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

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

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3.5 to 21 kVA N+1
Inverter
Owner's Manual

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

  • Page 1 3.5 to 21 kVA N+1 Inverter Owner's Manual...
  • Page 2: Important Safety Instructions

    I M P O R TA N T S A F E T Y I N S T R U C T I O N S SAVE THESE INSTRUCTIONS This manual contains important instructions for all static inverters, that must be followed during installation, operation, and maintenance of the equipment. WARNING Opening enclosures expose hazardous voltages.
  • Page 3 WARNING To reduce the risk of fire or electric shock, install in a temperature and humidity controlled indoor area free of conductive contaminants. This equipment is intended only for installations in a RESTRICTED ACCESS LOCATION. ATTENTION Pour réduire le riske d'inccendie ou d'électrocution, installer dans une enciente intérieure contrôlée en température et humidité...
  • Page 4 3.5 to 21 kVA N+1 Inverter page ii...
  • Page 5 3.5 kVA to 21.5 kVA Inverter Owner's Manual For service call 1-800-523-0142 86-153460-01 03/02 Copyright © 2002 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...
  • Page 6: 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.
  • Page 7: Table Of Contents

    Owner’s Manual C o n t e n t s section description ........page Important Safety Instructions .
  • Page 8 3.5 to 21 kVA N+1 Inverter section description ........page Chapter II - Installation &...
  • Page 9 Owner’s Manual section description ........page Chapter IV - Theory of Operation Scope .
  • Page 10 3.5 to 21 kVA N+1 Inverter Figure Description ......... . .Page Dual Inverter and Waveform Diagram .
  • Page 11: How To Use This Manual

    Owner’s Manual 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 in the Glossary. To quickly find a specific topic, look in the Index. This manual uses Noteboxes to convey important information.
  • Page 12 3.5 to 21 kVA N+1 Inverter (This page left blank intentionally.) page x...
  • Page 13: Chapter I - Introduction

    Netzeingang angeschlossen wird. Scope This manual provides technical information for installation, operation, and maintenance of MGE UPS Systems’ modular inverter systems series ranging from 3.5 kVA to 21 kVA. Please read this manual thoroughly before installing and operating the system. Please retain this manual for future reference.
  • Page 14: Standard Product

    3.5 to 21 kVA N+1 Inverter locations where commercial AC power is not available. 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. See chapter 8, Theory of Operation, for detailed information on inverter characteristics.
  • Page 15: Electrical Specifications

    Owner’s Manual Table 1-2: Inverter Module Dimensions Inverter Module HEIGHT (in/cm) DEPTH (in/cm) WIDTH (in/cm) WEIGHT (lb/kg) 64004-9MSK1 5.18 / 13.3 15.12 / 38.85 15.76 / 40.5 46 / 20.44 Note: Weight: 1 six-mod receiver = 135 lbs. 1 UPS Module = 46 lbs. Total System Weight, 21 kVA system = 411 lbs.
  • Page 16: Power Factor

    3.5 to 21 kVA N+1 Inverter 1.3.4 Power Factor Rated kVA is available over a power factor range of 0.6 lagging to 0.6 leading at nominal voltage. Watt rating should not be exceeded. 1.3.5 Total Harmonic Distortion Less than 1% for linear load conditions, 3% maximum for crest factor loads up to 3:1.
  • Page 17: Remote Alarm

    Owner’s Manual The system measurement information is displayed on the LCD “Display” panel. Switch SW3 is pushed down (or up) to scroll the LCD’s screens for more information. Individual inverter 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.
  • Page 18: Mechanical Specification

    3.5 to 21 kVA N+1 Inverter Table 1-4: Alarm Connections J21 terminal block screw position --- MAJOR ALARM --- MAJOR ALARM --- No Major Alarm --- No Major Alarm --- Minor Alarm --- No Minor Alarm --- Utility Alarm --- No Utility Alarm --- “X”...
  • Page 19: Audible Noise

    Owner’s Manual 1.7.6 Audible Noise Less than 65 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. At nominal ambient (+23C) and 75% load, typical audible noise is 50 dBA in the ON-LINE mode, 56 dBA in the OFF-LINE mode.
  • Page 20 3.5 to 21 kVA N+1 Inverter (This page left blank intentionally.) page 1 — 8 Introduction...
  • Page 21: Chapter Ii - Installation & Operation

    The installation must comply with the requirements of the National Electrical Code (ANSI/NFPA 70, latest issue) and local codes as applicable. We strongly recommend contracting MGE UPS Systems for system start-up. Do not allow unqualified personnel to handle, install, or operate MGE UPS Systems static inverter systems.
  • Page 22: Mechanical Mounting

    3.5 to 21 kVA N+1 Inverter 2.2.0 Mechanical Mounting The equipment can be either mounted on a floor, or rack-mounted in a 19”, 23”, or 25” rack. Optional mounting bracket kits can be ordered for rack mounting in a 19” or 23” rack. Ordering information is as follows: All receivers and inverter power modules are shipped separately from the factory.
  • Page 23 Owner’s Manual Figure 2-1: Installation Drawing, 7 kVA Inverter System Installation & Operation page 2 — 3...
  • Page 24 3.5 to 21 kVA N+1 Inverter Figure 2-2: Front View, 7 kVA, System Component Description Microcontroller Communications Controller Power Switch Port Status LEDs WARNING: WARNING: Disconnect AC (Mains) and DC supply before removing this cover. Disconnect AC (Mains) and DC supply before removing this cover.
  • Page 25: Location

    Owner’s Manual 2.2.1 Location The equipment is designed for installation in a protected environment. Factors to be considered in selecting a location include ventilation, temperature, humidity, and accessibility. Install the unit in a clean, dry location with an unrestricted air flow. The equipment is cooled by forced air. Allow at least 6 inches of air space around the equipment for proper cooling.
  • Page 26: Connections

    3.5 to 21 kVA N+1 Inverter Figure 2-3: Static Switch Jumper Positions Suggested DC circuit breaker ratings: Inverter rating 3.5 kVA 7 kVA 10.5 kVA 14 kVA 17.5 kVA 21 kVA DC breaker rating 125A 250A 375A 500A 650A 750A 2.3.1.3 Connections...
  • Page 27: Ac Input/Output Voltage Selection

    Owner’s Manual to the lower terminal connection landing. Note that there is room for three lugs with two holes spaced one inch apart. Cables and terminal lugs are not furnished with the inverter and must be ordered separately for the 3.5 kVA to 145 kVA units.
  • Page 28: System Personalization

    3.5 to 21 kVA N+1 Inverter connector. Swing the “Display” panel back to its vertical position and install the two screws to hold the panel in position. Do not tighten the screws very much, since they will be removed again.
  • Page 29: Power-Up Procedure

    Owner’s Manual 2.3.5.1 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 (paragraph 4 of chapter 1 gives full details of LCD readout): Line 1: INV:...
  • Page 30 3.5 to 21 kVA N+1 Inverter (This page left blank intentionally.) page 2 — 10 Installation & Operation...
  • Page 31: Chapter Iii - Maintenance

    MGE UPS Systems static inverter system and its associated equipment. We strongly recommend a contract with MGE UPS Systems Electronics Customer Support Services for preventive and remedial maintenance.
  • Page 32: Air Intake Cleaning

    AC Fan Replacement Procedure Every five years, replace the two AC fans on the “Static Switch” front panel, (MGE UPS SYSTEMS part number 04- 22130). This is accomplish by removing all the DC and AC power to the unit by turning OFF the main AC and DC source circuit breakers.
  • Page 33: Replacement Parts

    Troubleshooting and Servicing Should you encounter a problem in the operation of the inverter and need MGE UPS 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 display and LED indicators on the “Display”...
  • Page 34: Ac Output Circuit Breaker

    750A 3.4.2.2 AC Output Circuit Breaker It is not required, but highly recommended. A power “Distribution” panel is available from MGE UPS Systems at a nominal cost. Order part number XXXXXXXXX, which will accommodate up to 24 single-pole circuit breakers, “Square-D”...
  • Page 35: Dual Half-Bridge Inverter

    Owner’s Manual 3.4.2.9 Dual Half-Bridge Inverters In or to provide more choices of output voltage, two identical half-bridge inverters are used to produce either 120VAC or 240VAC depending on parallel or series connection of the outputs. A network that consists of a coupled inductors and high frequency capacitors form a second-order low pass filter and is connected across at each inverter’s output for removing PWM signal.
  • Page 36 3.5 to 21 kVA N+1 Inverter (This page left blank intentionally.) page 3 — 6 Maintenance...
  • Page 37: Chapter Iv - Theory Of Operation

    Owner’s Manual T h e o r y o f O p e r a t i o n This chapter describes the theory of operation of the S4 inverter system. SCOPE The following is a brief description of the mechanical configuration and how the S4 inverter system functions. It is not intended to provide complete details of all of the circuits within the unit, but gives some details as to the function of each block.
  • Page 38: Block Diagram Of The 21 Kva Inverter System

    3.5 to 21 kVA N+1 Inverter Figure 4-1: Block Diagram of the 21 kVA Inverter System page 4 — 2 Theory of Operation...
  • Page 39: Alarm Relays

    Owner’s Manual Figure 4-2: Block Diagram of the S4 Inverter Power System Alarm Relays Located just to the left side of the “Controller” printed circuit board card cage is the “Alarm” relay board. This is a plug in circuit board with a terminal block located on the front of the card. Wire routing to the card will be through a knock out located near the DC input, AC input/output knock out landings.
  • Page 40: Dc Input Power Connections

    3.5 to 21 kVA N+1 Inverter DC Input Power Connections The “Receiver” cabinet also contains the DC distribution bus bar system, which is called a “DC Raceway”. It consists of a sheet metal enclosure with two copper bus bars, 1.5” wide, 0.125” thick. These bus bars have ELCON connectors attached to them.
  • Page 41: Block Diagram Of Power Module

    Owner’s Manual Figure 4-3: Block Diagram of Power Module Theory of Operation page 4 — 5...
  • Page 42: Voltage And Current Waveforms Of Dc/Dc Battery Booster

    3.5 to 21 kVA N+1 Inverter Figure 4-4: Voltage and Current Waveforms of DC/DC Battery Booster page 4 — 6 Theory of Operation...
  • Page 43: Power Module Configuration

    Owner’s Manual 4.7.1 Power Module Configuration The power module output current is approximately 10A/volt when it is configured for 120VAC, 5A/volt when config- ured for 240VAC. Figure 4-2 to 4-4 are block diagrams of the power module. DC power enters the module via bus bars and is applied to a small EMI filter (called a “PI filter”).
  • Page 44: Inverter

    3.5 to 21 kVA N+1 Inverter 4.7.1.2 Inverter The boost transformer has two secondary windings, 22 turns, center tapped at 11 turns. The two secondary windings, which are rectified, make two separate outputs of +212.5V and –212.5V each. These DC voltages are applied to a filter “Capacitor”...
  • Page 45: Average Current Mode

    Owner’s Manual 4.7.1.2.4 Average Current Mode If the inverter “current command” control signal can be made to control a current source (or sink), then the pole/zero associated with the output L-C filter becomes a first order system, that is, a current source discharging or charging a capacitor.
  • Page 46: Internal Power Supply

    3.5 to 21 kVA N+1 Inverter the two signals is not zero, then the inverter has failed. The inverter must be disconnected and shut down. Shut down is accomplished by opening the inverters output relay as quickly as possible, turning of the drive to the IGBTs, inhibiting the battery booster, and issue a signal to the “Controller”...
  • Page 47: Controller" Input Signals

    Owner’s Manual zero to +5V. The +2.495V is used as the reference for the LMC660 amplifiers, signal transformers, which are used to measure the AC input and load voltages, and AC current transformers. 4.8.1.1 “Controller” Input Signals The DC current sensor used to measure the battery current is “LEM” HTA types and require +15VDC, return, and –15VDC.
  • Page 48: Digital Inputs

    3.5 to 21 kVA N+1 Inverter Function Micro Input at Input at Input at Input at Notes: port 0.250V 0.500V 4.500V 4.750V I backfeed P0.0 V>+/-1V Ibat, battery current. P0.1 133.27 125.45 2.00 -5.72* HTA-100 No. modules installed. P0.2 See below No.
  • Page 49: High Voltage Drivers

    Owner’s Manual 4.8.1.7 High Voltage Drivers The processor PCB also has a high voltage transistor array (ULN7002), which is used to control the tri-colored “STATUS” LEDs and “alarm relays”. The LEDs are powered directly from the 48V input bus through dropping resistors.
  • Page 50: Static Switch Driver

    3.5 to 21 kVA N+1 Inverter 4.8.2.1 Static Switch Driver On the right-hand side panel of the “receiver” cabinet is the “Static Switch” gate driver printed circuit board. This board serves two functions. One, it has a 120/240VAC, 50/50Hz bias transformer mounted to it which provides the auxiliary 48VDC for operating the “Controller”...
  • Page 51 Owner’s Manual The output of this current transformer is clamped to a maximum of +/-1.1V by means of back-to-back diodes, which is in parallel with a high value burden resistor. This signal is supplied to the “Controller”. If back-feed current should be detected when the inverter is operating, the system will be shut down, that is, latched OFF.
  • Page 52 3.5 to 21 kVA N+1 Inverter (This page left blank intentionally.) page 4 — 16 Theory of Operation...
  • Page 53: Glossary

    Owner’s Manual G l o s s a r y Appendix A Symbols Definition/Meaning And/or. Plus or Minus. Number. °C Degree Celsius. °F Degree Fahrenheit. Ø Phase angle. Ohm; unit of resistance. ® Trade Mark. Second. AC or ac Alternating current, also implies root-mean-square (rms). Ambient Temp.
  • Page 54 3.5 to 21 kVA N+1 Inverter DC or dc Direct current. Digital Meter The LCD display on the front panel of inverter system. 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 55 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. Volt-amps, unit for apparent power measurement, equal V x I.

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