MGE UPS Systems EXL 1000 User Manual
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MGE UPS Systems EXL 1000 User Manual

MGE UPS Systems EXL 1000 User Manual

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EXL 1000
Uninterruptible
Power System
Installation and
User's Guide

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Summary of Contents for MGE UPS Systems EXL 1000

  • Page 1 EXL 1000 Uninterruptible Power System Installation and User’s Guide...

  • Page 2: Important Safety Instruction

    Input power cables and output power cables for 7.5 kVA and 10 kVA models shall be rated for 6 AWG, 75°C or 6 AWG, 90°C copper wire. The EXL 1000 series UPS is intended for installation in a temperature controlled, indoor area free of conductive conta- minants.
  • Page 3 Operating temperature - 0° - 30°C at rated output. 40°C for 8 hours max. WARNING High voltages are present inside the EXL 1000 system. Any servicing requiring removal of the protective covers may be undertaken only by qualified personnel certified by MGE UPS Systems.
  • Page 4 EXL 1000 Uninterruptible Power System NOTE As standards, specifications and designs are subject to change, please ask for confirmation of the information given in this publication. This manual is a controlled document. Pages should not be removed individually from this binder.
  • Page 5 Uninterruptible Power System Installation and User’ s Guide For service call 1-800-438-7373 86-891000-00 C01 06/98 Copyright © 1997 MGE UPS Systems, Inc.. All rights reserved. Printed in U.S.A. MGE UPS Systems 1660 Scenic Avenue Costa Mesa, CA 92626 (714) 557-1636...
  • Page 6 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 24 months from the date of purchase.

  • Page 7: Table Of Contents

    3.2 ....Checks before Start-up 3 — 5 3.3 ....Powering up the EXL 1000 3 — 6 3.4 .
  • Page 8 EXL 1000 Uninterruptible Power System Maintenance and Service 5.0 ....Scope 5 — 1 5.1 ....User Preventive Maintenance 5 —...
  • Page 9 1-2 ....EXL 1000 5kVA front and rear view 1 — 5 1-3 ....EXL 1000 7.5 & 10 kVA front and rear view 1 — 5 1-4 .
  • Page 10 EXL 1000 Uninterruptible Power System figure description page number 3-13 ....Indicators during normal operation 3 — 7 3-14 ....Diagram of normal operation on utility power 3 —...
  • Page 11 Installation and User’s Manual Tables table description page number 1-1 ....Model and Part numbers for installation of 5 kVA, 7.5kVA and 10kVA 1 — 2 2-1 .

  • Page 12: How To Use This Manual

    EXL 1000 Uninterruptible Power System This manual has been designed to provide you with all the information you need to install and use your EXL 1000 UPS system. How to use this manual This manual is designed for ease of use and easy location of information.

  • Page 13: Scope

    Introduction Scope This manual provides technical information required for operation and maintenance of the EXL 1000 series uninter- ruptible power system (UPS). Please read this manual before operating the EXL 1000 equipment. Please retain this manual for future reference. The manual is divided into seven100 sections: Section I —...

  • Page 14: Model And Part Numbers

    EXL 1000 Uninterruptible Power System A Glossary in the rear of this manual provides definitions of terms used within the text. General Description The EXL1000 series are a family of Uninterruptible Power Supplies (UPS) designed for safe reliable VAC backup power for the computer room, office or industrial environments.
  • Page 15 Installation and User’s manual module which powers the inverter module which powers a user’s output load. This happens only when the AC input fails, is out of tolorance or is removed. 5. Inverter - This power module converts the + and - 385Vdc output from the chopper to 208 or 240VAC line to line which continually outputs and powers the user’s load.

  • Page 16: Configuration

    EXL 1000 Uninterruptible Power System Figure I d e n t i f i c a t i o n P l a t e PULSAR EXL 1000 Article - Article - Artikel 6762690 N Série - Serial Number - Artikel...
  • Page 17 Installation and User’s Manual Figure E X L 1 0 0 0 5 k VA f ro n t a n d r e a r v i ew Basic control and Location of optional communications ports indication panel Diagnostics and configuration connector Special command and fau lt...
  • Page 18 EXL 1000 Uninterruptible Power System Figure F u n c t i o n a l d i a g r a m "static bypass" module AC input load Input circuit breaker "manual maintenance bypass" switch Rectifier module Inverter module...

  • Page 19: Storage

    IMPORTANT The battery is of the sealed type. Battery storage or prolonged shutdown of EXL 1000 should never exceed 6 months at 68°F (20°C) without recharging, for a battery initially at 100% charge. Battery recharge requires system start-up. The battery warranty is void if the 6 month recharge interval is not respected.
  • Page 20 EXL 1000 Uninterruptible Power System Figure U n p a ck i n g t h e E X L 1 0 0 0 U P S remove ramp for 7.5 & 10 kVA UPS ramp ramp for 5kVA UPS...
  • Page 21 Installation and User’s manual Figure R e m ov e s t a b i l i z i n g m a t e r i a l f ro m u n d e r E X L 1 0 0 0 U P S Figure U s e s u p p l i e d r a m p t o b r i n g E X L 1 0 0 0 o f f o f s h i p p i n g b a s e ramp (7.5/10kVA)

  • Page 22: General

    Additional cabinets (extended battery, distribution/ transformer, etc.) must be placed to the right of EXL 1000. If the above installation conditions are not respected, maintenance and servicing of the unit may require system shutdown. 2 — 4 Installation...

  • Page 23: Special Precautions

    10 kVA must be 6 AWG 75°C minimum. Cables must be enclosed in a .75 inch flexible conduit. Cables should be suffi- ciently long to enable forward movement of EXL 1000 without disconnection. Allow an extra 5 feet (1.5 meters) slack in the cables.
  • Page 24 EXL 1000 Uninterruptible Power System Connection sequence: • Remove maintenance bypass switch knob using a narrow flathead screwdriver (7.5 & 10 kVA models only). • Remove the conduit landing cover panel that is secured with six torx screws. • Connect flexible conduit to conduit landing.
  • Page 25 Installation and User’s Manual Figure R e m ova l o f c o n d u i t l a n d i n g c ov e r p a n e l ( 5 k VA ) Figure C a b l e c o n n e c t i o n s ( 5 k VA ) detail of connection...
  • Page 26 EXL 1000 Uninterruptible Power System Figure R e m ova l o f m a i n t e n a n c e by p a s s sw i t c h k n o b a n d c o n d u i t l a n d i n g c ov e r p a n e l ( 7 .

  • Page 27: Controls And Indicators

    Operation Controls and EXL 1000 operating controls include basic controls and indicators (figure 3-1), concerning the overall operating indicators status of the UPS and the special command and diagnostic display panel (figure 3-10), which includes specific controls and a 2-digit display for the UPS fault numbers. These numbers provide UPS diagnostics.
  • Page 28 "load protected" light "inverter on" button "inverter off" button The “Load protected” LED indicates that the EXL 1000 is operating normally. The load is supplied by the inverter output. This LED also goes on during normal start-up of EXL 1000.
  • Page 29 Installation and User’s manual The “Fault” LED indicates an operating fault or an environment fault. However, the load continues to be supplied by the inverter. Figure “ Fa u l t ” L E D + – “Fault” LED The “Load Not Protected” LED indicates that the load is supplied through the "static bypass"...

  • Page 30: Controls And Diagnostic Display

    EXL 1000 Uninterruptible Power System The grey “inverter off” button is used to stop the inverter. Figure “ I nv e r t e r O f f ” bu t t o n + – “Inverter off” button 3.1.2 Controls and The controls and diagnostics display panel (figure 3-10)

  • Page 31: Checks Before Start-Up

    Check that there is a minimum of 4 inches (100mm) clearance at the back for ventilation • Check that the EXL 1000 no longer rests on its 4 wheels (leveling screws in place) • Check that the load-circuit circuit breakers (where applicable) are in the off (O) position.

  • Page 32: Manual Inverter Start-Up

    EXL 1000 Uninterruptible Power System Powering up the First put the input circuit breaker in the “on” position, then put the battery circuit breaker in the "on" position. The audible EXL 1000 alarm will sound and the green “load protected” LED will light.

  • Page 33: Powering Down The Inverter

    Installation and User’s manual Powering down Powering down the EXL 1000 for long periods is not recommended because the battery should remain charged. the inverter However, to carry out a power down, proceed as follows: • Shutdown the inverter (section 3.5) •...

  • Page 34: Operation On Battery Power

    AC input load rectifier inverter battery charger Battery duration EXL 1000 has a battery monitoring function that calculates remaining backup time. This function implemented with a communications option. A low battery shutdown warning signal is available via the standard communication connector for remote indications. It warns the user of upcoming battery shutdown at a user- determined level of remaining power.

  • Page 35: Return Of Ac Input Power

    If the end of battery backup power was not reached when the AC input power failure ends or power returns to within AC input power tolerances; EXL 1000 returns to normal operating status where the inverter will receive power from the rectifier and not the battery.

  • Page 36: Alarms

    1.05 1.1 3.13 Alarms The status of the EXL 1000 can be determined by the status LEDs and the audible alarm (see section 3.14). Any state other than normal operation (green “load protected” LED on) is considered a fault by the diagnostics system.

  • Page 37: Diagnostics Display Messages

    Following is a list of the numeric messages codes and their meanings. Figure 3-19 is a diagram of the EXL 1000’s major components and shows which subsystems are responsible or affected by various fault codes. battery circuit breaker in "off" position indicates that the battery circuit is open (battery circuit breaker is in "off"...
  • Page 38 EXL 1000 Uninterruptible Power System inverter overtemperature indicates overheating inside the UPS; check that the EXL 1000 ventilation system is working and that the ambient temperature is within tolerances (see "appendices"). inverter overload indicates an overload when the load is being supplied via the inverter.
  • Page 39 Reduce the load internal communication fault indicates an EXL 1000 internal fault; contact the after-sales support department internal communication self-test fault see fault "71". CPU board self-test fault see fault "71".

  • Page 40: Manual Bypass

    The TEST 1 and TEST 2 positions are reserved for the after-sales sup- port personnel. Leave the switch set to the "BYPASS" position until the arrival of the after-sales support personnel. Use of the switch other than as indicated above may damage EXL 1000 and void the warranty. 3 — 14...

  • Page 41: Standard Functions

    Communication Standard Functions The communication connector, positioned on the back for EXL 1000 5/7.5/10kVA, supplies the following information: • operation on the "static bypass". • low battery shutdown warning. • load supplied by the inverter. • operation on battery power.

  • Page 42: Options

    AC input source or the battery. The inverter shuts down after a two minute delay. Options Three options may be used simultaneously on the EXL 1000, thus enabling communication with a wide number of computers and control devices.
  • Page 43 More complete information on the U-Talk option can be found in chapter 6 of this manual. JBUS/RS232 and JBUS/RS485 These options enable remote monitoring of the EXL 1000. Like the Monitor Plus and U-Talk options, this option can be used with the battery monitoring function to provide...
  • Page 44 EXL 1000 Uninterruptible Power System (this page left blank intentionally) 4 — 4 Communication 86-891000-00...

  • Page 45: Certified Mge Representatives

    However, this chapter indicates important procedures to ensure continuous and correct operation. WARNING High voltages are present inside the EXL 1000 system. Any servicing requiring removal of the protective covers may be undertaken only by qualified personnel certified by MGE UPS Systems.

  • Page 46: Environmental Protection

    Contact your MGE UPS Systems distributor for the list of courses offered. 5.2.5 Maintenance Your MGE UPS Systems contact can supply you with the catalogue of maintenance contracts that indicate how you Contracts can transfer responsibility for maintenance to qualified technicians always on call.

  • Page 47: Battery Cabinet For An

    24 minutes or up to 40 minutes for the 5 kVA model, by the addition of an optional auxiliary battery cabinet. If EXL 1000 was not factory-set for the additional cabinets, the new configuration must be entered by an MGE UPS Systems after-sales support technician.

  • Page 48: At Rated Output Power

    • "manual bypass" switch set to the "NORMAL" position Position the battery cabinet on the right side of EXL 1000. Connect the terminal block in the battery cabinet to the XR3 terminal block in EXL 1000 as follows: •...
  • Page 49 C o n n e c t i o n o f a n a d d i t i o n a l b a t t e r y c a b i n e t ( 7 . 5 & 1 0 k VA M o d e l s ) connection terminal blocks of EXL 1000 7.5 and 10 kVA battery cabinet terminal block...

  • Page 50: Shunt Trip Connection

    After the EPO function is activated, the UPS output remains live for approximately 3 seconds. Battery circuit To accomodate the EPO function, the EXL 1000 UPS and battery cabinets come equipped with battery circuit breakers breaker shunt trip with shunt trip mechanisms. By applying 24 Vdc or 24 VAC...

  • Page 51: Exl 1050, Exl 1075 And Exl 1100

    C o n n e c t i o n d i a g r a m fo r b a t t e r y c i rc u i t b r e a k e r s h u n t t r i p o n t e r m i n a l b l o ck X R 3 EXL 1000 not used...
  • Page 52 EXL 1000 Uninterruptible Power System (this page left blank intentionally) 6 — 6 Options 86-891000-00...

  • Page 53: Safety Recommendation

    U-Talk Introduction This chapter describes all the information you need to install and use your EXL 1000 U-TALK communications system. If you have purchased the UPS Manager 3.0 option, this chapter will give you the information required to install your board (ignore the "EXL 1000 U-TALK protocol"...

  • Page 54: Installation Of The U-Talk Board 7

    Two torque screws hold each board or rear cover on. Next, insert the RS232 board into grooves. The EXL 1000 UPS can be equipped with up to three optional boards. It is immaterial which board is in which slot.

  • Page 55: Description Of Rs232 Board 7

    C l o s e - u p o f f i g u r e 7 - 2 , s e c t i o n A 7.3.1 Function The RS232 communications board enables data concerning EXL 1000’s operating status to be sent to a computer. The system provides a communications channel with an RS232 interface. 7.3.2...

  • Page 56: Ups Manager Software

    EXL 1000 Uninterruptible Power System Configuration for When using UPS Manager software, and unless otherwise indicated in the software instruction manual, check that the UPS Manager positions of jumpers D1 to D8 of the RS232 board conform to figure 7-4.
  • Page 57 Installation and User’s Manual Figure C o n f i g u r i n g t h e Tr a n s m i s s i o n F o r m a t ( fa c t o r y s e t t i n g s s h a d e d ) 8 bits, no parity and 1 stop bit 8 bits, evenparity and 1 stop bit 7 bits, no parity and 1 stop bit...
  • Page 58 EXL 1000 Uninterruptible Power System (this page left blank intentionally) 7 — 6 U-Talk 86-891000-00...
  • Page 59 Appendices General EXL 1000 series are two-phase line to line input, two-phase line to line output, Uninterruptible Power Supplies. Each UPS Characteristics may be configured in a number of ways via a special interface. A modification in the configuration requires on-site servicing by the after-sales support department.
  • Page 60 EXL 1000 Uninterruptible Power System configuration low battery shutdown warning (minutes): 1, 2, 3, 4, 5, ...20 inverter start-up automatic or manual battery charger: internal or external transfer to bypass outside tolerances: yes / no standard color: RAL 9002 EXL 1050...
  • Page 61 Installation and User’s manual dimensions and weight EXL 1050 EXL 1075 EXL 1100 height: 28.7 in/730 mm 35.8 in/910 mm 35.8 in/910 mm width: 14.17 in/360 mm 15.75 in/400 mm 15.75 in/400 mm depth: 16.53 in/420 mm 21.65 in/550 mm 21.65 in/550 mm weight: 200 lbs/90 kg...

  • Page 62: Maximum Current Ratings

    EXL 1000 Uninterruptible Power System Table M a x i mu m c u r r e n t r a t i n g s absorbed line currents (A) Model rated output AC input current AC output current battery option...
  • Page 63 Glossary backup time the period of time that the EXL 1000 can supply full rated load while running on battery without AC input power. This time will increase with installation of an auxilliary battery cabinet. battery circuit breaker DC-power circuit breaker that protects the battery circuit.
  • Page 64 EXL 1000 Uninterruptible Power System powered down no power is present on input and output of EXL 1000 (battery circuit breaker off, upstream circuit breaker off). rated current rated output current of EXL 1000. rectifier electronic device or circuit that converts AC input power to DC power that supplies the inverter module and battery charger.
  • Page 65 STREET ADDRESS ___________________________________________________________ CITY __________________________________ STATE ___________ ZIP ______________ I would like to order ________ (quantity @ $50.00 each) additional copies of the: EXL 1000 Uninterruptible Power System Installation and User's Guide 86-891000-00 I would like to report the following problems with this document:...
  • Page 68 Nothing will stop you now ™ 1660 Scenic Avenue, Costa Mesa, California 92626 • (714) 557-1636 • www.mgeups.com...

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