page 76 . m g e o p s . c o m Contact MGE Office Protection Systems United States MGE Office Protection Systems 13 Whatney, Suite #101 Irvine, CA 92618 (949) 268-2800 www.mgeops.com 1 3 W h a t n e y, S u i t e # 1 0 1 , I r v i n e , C a l i f o r n i a 9 2 6 1 8 • w w w. m g e o p s . c o m...

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