MGE UPS Systems EX-5, EX-7, EX-11RT User Manual

4 (1)

w w w . m g e u p s . c o m

EX 5/7/11RT Systems

Installation and User Manual

Installation and User Manual

EX 5/7/11RT Systems

Installation and User Manual

Revision History

EX 5/7/11RT Systems

Installation and User Manual, 86-86000-00

Revision:

A01

ECN#:003984

07/2004

 

A02

ECN#:004086

11/2004

 

A03

ECN#:004284

05/2005

 

B00

ECN#:004379

01/2006

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 (714) 557-1636

Technical Support:

1-800-523-0142 (during business hours)

Customer Care Center: 1-800-438-7373 (Hours: 24/7)

86-86000-00 B00

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EX 5/7/11RT Systems

(This page left blank intentionally)

iv

86-86000-00 B00

Contents

 

section

description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .page

 

 

Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . .iii

 

 

IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . .

. . .c vi

 

 

Certification Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .c vi

 

 

CAUTION: Safety of persons . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .c vii

 

 

CAUTION: Product Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .c vii

 

 

Special Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .c vii

 

 

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .c vii

 

 

CAUTION: Record All Serial Numbers! . . . . . . . . . . . . . . . . . . . .

. .c viii

 

 

Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .c ix

 

 

Section Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .c ix

Section 1

Introduction

 

 

1.0

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1 — 1

 

1.1

System Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . .

.1 — 3

 

1.2

Standard Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1 — 4

 

1.2.1

Tower Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1 — 4

 

1.2.2

Rack Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1 — 5

 

1.3

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 . . . . . . . . . . . . . . . . . .

.1 — 6

 

1.3.3

EX RT Transformer Module . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1 — 7

 

1.4

Power Module Display and Control Panel . . . . . . . . . . . . . . . . .

.1 — 7

 

1.5

Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1 — 8

 

1.5.1

Power Module Rail Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1 — 8

 

1.5.2

Battery/Transformer/CLA Module Rail Kit . . . . . . . . . . . . . . . . . .

.1 — 8

 

1.5.3

Multiple Battery Module Backup Time at Full Load . . . . . . . . . .

.1 — 9

 

1.5.4

Battery Extension Cable Kit . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1 — 9

 

1.5.5

Battery Integration Kit with Casters . . . . . . . . . . . . . . . . . . . . . .

1 — 10

 

1.5.6

Input/Output Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 — 10

 

1.5.7

Transformer Module - For use with EX 5/7/11RT

 

 

 

Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 — 11

 

1.5.8

CLA Charger Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 — 12

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EX 5/7/11RT Systems

section

description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

page

Section 2 Setup and Installation

2.0

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.2 — 1

2.1

Unpacking and Parts Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 — 1

2.2

Contents of Standard EX 5/7/11RT Systems . . . . . . . . . . . . . . .

2 — 2

2.3

Installation in Tower Configuration . . . . . . . . . . . . . . . . . . . . . . . .

2 — 4

2.4

Installation in Rack Mounting Configuration . . . . . . . . . . . . . . . . .

2 — 5

2.4.1Adjustment of front panel logo and control panel

for rack orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.2 — 5

2.4.2 Prepare Battery Module for Rack Mounting . . . . . . . . . . . . . . . .

2 — 6

2.4.3Power, Battery, Transformer, and CLA Charger Module

 

Rack Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

2 — 7

2.5

Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.

2 — 9

2.5.1

Connecting the RS232 Communication Port . . . . . . . . . . . . . .

.

2 — 9

2.5.2

Connecting the Dry (Relay) Contact Communication Port . . . .2

— 10

2.5.3

Installation of Optional Transverse Card . . . . . . . . . . . . . . . . . .

2

— 10

2.6

Remote Emergency Power Off (REPO) Communication Port . .

2

— 12

2.7

System Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

— 13

2.7.1Connections with Common Normal and Bypass AC

sources (Single Mains) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.2 — 13

2.7.2 Connecting EX RT Transformer Module . . . . . . . . . . . . . . . . . .

2 — 15

2.7.3Connections with Separate Normal and Bypass AC

sources (2 Mains) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 16

2.7.4System Connections as Frequency Converter

 

(without Bypass AC source) . . . . . . . . . . . . . . . . . . . . . . . . . . .

.2 — 17

2.8

Connection of Battery Module EXB . . . . . . . . . . . . . . . . . . . . . .

2 — 18

2.9

Connection of Optional CLA Module . . . . . . . . . . . . . . . . . . . . .

2 — 19

Section 3

Operation

3.0

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.3 — 1

3.1

Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 — 1

3.2

UPS Personalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 — 2

 

3.2.1 Accessing personalization with front panel buttons . . . . . . . . . . .

3 — 2

3.3Information Technology (IT) Network and Industrial

 

Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .3 — 5

3.3.1 UPS personalization through external software . . . . . . . . . . . . .

.3 — 6

3.3.2

Final startup sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.3 — 6

3.4

Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.3 — 7

3.4.1 Normal (double conversion) Mode . . . . . . . . . . . . . . . . . . . . . . .

.3 — 7

3.4.2

ECO Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.3 — 8

3.5

Operation on Battery Power . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.3 — 9

3.5.1 Transfer to Battery Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.3 — 9

3.6

Return of Normal AC source . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 — 10

3.7

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 — 10

c ii

Contents

86-86000-00 B00

 

 

 

Installation and User Manual

 

 

 

 

 

section

description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . .page

Section 4

Maintenance

 

 

4.0

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . .4 — 1

 

4.1

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . .4 — 1

 

4.2

Hot Swapping the Power Module . . . . . . . . . . . . .

. . . . . . . . . . . .4 — 3

 

4.3

Re-connecting the Power Module . . . . . . . . . . . .

. . . . . . . . . . . .4 — 4

 

4.4

Hot Swapping the Battery Module . . . . . . . . . . . .

. . . . . . . . . . . .4 — 5

 

4.4.1

Disconnecting the Battery Module . . . . . . . . . . . .

. . . . . . . . . . . .4 — 5

 

4.4.2

Re-connecting the Battery Module . . . . . . . . . . . .

. . . . . . . . . . . .4 — 5

Section 5

Appendix

 

 

 

5.0

Electrical Specifications . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . .5 — 1

 

5.1

System Input/Output Power Ratings . . . . . . . . . .

. . . . . . . . . . . .5 — 1

 

5.2

System Overload Characteristics . . . . . . . . . . . . .

. . . . . . . . . . . .5 — 1

 

5.3

System Backup Characteristics . . . . . . . . . . . . . .

. . . . . . . . . . . .5 — 2

 

5.4

System Short Circuit Protection . . . . . . . . . . . . . .

. . . . . . . . . . . .5 — 2

 

5.5

Accessories Electrical Characteristics . . . . . . . . .

. . . . . . . . . . . .5 — 2

 

5.6

Heat Rejection . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . .5 — 4

 

5.7

Environmental Characteristics . . . . . . . . . . . . . . .

. . . . . . . . . . . .5 — 4

MGE Warranty & Proprietary Rights for Single Phase Products

MGE Standard Single Phase Warranty

Proprietary Rights Statement

Warranty and Product Registration

User Information

Product information

Warranty Extension (Warranty+) not available on products

Customer Care Center - Single Phase Products

Technical Support and Product Services

Who to Contact

Scheduling Field Service Engineer Support

Return Policy for Repair of Single Phase Products (RGA)

Glossary

Reorder Form

86-86000-00 B00

Contents

c iii

EX 5/7/11RT Systems

Figures

figure

description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .page

1-1:

Tower Configuration with Power Module, Battery Module,

 

 

and optional Transformer Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 4

1-2:

Rack Configuration with Power Module, Battery Module,

 

 

and optional Transformer Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 5

1-3:

Rear panel of the Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 6

1-4:

Rear Panel of the Battery Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1 — 6

1-5:

Rear Panel of the optional Transformer Module. (PN 86211) . . . . . . . .

.1 — 7

1-6:

View of typical control panel interface. . . . . . . . . . . . . . . . . . . . . . . . . . .

.1 — 7

1-7:

Power Module Rail Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1 — 8

1-8:

Battery/Transformer/CLA Module Rail Kit. . . . . . . . . . . . . . . . . . . . . . . . .1 — 8

1-9:

Typical back-up time with multiple EXB’s at full load. . . . . . . . . . . . . . . .1 — 9

1-10:

Typical Battery Integration kit with casters setup. . . . . . . . . . . . . . . . . .1 — 10

1-11:

Typical Transformer Module contents and connections. . . . . . . . . . . . .1 — 11

1-12:

CLA Module Contents and Connections. . . . . . . . . . . . . . . . . . . . . . . . .

1 — 12

2-1:

Contents of EX 5/7/11RT Power Module. . . . . . . . . . . . . . . . . . . . . . . . .2 — 2

2-2:

Contents of EXB 5/7/11RT Battery Module. . . . . . . . . . . . . . . . . . . . . . .

.2 — 3

2-3:

Tower Configuration of Standard System and

 

 

Optional Transformer Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 5

2-4:

Typical orientation of the logo and control panel.

 

 

(Power Module shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.2 — 6

2-5:

Accessing Battery Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.2 — 6

2-6:

Rack mounting of the Power Module onto the rails. . . . . . . . . . . . . . . . .2 — 7

2-7:

Input/Output Box Bracket System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.2 — 8

2-8:

RS232 Communication Cable Connection. . . . . . . . . . . . . . . . . . . . . . . .2 — 9

2-9:

Relay Pin Connections for Communication Port. . . . . . . . . . . . . . . . . . .

2 — 10

2-10:

Communication Card Slot with Network

 

 

Management Card installed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 10

2-10a: Activation of Remote Emergency Power Off function

 

 

using a contact normally open switch. . . . . . . . . . . . . . . . . . . . . . . . . . .

2 — 12

2-10b: Activation of Remote Emergency Power Off using a

 

 

contact normally closed switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 12

2-11:

Power Module I/O Box Terminal Block Diagram. . . . . . . . . . . . . . . . . . .

2 — 13

2-12:

Normal AC Input and Output Cables installation. . . . . . . . . . . . . . . . . . .

2 — 14

2-13:

View of EX RT Transformer Module connected downstream

 

 

for 120/208/240 Vac outputs (shown with one EXB). . . . . . . . . . . . . . . .

2 — 15

2-14:

Normal AC Input, Bypass AC, and Output Cables Installation,

 

 

and Simplified Connection Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 16

2-15:

Accessing Terminal Blocks for Input and Output power cables. . . . . . .2 — 17

2-16:

Rear view of Battery Module cable connections. . . . . . . . . . . . . . . . . . .

2 — 18

2-17:

Rear view of CLA Module cable battery and AC input connections . . . .

2 — 19

c iv

Contents

86-86000-00 B00

Installation and User Manual

Figures (continued)

figure description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page

3-1: Initial Startup Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 1 3-2: Control Panel with scroll up and down buttons. . . . . . . . . . . . . . . . . . . . .3 — 2 3-3: Configuration used to provide cascade redundancy to critical loads . . . .3 — 3 3-4: Normal (double conversion) mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 7

3-5: ECO mode display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 8 3-6: Transfer, Threshold and End of backup time . . . . . . . . . . . . . . . . . . . . . .3 — 9 3-7: Shutdown display, circuit breaker, and AC source switch. . . . . . . . . . . .3 — 10

4-1:

Disconnecting the Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.4

— 3

4-2:

Reconnect the Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.4

— 4

4-3:

Rear view of the Battery Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.4

— 5

5-1:

Power supplied as a function of input voltage (left),

 

 

 

and permissible UPS overloads as a function of time (right) . . . . . . . . .

.5

— 1

Tables

 

 

 

table

description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .page

1-1:

EX RT Model Descriptions and Contents. . . . . . . . . . . . . . . . . . . . . . . . .1 — 1

1-2:

Optional Accessories (See section 1.5 for description) . . . . . . . . . . . . .

.1

— 2

1-3:

UPS Characteristics System Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

— 3

1-4:

Transformer Module Characteristics Ratings . . . . . . . . . . . . . . . . . . . . .

.1

— 3

1-5:

Battery Module Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

— 4

1-6:

System Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

— 5

1-7:

Battery backup time chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 — 12

3-1:

Local Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.3

— 3

3-2:

Output Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.3

— 3

3-3:

ON/OFF Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.3

— 4

3-4:

Battery Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 4

3-5:

System Operation in I/T and Industrial Modes. . . . . . . . . . . . . . . . . . . . .3 — 5

4-1:

Troubleshooting not requiring MGE after-sales support . . . . . . . . . . . .

.4 — 1

4-2:

Troubleshooting requiring MGE after-sales support . . . . . . . . . . . . . . .

.4 — 2

5-1:

EX 5/7/11 RT Voltages and Frequency Characteristics . . . . . . . . . . . . .

.5 — 1

5-2:

Backup Time (in minutes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.5 — 2

5-3:

Battery Recharge time to recover 90% of the rated backup time

 

 

 

after discharge at full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.5 — 3

5-4:

Efficiency online (RL load) and batteries fully charged . . . . . . . . . . . . .

.5 — 3

5-5:

Efficiency online (RCD load) and batteries fully charged . . . . . . . . . . . .

.5 — 3

5-6:

Efficiency on battery (RCD load). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.5 — 3

5-7:

Efficiency on ECO mode (all kinds of load) and batteries fully charged.

.5 — 4

5-8:

Full load heat rejection in BTUs/hr . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.5 — 4

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c v

EX 5/7/11RT 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.

The EX 5/7/11RT models that are covered in this manual are intended for installation in an environment within 0 to 40° C, free of conductive contaminant.

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. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

Certification Standards

IEEE 587-1980/ANSI C62.41 1980 Standards for Surge Withstand Ability

FCC rules and regulations of Part 15, Subpart J, Class A

UL listed under 1778, Standards for Uninterruptible Power Supply Equipment

IEC 61000-4-2 (ESD): level 4.

IEC 61000-4-3 (Radiated field): level 3.

IEC 61000-4-4 (EFT): level 4.

IEC 61000-4-5 (Fast transients): level 4.

IEEE-C6241 Category B (ring wave).

IEC 61000-4-6 (electromagnetic field).

IEC 61000-4-8 (conducted magnetic field).

c vi

Important Safety Information and Standards

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Installation and User Manual

CAUTION: Safety of persons

The system has its own power source (the battery). Consequently, the power outlets may be energized even if the systems is disconnected from the AC power source.

Dangerous voltage levels are present within the system. It should be opened exclusively by qualified service personnel.

The system must be properly grounded.

The battery supplied with the system contains small amounts of toxic materials. To avoid accidents, the directives listed below must be observed:

-Never burn the battery (risk of explosion).

-Do not attempt to open the battery (the electrolyte is dangerous for the eyes and skin). -Comply with all applicable regulations for the disposal of the battery.

-Batteries constitute a danger (electrical shock, burns). The short-circuit current may be very high. Precautions must be taken for all handling: remove watches, rings, bracelets and any other metal objects, use tools with insulated handles. -Do not lay tools or metal parts on top of batteries.

CAUTION: Product Safety

The UPS connection instructions and operation described in the manual must be followed in the indicated order.

A protection circuit breaker must be installed upstream and be easily accessible. The system can be disconnected from the AC power source by opening this circuit breaker.

Check that the indications on the rating plate correspond to your AC powered system and to the actual electrical consumption of all the equipment to be connected to the system.

Never install the system near liquids or in an excessively damp environment.

Never let a foreign body penetrate inside the system.

Never block the ventilation grates of the system.

Never expose the system to direct sunlight or source of heat.

If the system must be stored prior to installation, storage must be in a dry place.

The admissible storage temperature range is -25ºC to +55ºC.

Special Precautions

All handling operations will require at least two people (unpacking, installation in rack system).

Before and after the installation, if the UPS remains de-energized for a long period, the UPS must be energized for a period of 24 hours, at least once every 6 months (for a normal storage temperature less than 25°C). This charges the battery, thus avoiding possible irreversible damage.

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, don’t hesitate to contact your MGE representative.

Environment

This product has been designed to respect the environment:

It does not contain any Chlorofluorocarbon (CFC) or Hydrochlorofluorocarbon (HCFC).

UPS recycling at the end of service life:

MGE UPS SYSTEMS, INC. undertakes to recycle, by certified companies and in compliance with all applicable regulations, all UPS products recovered at the end of their service life (contact your MGE UPS SYSTEMS, INC. branch office).

Packing:

UPS packing materials must be recycled in compliance with all applicable regulations.

WARNING: This product contains lead-acid batteries. Lead is a dangerous substance for the environment if it is not properly recycled by specialized companies.

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c vii

EX 5/7/11RT Systems

CAUTION: Record All Serial Numbers!

RECORD ALL SERIAL NUMBERS FOR EX 5/7/11RT 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

NUMBERS IF SERVICE IS REQUIRED!

EX 5RT System

EX 7RT System

EX 11RT System

Power Module SERIAL NUMBER: ___________________________________________________

Battery Module SERIAL NUMBER: ____________________________________________________

Transformer Module SERIAL NUMBER: _______________________________________________

CLA Module SERIAL NUMBER: ______________________________________________________

ADDITIONAL MODULES SERIAL NUMBERS:

____________________________ ______________________________

____________________________ ______________________________

____________________________ ______________________________

____________________________ ______________________________

____________________________ ______________________________

____________________________ ______________________________

____________________________ ______________________________

____________________________ ______________________________

____________________________ ______________________________

____________________________ ______________________________

c viii

CAUTION: Record all serial numbers!

86-86000-00 B00

Installation and User Manual

Symbol Usage

This manual uses the following icon symbols with text to convey important information and tips.

 

 

WARNING

Indicates information provided to protect the user and service personnel

 

 

 

 

against safety hazards and/or possible equipment damage.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CAUTION

Indicates information provided to protect the user and service personnel

 

 

 

 

against possible equipment damage.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

IMPORTANT

Indicates information provided as an operating instruction, or as an

 

 

 

 

operating tip.

 

 

NOTE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Indicates information provided as an operating tip or an equipment feature.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Visual

Action

Audio

LED OFF LED ON LED Flashing

 

 

 

 

Section Descriptions

1Introduction

Introduction is a general description of system configurations of the EX 5/7/11RT, and its mechanical electrical characteristics. Additionally there is an optional accessories section with important information on MGE products that will enhance the performance of the EX 5/7/11RT. Please contact your MGE representative for detailed information on these options.

2Setup and Installation

Setup and Installation guides the user through tools and equipment required for connecting the EX 5/7/11RT and battery installation or replacement. Included are assembly instructions, power cable connections with wire diagrams for configuring the product to hardware specifications.

3Operation

Operation describes the EX 5/7/11RT systems characteristics of indicators and controls, modes and specifications. The user procedures include performing software programming that will maintain optimal performance.

4Maintenance

Maintenance includes a troubleshooting guide of symptoms and possible solutions, hot swapping the Power module, Battery module, and testing scenarios.

5Appendix

Electrical and Mechanical specifications for the EX 5/7/11RT.

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EX 5/7/11RT Systems

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c x

86-86000-00 B00

Introduction

1.0Scope

Introduction is a general description of system configurations of the EX 5/7/11RT, and its mechanical electrical characteristics. Additionally there is an optional accessories section with important information on MGE products that will enhance the performance of the EX 5/7/11RT. Please contact your MGE representative for detailed information on these options.

Table 1-1: EX RT Model Descriptions and Contents.

System Description

 

 

 

 

System Contents

 

 

Output

 

 

 

 

 

 

Voltage

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Power Module

 

Battery Module

Transformer

 

Model #

Part #

 

 

Module

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

86215

 

86216

 

86217

86207

 

86209

86211

 

 

 

 

 

 

 

 

 

 

 

 

 

5 kVA

86050

X

 

 

 

 

X

 

 

 

200/208/220/

HV EX 5RT

 

 

 

 

 

 

 

230/240/250

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5 kVA

86201

X

 

 

 

 

X

 

 

X

120/208/240

LV EX 5RT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7 kVA

86070

 

 

X

 

 

X

 

 

 

200/208/220/

HV EX 7RT

 

 

 

 

 

 

 

230/240/250

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7 kVA

86203

 

 

X

 

 

X

 

 

X

120/208/240

LV EX 7RT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

11 kVA

86110

 

 

 

 

X

 

 

X

 

200/208/220/

HV EX 11RT

 

 

 

 

 

 

 

230/240/250

 

 

 

 

 

 

 

 

 

 

 

 

11 kVA

86205

 

 

 

 

X

 

 

X

X

120/208/240

LV EX 11RT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Also: All units include rail kits for rack mounting and stabilizing feet for tower configuration.

NOTE

The Power Module is factory configured for single Mains input at 208VAC,

 

60Hz. Other input-output voltage settings are available. See section 3.2.1.

 

Input voltage must be the same as output voltage on HV units!

 

 

Thank you for selecting an MGE UPS SYSTEMS, INC. (MGE) product to protect your electrical equipment.

The product you selected is a part of the EX RT series. The EX RT series is a family of Uninterruptible Power Supply (UPS) designed to provide safe, and reliable AC power backup for sensitive electrical equipment. To discover the entire range of MGE products, we invite you to visit our website at www.mgeups.com or contact your representative at (800) 523-0142.

For a complete description of the EX RT product family and its available options, please refer to the following tables.

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1 — 1

EX 5/7/11RT Systems

Table 1-2: Optional Accessories (See section 1.5 for description)

Part Number

Description

 

 

86001

Rail Kit for Power Module EX 5/7/11RT

 

 

86002

Rail Kit for Battery/Transformer/CLA Module

 

 

86005

Battery Integration Kit with Casters

 

 

86006

Battery Extension Cable Kit

 

 

86008

Empty Battery Chassis EXB RT W/EPO

 

 

86009

I/O Box 5/7kVA UL/US

 

 

86010

I/O Box 11kVA UL/US

 

 

86012

I/O Box Bracket System

 

 

86013

Rear Bracket Supports

 

 

86207

Battery Module EXB 5/7RT

 

 

86209

Battery Module EXB 11RT

 

 

86211

EX RT Transformer Module

 

 

86213

CLA Charger Module

 

 

86215

5kVA Power Module EX 5RT

 

 

86216

7kVA Power Module EX 7RT

 

 

86217

11kVA Power Module EX 11RT

 

 

1 — 2

Introduction

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Installation and User Manual

1.1System Electrical Characteristics

Table 1-3: UPS Characteristics System Ratings.

 

 

 

 

 

 

 

 

UPS Characteristics

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MAIN 1 (Normal AC Source) default

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Input

 

 

 

Input Current (A)

 

 

Input

 

Output

Output

 

 

 

Power

 

 

 

 

 

 

 

 

 

 

 

Inrush

 

 

 

 

 

 

 

 

 

 

 

Voltage

 

 

 

 

 

 

 

 

 

Breaker

 

Voltage

Current

 

Rating

 

Min

Max

 

Online

 

Bypass

 

 

Current

 

 

(VAC)

 

 

 

 

 

 

 

 

 

(A)

 

(VAC)

(A)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5 kVA

 

 

18

 

32

 

21.6

 

19

40

 

 

 

19.25

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7 kVA

208

 

25

 

45

 

30.3

 

26.65

50

 

208

23.5

 

200A/1ms

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

11 kVA

 

 

38

 

64

 

44

 

42

70

 

 

 

47.5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Table 1-4: Transformer Module Characteristics Ratings.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Transformer Module Characteristics

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Input Voltage (VAC)

 

 

 

 

 

 

 

 

208/240

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Output Voltage (VAC)

 

 

 

120/120

 

 

 

208

 

 

 

240

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Max. Output Current (A)

 

 

33.3/33.3

 

 

 

52

 

 

 

45

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CAUTION

Power Module is factory configured at 208Vac, 60 Hz input and output.

 

 

 

 

 

 

 

 

 

Without transformer, Input and Output of the UPS must always be

 

 

 

 

 

 

 

 

the same.

 

 

 

 

 

 

 

 

 

 

 

 

 

On 11KVA, 10% de-rating for 200/208VAC. Isolated 120/208/240VAC are available with EX RT Transformer Module.

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Introduction

1 — 3

EX 5/7/11RT Systems

Table 1-5: Battery Module Ratings.

Part Number

86207

86209

 

 

 

Battery Type

12VDC/7Ah

12VDC/9Ah

 

 

 

Battery Output Voltage

240VDC

240VDC

 

 

 

1.2Standard Configuration

The EX 5/7/11RT systems can be set up in tower or rack configurations.

1.2.1Tower Configuration

Figure 1-1: Tower Configuration with Power Module, Battery Module, and optional Transformer Module.

EXB

RT

 

 

 

 

EX 11

RT

 

 

 

 

 

Trans

form

er

 

EX RT

 

 

 

 

 

 

 

 

 

 

 

 

 

ON

 

 

 

OFF

 

BATTERY MODULE

POWER MODULE

TRANSFORMER MODULE

1 — 4

Introduction

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Installation and User Manual

1.2.2Rack Configuration

Figure 1-2: Rack Configuration with Power Module, Battery Module, and optional Transformer Module.

Standard Configuration

Configuration with Transformer

POWER MODULE

 

 

(EX 5/7/11 RT)

 

 

 

EX RT Tran

sformer

 

 

 

EX 11 RT

 

 

EXB RT

 

BATTERY MODULE

 

 

(EXB 5/7/11 RT)

 

 

Table 1-6: System Dimensions and Weights.

TRANSFORMER MODULE

POWER MODULE (EX 5/7/11 RT)

BATTERY MODULE (EXB 5/7/11 RT)

Model

Dimensions (HxWxD)

Weights

 

 

 

 

EX 5/7RT Power Module

(3U)

5.16” x 17.49” x 26.25”(*)

49.6 lbs (22.5 kg)

(131 x 444 x 667mm)

 

 

 

 

 

 

EX 11RT Power Module

(3U)

5.16” x 17.49” x 26.25”(*)

60.6 lbs (27.6 kg)

(131 x 444 x 667mm)

 

 

 

 

 

 

EXB 5/7RT Battery Module

(3U)

5.16” x 17.49” x 25”

142 lbs (64.5 kg)

(131 x 444 x 635mm)

 

 

 

 

 

 

EXB 11RT Battery Module

(3U)

5.16” x 17.49” x 25”

151 lbs (68.5 kg)

(131 x 444 x 635mm)

 

 

 

 

 

 

EX RT Transformer Module

(3U)

5.16” x 17.49” x 25”

173 lbs (78.5 kg)

(131 x 444 x 635mm)

 

 

 

 

 

CLA Charger Module

(3U) 5.16” x 17.5” x 25

26.5 lbs (12 kg)

 

 

 

 

(*)For depth constraint applications, a shorter version of I/O Box for Power Module is available. With this version of I/O Box, the overall depth of the EX 5/7/11RT is only 24.75” (629mm). Call Customer Care Center at 1-800 438-7373 for more details.

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Introduction

1 — 5

MGE UPS Systems EX-5, EX-7, EX-11RT User Manual

EX 5/7/11RT Systems

1.3Rear Panel Components

1.3.1Power Module EX 5/7/11 RT

Figure 1-3: Rear panel of the Power Module.

 

1

Slot for optional communication cards.

 

1

 

4

2

Dry (relay) contacts Communication Port.

5

3

Remote Emergency Power Off (REPO) function.

 

 

 

(See section 2.6.)

 

 

Connector for automatic detection of Battery Module(s).

 

 

RS232 communication port.

 

6

Battery/CLA Module power connector.

 

 

 

 

Manual Bypass switch.

9

7

Normal AC source circuit breaker.

 

 

10

 

Knockout for entry of AC Output conduit.

 

8

 

 

11

 

Knockout for entry of Normal AC source conduit.

1.3.2Battery Module EXB 5/7/11RT With Remote Emergency Power Off (REPO) Function

Figure 1-4: Rear Panel of the Battery Module.

12

12Connectors for automatic detection of additional battery module(s) (to the UPS or to other Battery Modules).

Battery power connectors (to the UPS or to other Battery Modules).

13

14

1 — 6

Introduction

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Installation and User Manual

1.3.3EX RT Transformer Module

Figure 1-5: Rear Panel of the optional Transformer Module. (PN 86211)

Load 3: 1 NEMA L6-30R, 240Vac

Load 4: 4 NEMA 5-15/20R, 120Vac

Load 2: 4 NEMA 5-15/20R, 120Vac

 

Load 3 Circuit Breaker

Load 4 Circuit Breaker

Load 2 Circuit Breaker

AC Input

Main Output Circuit Breaker

Transformer I/O Box

 

AC Output

Load 1 Circuit Breaker

 

Transformer Protect

Load 1: 1 NEMA L6-30R, 208Vac

 

Breaker

 

1.4Power Module Display and Control Panel

Figure 1-6: View of typical control panel interface.

15

16

17

18

E X 1 1 R T

15Load protected/On-line Operation LED.

Operation on battery LED.

Operation on bypass LED.

Fault LED.

19LCD display.

UPS OFF button.

OFF

ON

 

 

 

Function buttons (scroll up/scroll down).

 

 

 

 

 

 

 

 

23

 

 

button (or function button in personalization

 

 

mode).

 

20

21

22

23

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Introduction

1 — 7

EX 5/7/11RT Systems

1.5Optional Accessories

Optional Accessories describes the options available for upgrades and enhancement of the EX 5/7/11RT 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 warranty.

1.5.1Power Module Rail Kit

(Part Number 86001)

This kit is for rack mounting the Power Module in a 19" enclosure. See section 2.4.3 for rack installation of Power Module.

Figure 1-7: Power Module Rail Kit.

24

25

27

24

Front mounting brackets.

 

 

 

 

 

 

Rear support brackets, part number 86013.

 

 

 

 

This can be ordered separately.

 

26

 

 

Telescopic rails, 25.16" to 39.61"

 

 

 

length (639 mm to 1005 mm).

Input/Output Box bracket system, part number 86012.

1.5.2 Battery/Transformer/CLA Module Rail Kit

(Part number 86002)

This kit is for rack mounting of the Battery/Transformer/CLA Module in 19" enclosure. See section 2.4.3 for rack installation of module.

Figure 1-8: Battery/Transformer/CLA Module Rail Kit.

24

25

26

Front mounting brackets.

Rear support brackets, part number 86013. This can be ordered separately.

61"

length (639 mm to 1005 mm).

1 — 8

Introduction

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EX 5/7/11RT Systems

Installation and User Manual

 

 

 

1.5.3Multiple Battery Module Backup Time at Full Load

Standard EX 5/7/11RT systems (one Power Module, and one Battery Module), offers a standard backup time of 5 to 12 minutes at full load.

To increase backup 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)

Figure 1-9: Typical back-up time with multiple EXB’s at full load.

Standard

 

Optional

EX 5/7/11RT systems

 

Configurations

 

 

 

 

 

 

 

 

 

EX 5/7/11RT EXB 5/7/11RT + EXB 5/7/11RT + EXB 5/7/11RT + EXB 5/7/11RT + EXB 5/7/11RT + EXB 5/7/11RT

5 kVA

:

9 min

25 min

45 min

60 min

84 min

100 min

7 kVA

:

7 min

20 min

32 min

45 min

57 min

72 min

11 kVA:

 

5 min

14 min

22 min

30 min

42 min

53 min

See Appendix for additional Back-up time information.

1.5.4Battery Extension Cable Kit

(6 ft./1.8 m, Part number 86006)

This extended battery cable kit will be used instead of the standard battery cable when Battery Modules (EXBs) are distant from each other (located in two different enclosures, for instance).

The battery extension cable kit includes a 6 ft. long, straight connector battery power cable and a 6 ft. long battery detection cable.

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Introduction

1 — 9

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