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EX 5/7/11RT Systems
Installation and User Manual
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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
A02
A03
B00
ECN#:003984
ECN#:004086
ECN#:004284
ECN#:004379
07/2004
11/2004
05/2005
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)
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EX 5/7/11RT Systems
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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
1.1
1.2
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 1
System Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . .1 — 3
Standard Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 4
1.2.1 Tower Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 4
1.2.2 Rack Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 5
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
1.3
Emergency Power Off (REPO) Function . . . . . . . . . . . . . . . . . . .1 — 6
1.3.3 EX RT Transformer Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 7
Power Module Display and Control Panel . . . . . . . . . . . . . . . . . .1 — 7
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
1.4
1.5
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
2.1
2.2
2.3
2.4
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 1
Unpacking and Parts Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 1
Contents of Standard EX 5/7/11RT Systems . . . . . . . . . . . . . . .2 — 2
Installation in Tower Configuration . . . . . . . . . . . . . . . . . . . . . . . .2 — 4
Installation in Rack Mounting Configuration . . . . . . . . . . . . . . . . .2 — 5
2.4.1 Adjustment of front panel logo and control panel
for rack orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 5
2.4.2 Prepare Battery Module for Rack Mounting . . . . . . . . . . . . . . . .2 — 6
2.4.3 Power, Battery, Transformer, and CLA Charger Module
Rack Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 7
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
Remote Emergency Power Off (REPO) Communication Port . .2 — 12
System Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 13
2.7.1 Connections with Common Normal and Bypass AC
2.5
2.6
2.7
sources (Single Mains) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 13
2.7.2 Connecting EX RT Transformer Module . . . . . . . . . . . . . . . . . .2 — 15
2.7.3 Connections with Separate Normal and Bypass AC
sources (2 Mains) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 16
2.7.4 System Connections as Frequency Converter
(without Bypass AC source) . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 17
Connection of Battery Module EXB . . . . . . . . . . . . . . . . . . . . . .2 — 18
Connection of Optional CLA Module . . . . . . . . . . . . . . . . . . . . .2 — 19
2.8
2.9
Section 3
Operation
3.0
3.1
3.2
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 1
Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 1
UPS Personalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 2
3.2.1 Accessing personalization with front panel buttons . . . . . . . . . . .3 — 2
Information Technology (IT) Network and Industrial
3.3
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 5
3.3.1 UPS personalization through external software . . . . . . . . . . . . . .3 — 6
3.3.2 Final startup sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 6
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 7
3.4.1 Normal (double conversion) Mode . . . . . . . . . . . . . . . . . . . . . . . .3 — 7
3.4.2 ECO Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 8
Operation on Battery Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 9
3.5.1 Transfer to Battery Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 9
Return of Normal AC source . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 10
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 10
3.4
3.5
3.6
3.7
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section
description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page
Section 4
Maintenance
4.0
4.1
4.2
4.3
4.4
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 1
Hot Swapping the Power Module . . . . . . . . . . . . . . . . . . . . . . . . .4 — 3
Re-connecting the Power Module . . . . . . . . . . . . . . . . . . . . . . . .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
5.1
5.2
5.3
5.4
5.5
5.6
5.7
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 — 1
System Input/Output Power Ratings . . . . . . . . . . . . . . . . . . . . . .5 — 1
System Overload Characteristics . . . . . . . . . . . . . . . . . . . . . . . . .5 — 1
System Backup Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . .5 — 2
System Short Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . .5 — 2
Accessories Electrical Characteristics . . . . . . . . . . . . . . . . . . . . .5 — 2
Heat Rejection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 — 4
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
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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
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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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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.
86-86000-00 B00
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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!
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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
IMPORTANT
NOTE
Indicates information provided to protect the user and service personnel
against possible equipment damage.
Indicates information provided as an operating instruction, or as an
operating tip.
Indicates information provided as an operating tip or an equipment feature.
Visual
Action
Audio
LED OFF
LED ON
LED Flashing
Section Descriptions
1
Introduction
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.
2
Setup 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.
3
Operation
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.
4
Maintenance
Maintenance includes a troubleshooting guide of symptoms and possible solutions, hot swapping the Power
module, Battery module, and testing scenarios.
5
Appendix
Electrical and Mechanical specifications for the EX 5/7/11RT.
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Introduction
1.0
Scope
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.
Output
System Description
System Contents
Battery Module
Voltage
Transformer
Module
Power Module
86216
Model #
Part #
86215
X
86217
86207
X
86209
86211
5 kVA
200/208/220/
230/240/250
86050
86201
86070
86203
86110
86205
HV EX 5RT
5 kVA
X
X
X
X
X
120/208/240
LV EX 5RT
7 kVA
200/208/220/
230/240/250
X
X
HV EX 7RT
7 kVA
X
X
120/208/240
LV EX 7RT
11 kVA
200/208/220/
230/240/250
X
X
X
X
HV EX 11RT
11 kVA
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
tive 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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Introduction
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EX 5/7/11RT Systems
Table 1-2: Optional Accessories (See section 1.5 for description)
Part Number
Description
86001
86002
86005
86006
86008
86009
86010
86012
86013
86207
86209
86211
86213
86215
86216
86217
Rail Kit for Power Module EX 5/7/11RT
Rail Kit for Battery/Transformer/CLA Module
Battery Integration Kit with Casters
Battery Extension Cable Kit
Empty Battery Chassis EXB RT W/EPO
I/O Box 5/7kVA UL/US
I/O Box 11kVA UL/US
I/O Box Bracket System
Rear Bracket Supports
Battery Module EXB 5/7RT
Battery Module EXB 11RT
EX RT Transformer Module
CLA Charger Module
5kVA Power Module EX 5RT
7kVA Power Module EX 7RT
11kVA Power Module EX 11RT
1 — 2
Introduction
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Installation and User Manual
1.1
System Electrical Characteristics
Table 1-3: UPS Characteristics System Ratings.
UPS Characteristics
MAIN 1 (Normal AC Source) default
Input Current (A)
Input
Voltage
(VAC)
Input
Output Output
Inrush
Power
Rating
Breaker
Voltage Current
Current
Min
Max
Online Bypass
(A)
(VAC)
(A)
5 kVA
7 kVA
18
25
38
32
45
64
21.6
30.3
44
19
26.65
42
40
19.25
208
50
70
208
23.5 200A/1ms
47.5
11 kVA
Table 1-4: Transformer Module Characteristics Ratings.
Transformer Module Characteristics
208/240
Input Voltage (VAC)
Output Voltage (VAC)
Max. Output Current (A)
120/120
208
52
240
45
33.3/33.3
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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EX 5/7/11RT Systems
Table 1-5: Battery Module Ratings.
Part Number
86207
86209
Battery Type
12VDC/7Ah
240VDC
12VDC/9Ah
240VDC
Battery Output Voltage
1.2
Standard Configuration
The EX 5/7/11RT 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.
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BATTERY MODULE
POWER MODULE
TRANSFORMER MODULE
1 — 4
Introduction
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Installation and User Manual
1.2.2 Rack Configuration
Figure 1-2: Rack Configuration with Power Module, Battery Module, and optional Transformer Module.
Standard Configuration
POWER MODULE
Configuration with Transformer
(EX 5/7/11 RT)
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BATTERY MODULE
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Table 1-6: System Dimensions and Weights.
Model
Dimensions (HxWxD)
Weights
(3U) 5.16” x 17.49” x 26.25”(*)
(131 x 444 x 667mm)
EX 5/7RT Power Module
EX 11RT Power Module
EXB 5/7RT Battery Module
EXB 11RT Battery Module
EX RT Transformer Module
CLA Charger Module
49.6 lbs (22.5 kg)
60.6 lbs (27.6 kg)
142 lbs (64.5 kg)
151 lbs (68.5 kg)
173 lbs (78.5 kg)
26.5 lbs (12 kg)
(3U) 5.16” x 17.49” x 26.25”(*)
(131 x 444 x 667mm)
(3U) 5.16” x 17.49” x 25”
(131 x 444 x 635mm)
(3U) 5.16” x 17.49” x 25”
(131 x 444 x 635mm)
(3U) 5.16” x 17.49” x 25”
(131 x 444 x 635mm)
(3U) 5.16” x 17.5” x 25
(*) 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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EX 5/7/11RT Systems
1.3
Rear Panel Components
1.3.1
Power Module EX 5/7/11 RT
Figure 1-3: Rear panel of the Power Module.
1
2
3
Slot for optional communication cards.
Dry (relay) contacts Communication Port.
1
4
5
2
3
Remote Emergency Power Off (REPO) function.
(See section 2.6.)
4
5
Connector for automatic detection of Battery Module(s).
RS232 communication port.
6
Battery/CLA Module power connector.
Manual Bypass switch.
6
7
7
8
9
8
Normal AC source circuit breaker.
10
11
9
Knockout for entry of AC Output conduit.
Knockout for entry of Normal AC source conduit.
Knockout for entry of Bypass AC source conduit.
10
11
1.3.2
Battery Module EXB 5/7/11RT With Remote Emergency Power Off (REPO) Function
Figure 1-4: Rear Panel of the Battery Module.
12
12
13
14
Connectors 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).
Battery Circuit Breaker with shunt trip.
13
14
1 — 6
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Installation and User Manual
1.3.3
EX RT Transformer Module
Figure 1-5: Rear Panel of the optional Transformer Module. (PN 86211)
Load 3: 1 NEMA L6-30R, 240Vac
Load 2: 4 NEMA 5-15/20R, 120Vac
Load 3 Circuit Breaker
Load 4: 4 NEMA 5-15/20R, 120Vac
Load 4 Circuit Breaker
Load 2 Circuit Breaker
Main Output Circuit Breaker
AC Input
Transformer I/O Box
AC Output
Load 1 Circuit Breaker
Load 1: 1 NEMA L6-30R, 208Vac
Transformer Protect
Breaker
1.4
Power Module Display and Control Panel
Figure 1-6: View of typical control panel interface.
15
16
17
18
15
16
17
18
19
20
21
23
Load protected/On-line Operation LED.
Operation on battery LED.
Operation on bypass LED.
Fault LED.
E X 1 1 R T
19
LCD display.
UPS OFF button.
OFF
ON
22
Function buttons (scroll up/scroll down).
UPS ON button (or function button in personalization
mode).
20
21
22
23
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EX 5/7/11RT Systems
1.5
Optional 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.
1.5.1
Power 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
26
Front mounting brackets.
27
24
25
Rear support brackets, part number 86013.
This can be ordered separately.
Telescopic rails, 25.16" to 39.61"
length (639 mm to 1005 mm).
26
Input/Output Box bracket system, part
number 86012.
27
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
24
25
Front mounting brackets.
Rear support brackets, part number
86013. This can be ordered separately.
26
26
Telescopic rails, 25.16" to 39.61"
length (639 mm to 1005 mm).
1 — 8
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EX 5/7/11RT Systems
Installation and User Manual
1.5.3
Multiple 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.
Optional
Standard
Configurations
EX 5/7/11RT systems
EXB 5/7/11RT
EXB 5/7/11RT
EXB 5/7/11RT
EXB 5/7/11RT
EXB 5/7/11RT
EX 5/7/11RT EXB 5/7/11RT
+
+
+
+
+
5 kVA
7 kVA
:
9 min
7 min
25 min
20 min
45 min
32 min
60 min
45 min
84 min
57 min
100 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.
1.5.4
Battery 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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EX 5/7/11RT 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.
Figure 1-10: Typical Battery Integration kit with casters setup.
TRANSFORMER MODULE
(optional)
POWER MODULE
BATTERY MODULES
(up to 6)
(Modules Not Included In Kit)
1.5.6
Input/Output Box
F
F
O
O
- I/O Box 5/7kVA Part number 86009
- I/O Box 11kVA Part number 86010
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EX 5/7/11RT Systems
Installation and User Manual
1.5.7
Transformer Module - For use with EX 5/7/11RT Power Module
This module provides isolated 120/208/240Vac outputs.
Figure 1-11: Typical Transformer Module contents and connections.
EX RT Transformer Module Contents
Transformer Module
Tower Stand Expanders
Quick Start Manual
Stabilizer Bracket
(4 screws included)
Transformer
Cable
Transformer Rail Kit
41
BATTERY MODULE
EXB RT
POWER MODULE
EX 5/7/11RT
TRANSFORMER
MODULE EX RT
AC NORMAL
INPUT
TRANSFORMER MODULE
OUTPUT TO LOAD
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EX 5/7/11RT 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
5/7/11RT 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.
Figure 1-12: CLA Module Contents and Connections.
CLA Module Contents
Transformer Rail Kit
Tower Stand Expanders
Battery Power Cable
CLA Module Quick Start
41
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Battery Detection Cable
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Typical High Power
Battery Cabinet
(not included)
CLA
EX 5/7/11RT
50A
15A Utility
~
AC Source
(cable not included)
(see section 2.10 for cable
connection information)
(cable not included)
Table 1-7: Battery backup time chart.
Total battery voltage : 240 VDC (20 x 12VDC, one string).
Recommended Batteries
Battery Backup Time
EX 5RT
EX 7RT
65 Ah
EX 11RT
100 Ah
2 hours
4 hours
8 hours
50 Ah
100 Ah
200 Ah
130 Ah
260 Ah
200 Ah
400 Ah
IMPORTANT
The battery capacity must be set within the UPS (5 Ah increment)
See UPS Personalization section 3.2.
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Setup and Installation
2.0
2.1
Scope
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.
Unpacking and Parts Check
Once the EX 5/7/11RT 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.
All Modules are shipped in separate boxes.
Prior to any installation, the following items should be observed upon receipt of the EX 5/7/11RT.
1. Inspect shipment for any damage prior to receipt. Damage claims should be filed directly with the courier.
Replacements for damaged components should be ordered through MGE Customer Support Services at
1-800-438-7373.
2. Remove wrapping and foam corners to verify that the equipment nameplate (located on the rear of the units)
details a system that corresponds with the equipment ordered.
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EX 5/7/11RT Systems
2.2
Contents of Standard EX 5/7/11RT Systems
Contents of EX 5/7/11RT Power Module: (PN 86215 / 86216 / 86217)
30
EX 5/7/11RT Power Module.
Two sets of tower stands.
31
32
33
34
35
36
RS232 communication cable.
Product documentation.
Input/Output Box. (PN 86009 for EX 5/7RT; 86010 for EX 11RT)
Solution-Pac 2 CD.
Power Module Rail Kit, PN 86001.
IMPORTANT
Packaging must be destroyed according to waste management standards.
Recycling icons are displayed for easy selection.
Figure 2-1: Contents of EX 5/7/11RT Power Module.
30
31
32
34
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33
35
- I/O Box 5/7kVA Part number: 86009
- I/O Box 11kVA Part number: 86010
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Installation and User Manual
Contents of EXB 5/7/11RT Battery Module: (PN 86207 /86209)
29
Stabilizer Bracket and hardware.
38
39
EXB 5/7/11RT.
Tower stand expanders.
Battery Power cable.
40
41
Battery/EX RT Transformer/CLA Module rail kit, PN 86002.
Battery detection cable.
EXB Documentation.
42
43
44
Bezel hex drive.
Figure 2-2: Contents of EXB 5/7/11RT Battery Module.
38
39
40
42
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41
43
44
(not to scale)
- EXB 5RT Battery Module Part number: 86207.
- EXB 7RT Battery Module Part number: 86207.
- EXB 11RT Battery Module Part number: 86209.
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EX 5/7/11RT Systems
2.3
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
5
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Tower Configuration with Optional Transformer Module
Use the same procedure
for tower mounting multiple
battery modules, if applicable.
5
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Installation and User Manual
2.4
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.
To prepare the front panel logo and LCD display for rack orientation, of all modules. (including Transformer or CLA
Module, if equipped).
Proceed as follows:
1. Unclip logo plate, and pull the LCD display from front panel.
2. Rotate them 90 degree counter clockwise as shown.
3. Place items back onto the panel.
Figure 2-4: Typical orientation of the logo and control panel. (Power Module shown)
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EX 5/7/11RT 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.
Proceed as follows:
44
1. Unscrew the six screws securing front panel using Bezel hex driver
2. Unscrew the brackets securing the battery connectors.
3. Disconnect Battery plugs.
.
4. Unscrew the brackets securing the battery pack. Remove battery bracket pack covers.
5. Pull the left and right battery packs out and set aside for reinstalling after the Battery Module cabinet has been
rack mounted.
6. Mount Battery Module cabinet on rack.
7. Re-install the battery pack in reverse order.
Figure 2-5: Accessing Battery Pack.
3
3
2
T
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B
X
E
2
4
4
om
ps.c
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1
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44
(not to scale)
1
5
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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:
24
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.)
25
2. Attach rear support brackets
to module. These brackets prevent the module from sliding out of the rack.
26
3. Attach rails
together and secure with wing nuts, and finger tighten. (both sides).
4. Attach both rails to rear and front of rack with supplied flathead screws (as shown).
5. Use caution when sliding unit into rack. Temporarily secure unit to rack with thumb screws on front mounting
brackets.
6. Secure rear support brackets to rails.
Figure 2-6: Rack mounting of the Power Module onto the rails.
4
4
3
4
2
4
1
2
4
5
4
1
6
6
6
6
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EX 5/7/11RT 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.
27
1&2. Secure small brackets to larger bracket from the underside
.
3.
4.
Secure small attached brackets to the I/O Box with four screws.
27
Secure large bracket
to rails at the rear of module with four nuts.
Figure 2-7: Input/Output Box Bracket System.
1
2
3
4
Install input/output cables
per section 2.7 prior to this step.
4
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Installation and User Manual
2.5
Communication Ports
EX 5/7/11RT Power Module provides 3 communication method's that can be used simultaneously:
5
◗
A female DB9
provides RS232 communications using MGE Serial HID UPS Transfer (SHUT)
protocol. This COM Port is compatible with Solution Pac 2 to perform graceful shutdown.
2
◗
◗
The Dry Contact Port
is used for basic signaling or for protection of IT systems like IBM iSeries
(formerly AS400) and more.
1
The slot
is compatible with most MGE UPS SYSTEMS, INC. Transverse communication card (see
2.5.1
Connecting the RS232 Communication Port
32
1. Connect the RS232
communications cable to the serial port on the computer.
32
5
2. Connect the other end of the communications cable
EX 5/7/11RT.
to the RS232
communications port on the
The EX 5/7/11RT 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).
Figure 2-8: RS232 Communication Cable Connection.
32
1
5
2
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EX 5/7/11RT Systems
2
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.
Pin 1, 2: not used.
Pin 3: Remote Power Off signal (5 to 27 VDC, 10 mA max).
5
4
3
2
1
Pin 4: Operation on mains (not on battery). (48VDC, 2A max.)
Pin 5: User common.
9
8
7
6
Pin 6: Operation on automatic bypass.
Pin 7: Low battery.
NC
NO
common
NO
NO
NO
Pin 8: Load protected
Pin 9: Operation on battery.
Legend:
When the status is active, the contact between
the common (Pin 5) and the relevant information
pin is closed.
NO:
NC:
contact normally open.
contact normally closed.
2.5.3
Installation of Optional Transverse Card
It is not necessary to shut down the UPS to install the optional communications card, except for USB card. Following
is a typical installation of the Transverse card (optional Network Management card PN 66074 is shown below).
Proceed as follows:
1. Remove the slot cover secured by two screws.
1
2. Insert the Transverse card into the slot
3. Secure the card with both screws.
.
4. Refer to user manual of the Network Management Card for set-up.
Figure 2-10: Communication Card Slot with Network Management Card installed.
1
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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. (Meta UPS Card and U-Talk/Basic Acquisition Cards are used exclusively with Multi-slot.)
Dual U-Talk/Basic Card
JBus Card
(PN: 66060) CAN NOT BE USED WITH THIS UPS.
(PN: 66061) Provides RS232 and RS485 connections for using the JBUS/ModBus
protocol. Both connections are female DB9. Only one connector can be used for
proper operation.
Dual port SHUT Card
USB Card
(PN: 66066) Has two independent female DB9 communication ports that use Serial
HID UPS Transfer (SHUT) protocol. Used with the UPS Control LCD display.
(PN: 66067) For direct communications (via USB) with the customer’s server and
automatic UPS recognition by the power management software of Windows 2000,
XP or 2003 Server, or Macintosh OS 9 and 10.
Dual port AS/400 Relay
Status Card
(PN: 66068) CAN NOT BE USED WITH THIS UPS.
6 Alarm Relay Card
(PN: 66069) Provides status in the form of 6 Alarm relays (250V 2A rated relays).
Connection provided are 12 terminal block wire clips.
XML-Web Card
(PN: 66073) Features a web interface and keeps log files about UPS operation.
Network Management Card (PN: 66074) Features a web interface, Simple Network Management Protocol
(SNMP), Simple Mail Transfer Protocol (SMTP) email notification and keeps log files
about UPS operation.
Environmental Sensor
(PN:66846) For Network Management Card: Monitors temperature, humidity, and
status of 2 dry contact inputs.
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EX 5/7/11RT Systems
3
2.6
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:
◗
Disconnect the AC input to the Power Module by opening up the upstream circuit breaker connecting the
utility power to the Power Module.
◗
◗
Turn off the circuit breaker of the Battery Module connecting to the Power Module.
Turn off the circuit breaker of the subsequent Battery Modules, if applicable.
All these steps above should be performed via a single device.
To simplify the last two steps, the Power Module provides an RJ-11, six contact connector on the back panel, called
Remote Emergency Power Off (REPO) port. Upon applying a voltage source (5-27VDC, 10mA max.) to pins 2, 4 of
this port, the Power Module will send a signal to trip off the shunt trip on each circuit breaker of all Battery Modules
via the battery detection cable simultaneously. Refer to the diagram below for details.
Figure 2-10a: Activation of Remote Emergency Power Off function using a contact normally open switch.
RJ 11
Connections provided by user.
3
6 5 4 3 2 1
+
5VDC to 27VDC
10mA (max.)
_
Figure 2-10b: Activation of Remote Emergency Power Off using a contact normally closed switch.
RJ 11
Connections provided by user.
3
6 5 4 3 2 1
+
5VDC to 27VDC
10mA (max.)
_
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2.7
System Connections
WARNING
This type of connections must be carried out by qualified electrical personnel.
14
Before carrying out any connections, check that battery circuit breaker
OFF and that the upstream protection devices (Normal and Bypass AC
sources) are open (OFF/OPEN).
is
2.7.1
Connections with Common Normal and Bypass AC Sources (Single Mains)
Figure 2-11: Power Module I/O Box Terminal Block Diagram.
Output
Bypass AC source
200/208/220/230/240Vac
200/208/220/230/240Vac
Normal AC source
200/208/220/230/240Vac
L6
L5
L2
L1
L1
L4
L3
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)
- Max. 6AWG (EX 5/7RT)
Jumper
(see note)
NOTE
◗ The Power Module is factory configured for single input, whereas both Normal AC
and Bypass AC sources are identical, by means of jumper between L1 and L3.
◗ Jumper must be removed for separate Normal AC and Bypass AC sources
(2 Mains) or with Frequency Converter application.
7
◗ Keep Manual Bypass Switch
at Normal position.
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EX 5/7/11RT 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.
Jumper must be between L1 and L3. System is factory configured for 208VAC
output.
2. Attach I/O Box to the Power Module with three screws.
Figure 2-12: Normal AC Input and Output Cables installation.
Power Module I/O Box
Output
Bypass AC source
200/208/220/230/240Vac
200/208/220/230/240Vac
Normal AC source
200/208/220/230/240Vac
L6
L5
L2
L1
L1
L4
L3
F
OF
O
1
Normal AC Input
Output
Jumper
From Utility
208 VAC
To Load
208VAC
2
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Output to Load
or
Transformer Module
(if applicable)
Simplified Connection Diagram
Bypass AC
UPSTREAM
CIRCUIT
BREAKER
(NOT SUPPLIED)
Normal AC
AC INPUT
To Load or
Transformer Module
(if applicable)
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Installation and User Manual
2.7.2
Connecting EX RT Transformer Module
(Part number 86211)
This module is to provide isolated 120/208/240 VAC outputs to the protected loads.
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
L3
L2
L1
Lb
Ld
N
Lc
La
TRANSFORMER
MODULE EX RT
AC Output to Load
(120VAC shown)
AC Input from
Power Module
(208VAC shown)
AC NORMAL
INPUT
TRANSFORMER MODULE
OUTPUT TO LOAD
WARNING
To avoid overloading transformer windings, provide branch over current
protection for all transformer output terminals.
To avoid overloading 120VAC output windings, distribute loads evenly
between Load 2 and Load 4 (on rear of Transformer Module ) and between
120VAC output terminals (Lb-N, La-N.)
Terminal Block Transformer Module Connection diagram
(located on bottom of Transformer I/O Box)
L3
L2
L1
Lb
Ld
N
Lc
La
Terminal Block capability :
120Vac
120Vac
208Vac
240Vac
AWG 4 solid or stranded wire.
208Vac
240Vac
AC Output
AC Input
Simplified Connection Diagram
Bypass AC
UPSTREAM
CIRCUIT
Transformer Module
BREAKER
(NOT SUPPLIED)
AC INPUT
Normal AC
To Load
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EX 5/7/11RT Systems
2.7.3
Connections with Separate Normal and Bypass AC sources (2 Mains)
CAUTION:
This connection requires isolation Transformer Module. Call MGE
Technical Support for details.
Figure 2-14: Normal AC and Bypass AC inputs, Output Cables Installation, and Simplified Connection Diagram.
Proceed as follows:
F
OF
O
1
1. Remove the cover plate under the I/O Box. Loosen the
terminal blocks L1 and L3, and remove the jumper.
L3
L1
CAUTION:
Always connect the earth ground wire
first.
2. Install Normal AC, Bypass AC and output cables as shown.
3. Reinstall the cover plate under the I/O Box with four screws.
4. Secure the I/O Box to the Power Module with three screws.
FF
O
O
2
See section 2.7.2 for connecting EX RT Transformer
module, if applicable.
Bypass
Normal
Output
3
4
FF
O
O
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To Load or
Transformer Module
(if applicable)
With separate Normal and Bypass AC inputs, supplied by separate sources.
BYPASS AC
MAINS 2
Isolation
Transformer
(PN 86211)
LOAD
MAINS 1
NORMAL AC
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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.
Remove the jumper connecting L3 and L1.
F
OF
O
CAUTION: Removing the jumper will
disable the Bypass AC
source. Do not connect
anything to the Bypass AC
terminal block.
1
2. Refer to section 2.7.1 to install Normal AC source
and output wires per I/O Box Terminal diagram.
Re-install the cover plate under the I/O Box.
Power Module I/O Box
3. Secure the I/O Box to Power Module with three
screws.
Output
Bypass AC source
200/208/220/230/240Vac
200/208/220/230/240Vac
See section 2.7.2 for connecting EX RT
Transformer Module, if necessary.
Normal AC source
200/208/220/230/240Vac
L6
L5
L2
L1
L1
L4
L3
FF
O
O
1
Normal AC Input
Output
Jumper
INPUT
From Utility
208 VAC
OUTPUT
To Load
208VAC
2
F
OF
O
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10
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=
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IP
Output to Load
or
Transformer Module
(if applicable)
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EX 5/7/11RT Systems
2.8
Connection of Battery Module EXB
14
1. Check that the battery circuit breaker (5)
is OFF (“0”) position.
40
6
13
2. Connect the battery power cable
Modules.
to the connectors
and
of the Power and Battery
42
4
12
3. Connect the battery detection cable
Modules.
between connectors
and
of the Power and Battery
Figure 2-16: Rear view of Battery Module cable connections.
12
4
42
40
13
6
14
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2.9
Connection of Optional CLA Module
40
42
1. Connect the battery power cable
between the Power Module and the CLA Module.
2. Connect the DC Input of the CLA Module to high power battery cabinet.
DC Input Cable cross-section (not provided): maximum 4 AWG solid or stranded wire.
3. Connect the utility AC input to terminal blocks L1 and L2 of the CLA.
and battery detection cable
(provided with the CLA Module)
◗
◗ AC input cable cross-section (not provided): maximum 16 AWG solid or stranded wires.
Field wiring connections to terminal block shall be made using the following:
– No. 14 AWG, 60º C copper wires for AC inputs.
– No. 10 AWG, 75º C copper wires for DC inputs.
Figure 2-17: Rear view of CLA Module cable battery and AC input connections
Connection Diagram
(inside CLA Module)
42
40
N
(L2)
L
(L1)
-
+
DC INPUT
AC INPUT
156-280Vac
240Vdc
Terminal tightening torque:
– 5 lb-in. for AC input terminals
– 18 lb-in. for DC input terminals
DC Input to
High Power
Battery Cabinet
Separate, 15A Utility
AC Source
@ 208 or 240
Use 15A DBL. Pole CB
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Operation
3.0
3.1
Scope
Operation describes EX 5/7/11RT systems characteristics of indicators and controls, modes and specifications and
theory of operating the EX 5/7/11RT. The user procedures include performing software programming that will
maintain smooth performance. Refer to Figure 1.6 for descriptions of circled numbers.
Initial Startup
NOTE
Both AC and DC sources must be present for normal startup of EX 5/7/11RT
systems. If the system is configured for cold start, the AC and DC sources are
required for initial startup only.
7
1. Check that the manual bypass switch
is on Normal position.
8
2. Set the Normal AC source circuit breaker
to the ON position.
14
3. Set the battery circuit breaker
to the ON position.
The load is powered via the Bypass AC source, but not protected by the UPS.
Batteries are recharging, an eight-hours recharge period is necessary to get full backup time.
17
LED
Figure 3-1: Initial Startup Display.
17
is ON.
OFF
ON
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EX 5/7/11RT Systems
3.2
UPS Personalization
WARNING
Before changing items from Tables, 3-1, 3-2, 3-3, and 3-4, the UPS system
must be turned OFF.
IMPORTANT
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 UPS
SYSTEMS, INC. Solution-Pac 2 CD-ROM.
3.2.1
Accessing personalization with front panel buttons
21
22
◗
◗
Press "scroll down"
and "scroll up"
function buttons together for more than 3 seconds.
22
Press the function button
placed under the “ENT” word to enter the set up mode and follow the
LCD messages using the buttons now defined as select keys. See Tables: 3-1, 3-2, 3-3, and 3-4 for
settings.
Figure 3-2: Control Panel with scroll up and down buttons.
UPS SET UP
EXIT ENT
OFF
ON
21
22
3 — 2
Operation
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Table 3-1: Local Settings.
Display
Factory setting
English
Options
Language
French, Spanish, German, Italian
Date/time format
Date/time change
Audible alarm
International
US
(DD-MM-YYYY/HH:MM)
Quick beeps
MM-DD-YYYY/HH:MM adjustable
Slow beeps
Table 3-2: Output Features.
Display
Factory setting
Options
Comments
Output voltage
208 Volts AC (***)
200/208/220/230/240/250
Input voltage must be equal to
output voltage
Frequency converter
Output frequency
Disabled
Enabled
50/60 Hz
Bypass AC source disabled
Auto ranging
User selectable under
frequency converter mode
ECO mode
Disabled
Enabled
See section 3.4.2.
Hot standby
Operating mode
Disabled
Enabled
Full redundancy (see Figure 3-3)
(*) See Table 3-5.
Industrial
IT Network
Bypass
When bypass NOK
When bypass OK (**)
(*) See Table 3-5.
Transfer
Interrupt time
Overload level
10 ms
102%
10 to 200 ms
(by steps of 10 ms)
Interrupt time calibration during
during load transfer when
Bypass AC source
is out of tolerances
50/70%
(*) : - Select "IT Network" for computer loads. Select “Industrial” for other applications or when there exists and absolute need
for service continuity (with potential 10msec. interrupt) when Bypass AC source is not within set tolerances.
See table 3-5 for more details
(**) UPS will switch to Bypass AC Source if it is within the set tolerances.
(***) Input voltage must be equal to output voltage.
Figure 3-3: Configuration used to provide cascade redundancy to critical loads.
BYPASS AC
Cascade redundancy configuration
offers better protection to critical
Protective Device
load, whereas the first UPS acts as
the Bypass AC Source for the
NORMAL AC
second UPS.
Utility
AC Source
Protective Device
NORMAL AC
LOAD
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EX 5/7/11RT Systems
Table 3-3: ON/OFF Features.
Display
Factory setting
Options
Enabled
Disabled
Comments
Cold start
Disabled
Enabled
Start on battery.
Forced reboot
UPS restarts automatically
when normal AC source
is restored.
Automatic restart
Enabled
Disabled
UPS restarts automatically
when normal AC source
is restored.
Sleep mode
Disabled
Enabled
Enabled
Disabled
Automatic shutdown on battery
if output load level <10%
Remote Command
Enables shutdown or restart
orders from software.
Table 3-4: Battery Features.
Display
Factory setting
Options
Comments
Battery test
Pre-Alarm
Every week
20%
No test/daily/monthly
0 to 100%
Low battery signal;1% increment
Runtime choice
UPS reads # and type
of Battery Modules
connected.
From 50 to 400 Ah
Requires CLA Module if using
options (see section 1.5.8)
Battery deep discharge
protection
Enabled
Disabled
If disabled, loss of
MGE UPS SYSTEMS, INC.
warranty.
3 — 4
Operation
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3.3
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
source in tolerance.
Load is transferred to Bypass AC source.
UPS returns to normal mode if overload
is removed.
Same as IT Network mode, but AC
to the UPS does not return to
normal mode if overload
is removed.
Overload, and Bypass
AC source not in tolerance.
The UPS shuts down and load is not
transferred to Bypass AC source.
Load is transferred to Bypass
AC source with 10 milli-
seconds output break.
The UPS does not return to
normal mode if overload
is removed.
Output short circuit and Bypass The load remains powered by the UPS.
Load is transferred to Bypass
AC source. The UPS does not
return to normal mode if the
short circuit is removed.
AC source in tolerance.
The UPS shuts down after 3 minutes
if the short circuit remains.
Output short circuit and Bypass The load remains powered by the UPS.
The load is transferred to
Bypass AC source with
10 milliseconds output break.
The UPS does not return to
normal mode if the short circuit
is removed.
AC source not in tolerance.
The UPS shuts down after 3 minutes
if the short circuit remains.
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EX 5/7/11RT 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
Then go to "Advanced settings" and "UPS settings".
Please note that the Linux/Unix/MacOS versions of Personal Solution-Pac do not include this feature.
3.3.2 Final Startup sequence
Press the <ON> button more than 3 seconds.
After UPS internal test sequence, the green LED
15
◗
goes on.
CAUTION
During the startup, if the Bypass AC source is out of
tolerance, there will be a 10msec output interrupt.
3 — 6
Operation
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3.4
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.
15
Two possible cases.
1. If Normal AC source available:
15
LED is ON.
The load is protected by the UPS.
21 22
function buttons
LOAD LEVEL
4kW / 5 kVA
OFF
ON
Scroll down
or scroll up
allow you to read the UPS measurements (Normal
AC source voltage, Bypass AC source voltage,
operating mode, battery capacity and UPS Serial
Number).
21
16
22
2. If Normal AC source not available:
15
CAUTION:
Do not operate the Manual
Bypass switch when the UPS is
in Normal mode.
REMAINING TIME
10 minutes
15
16
LED flashes.
LED is ON.
OFF
ON
The audible alarm sounds intermittently.
The load is now powered by the UPS battery.
This display shows remaining back-up time.
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Operation
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EX 5/7/11RT 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. Outside this range,
the UPS system will switch to online mode with 10ms
interrupt.
15
17
Three possible cases:
OFF
ON
1. If Normal AC source (Mains 1) and Bypass AC
Source (Mains 2) are available:
15
17
LED are ON.
and
15
The load is supplied with AC power but not protected
in ECO mode.
2. If Normal AC source (Mains 1) is available, but
Bypass AC source (Mains 2) is not available:
15
LED is ON.
OFF
ON
The audio alarm sounds intermittently.
The load is automatically supplied in Normal
mode via the Normal AC input.
15
16
3. Both Normal and Bypass AC sources not
available or out of tolerance:
15
16
LED is ON.
LED is ON.
The audio alarm sounds intermittently.
OFF
ON
The load is powered by the battery power from
the UPS.
The LCD display indicates the battery remaining
backup time.
3 — 8
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3.5
Operation on Battery Power
Figure 3-6: Transfer, Threshold and End of backup time.
3.5.1 Transfer to Battery Power
15
16
The load continues to be protected by the UPS when
the Normal AC source is not available. Power is
supplied by the battery.
There are three possible cases:
REMAINING TIME
10 minutes
First Case: Operation on battery
15
16
LED is ON.
LED is ON.
OFF
ON
The audio alarm beeps every 10 seconds.
15
16
◗
◗
This indicate the load is supplied by the battery.
The LCD display indicates the battery remaining
backup time.
Second Case: Low battery warning
REMAINING TIME
2 minutes
15
16
LED is ON.
LED flashes.
OFF
ON
The audio alarm beeps every 3 seconds.
◗
Low battery warning on LCD display. There is
very little remaining battery backup time. Close
all applications because UPS automatic
shutdown is pending.
15
16
Third Case: End of backup time
15
16
LED is OFF.
LED is OFF.
OFF
ON
The audio alarm is stopped.
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EX 5/7/11RT Systems
3.6
3.7
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.
20
1. Press the OFF button
seconds.
more than 3
17
CAUTION: The load is no longer protected by the
UPS. It is powered via the Bypass AC
source. If the UPS is set in frequency
converter mode, the load will not be
powered.
If the Bypass AC source is out of
tolerance, the UPS will generate a
calibrated 10msec output interrupt.
OFF
ON
20
14
2. Set the battery circuit breaker(s)
OFF position.
to the
14
3. Set the Normal AC source circuit breaker
to the OFF position.
8
17
LED
is now OFF.
CAUTION: Performing this step will disconnect
power to the load.
8
4. For the complete shutdown of the UPS (no
input and output power), the upstream circuit
breaker (not included) should be set to the
OFF position.
3 — 10
Operation
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Maintenance
4.0
4.1
Scope
Maintenance includes a troubleshooting guide of symptoms and possible solutions, hot swapping the Power Module
and Battery Module, and testing scenarios.
Troubleshooting
17
18
is on, there is an operating anomaly or an alarm.
◗
◗
If any of LEDs
or
Use "scroll up" or "scroll down" function button to reset the audible alarm.
Table 4-1: Troubleshooting not requiring MGE after-sales support.
Symptoms
17
Indication
Correction
LED
is on, and Bypass AC AC source is not connected
Rewire correctly to the Normal AC
source.
source is present
to the correct terminals.
the LCD display shows
BAD CONNECTION
REWIRE AC NORMAL
17
LED
is on,
Load supplied by Bypass AC source.
Push the ON button for more than 3
seconds.
the LCD display shows:
LOAD LEVEL
XX kW / XX KVA
17
LED
is on, and Bypass AC UPS overload
Check if any device is shorted or
failed.
source is present
the LCD display shows:
THERMAL OVERLOAD
1XX%
18
LED
is on, the LCD
Short circuit conditions on output
devices.
Check if any load has shorted or
failed.
display shows:
CURRENT OVERLOAD
15
LED
is on,
180° degree phase shift between
bypass and normal AC source.
Check if Bypass source is correctly
wired
(in case of upstream transformer use).
but the LCD display shows:
BYPASS REVERSE
REWIRE BYPASS
Audible alarm is on,
the LCD display shows:
I/O BOX REMOVED
Input/Output box not
installed correctly.
Check if the Input/Output box
is correctly installed. See section 2.7.
Check for correct I/O Box.
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Maintenance
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EX 5/7/11RT Systems
Table 4-2: Troubleshooting requiring MGE after-sales support.
Symptoms
17
Indication
Correction
18
LED
and
are on,
Internal fault
and transfer of load
on Bypass AC source
Call Customer Care (800) 438-7373.
(Hours: 24/7) or (800) 523-0142 (During
business hours)
Bypass AC Source is present
business
and audible alarm is on.
the LCD display shows:
xxx FAULT
17
LED
is on, and
Battery fault during the battery test. Follow the battery replacement
procedure in section 4.4.
audible alarm is on,
the LCD display shows
BATTERY FAULT
17
LED
is on,
Static switch failure
Call the Customer Care Center.
the LCD display shows:
SHUTDOWN
STATIC SW FAILED
Audible alarm is on,
the LCD display shows:
END OF WARRANTY
Batteries may have exceeded
their rated life period. Battery
capacity is severely reduced.
Follow the battery replacement
procedure in section 4.4.
NOTE: To reset the alarm permanently, press both function buttons
and
for more than 3 seconds.
22
21
4 — 2
Maintenance
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4.2
Hot Swapping the Power Module
This operation can be performed without interrupting the load.
Figure 4-1: Disconnecting the Power Module.
17
20
1. Stop the system with the OFF button
(press more than 3 seconds). System is now
powered by Bypass AC source.
Check if UPS is on Bypass AC source by
verifying that:
XXX FAULT
1CXXXXXXX
17
17
is not ON, do not
LED
is ON (If LED
OFF
ON
turn the manual bypass and call the after sales
support department).
7
2. Turn the manual bypass switch
BYPASS position.
to the
20
14
3. Switch the battery circuit breaker(s)
OFF position.
to the
ngs
tti
Se
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Ca
S
10
UP
E
t
0
10
ta
8
55
da
8FF
E0D
74
660
=
IP
0
0
A
C=
32
S2
M
R
se
Re
2
ON
1
E
T
RN
THE
E
d
oa
nl
w
Do
232
RS
42
40
CAUTION: Do not switch the Normal AC
source circuit-breaker
the OFF position.
to
8
7
Doing so will disconnect
power to the load.
φ
4. Loosen three screws to remove the
Input/Output box.
8
Step 4 in Tower
configuration
40
42
and
5. Disconnect the battery cables
from the Power Module.
The Power Module can be replaced.
The connected equipment is powered by the
Bypass AC source.
Step 4 in Rack
configuration.
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Maintenance
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EX 5/7/11RT Systems
4.3
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.
15
17
40
42
to the
2. Reconnect the cables
Power Module.
and
14
3. Switch the battery circuit breaker(s)
the ON position.
to
LOAD LEVEL
4 kW/ 5 kVA
OFF
ON
4. Check if Normal AC source circuit breaker
is on the ON position.
8
23
17
5. Check that the LED
is ON.
6. Turn the manual bypass switch from the
BYPASS to the NORMAL position.
7. Follow initial start up sequence (see section
3.1) in order to personalize the UPS.
23
8. Push the ON button
seconds.
for more than 3
15
The green LED
is ON, and the connected
equipment is now protected by the UPS.
4 — 4
Maintenance
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4.4
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, don’t hesitate to contact our Customer Care Center for more information, or refer to our web site at
Figure 4-3: Rear view of the Battery Module.
4.4.1
Disconnecting the Battery Module
Battery Module Power Module
14
1. Switch the battery circuit breaker(s)
the OFF position.
to
40
42
40
42
from the
2. Disconnect the cables
Power Module.
and
The Battery Module can be replaced.
The connected equipment is powered by the UPS,
but not protected.
It is also possible to replace the battery packs
instead of Battery Module.
CAUTION:
Always replace both
battery packs with
new ones.
To remove battery pack:
1. First, switch the battery circuit breaker(s) to
the OFF position.
See section 2.4.2 and follow instructions for
battery pack replacement.
4.4.2
Re-connecting the Battery Module
14
40
42
1. Reconnect the battery cables
the Power Module.
and
to
14
2. Switch the battery circuit breaker(s)
ON position.
to the
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4 — 6
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Appendix
5.0
5.1
Electrical Specifications
Electrical and Mechanical specifications for the EX 5/7/11RT.
System Input/Output Power Ratings
Table 5-1: EX 5/7/11 RT Voltages and Frequency Characteristics.
Source
Voltage
Frequency
Normal AC Source
Bypass AC Source
Load Output
156 to 280 VAC
160 to 242 VAC*
40 to 70 Hz
58 to 62 Hz**
200/208/220/230/240/250VAC
(120/208/240Vac
50/60 Hz autoranging
(or frequency converter)
are possible with
transformer module)
(*): depends on output voltage setting, can be modified by software.
(**): set to +/- 4% by default, (1, 2, 4, 8% are possible values), can be modified by software.
5.2
System Overload Characteristics
Figure 5-1: Power supplied as a function of input voltage (left), and permissible UPS overloads as a function of time (right).
Load Percentage
Load Percentage
1.5
100%
70%
1.25
1.1
1.02
0.5s
t
U
30s
60s
120s
120V 160V
280V
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Appendix
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EX 5/7/11RT Systems
5.3
System Backup Characteristics
Table 5-2: Backup Time (in minutes).
11 kVA with 9Ah battery modules:
10%
90
20%
40
30%
25
40%
18
50%
14
60%
11
70%
9
80%
7
90%
6
100%
5
Standard
Std + 1 EXB
Std + 2 EXB
Std + 3 EXB
Std + 4 EXB
Std + 5 EXB
191
293
392
525
637
93
61
96
135
172
201
43
71
99
120
142
30
53
84
102
113
24
44
60
86
20
34
51
67
87
17
27
43
56
68
15
24
35
48
60
14
22
30
42
143
199
261
312
102
53
7 kVA with 7Ah battery modules:
10%
20%
57
30%
37
80
124
185
245
287
40%
28
61
101
128
169
232
50%
21
53
60%
15
37
66
90
70%
12
30
55
75
80%
10
24
45
61
90%
8
100%
7
20
32
45
Standard
121
266
447
578
756
889
Std + 1 EXB
Std + 2 EXB
Std + 3 EXB
Std + 4 EXB
Std + 5 EXB
125
203
244
364
453
22
38
53
69
86
83
108
132
164
110
133
98
118
77
102
57
72
5 kVA (US model only) with 7Ah battery modules:
10%
170
20%
91
30%
49
40%
33
50%
25
60%
21
70%
16
80%
13
90%
11
100%
9
Standard
Std + 1 EXB
Std + 2 EXB
Std + 3 EXB
Std + 4 EXB
Std + 5 EXB
358
540
740
892
170
260
355
505
540
110
170
240
290
355
84
60
46
75
110
135
170
39
64
95
119
140
31
57
84
105
120
27
52
68
92
25
45
60
84
120
170
235
260
100
122
170
225
1220
110
100
5.4
5.5
System Short Circuit Protection
Short circuit current provided by EX 5/7/11RT in normal or battery mode:
EX 5/7RT
EX 11RT
110A for 80ms
150A for 80ms
Accessories Electrical Characteristics
EX RT Transformer Module
Nominal power
11 kVA
Nominal current
63 A
Input voltage
Output Voltage
Frequency
Isolation (EN 61558-1-2-4)
Operating temperature
Max. operating rel. humidity
Derating/altitude
208-240Vac
120/208/240Vac
50/60 Hz (+/-10%)
3.75 kV / 5 M ohms
From 0° to +40°C
95%
Pn-10% > 1000 m
EX RT CLA Module
AC input voltage
156-280 Volts AC
40-70 Hz
Input frequency
Battery charge current
6 A DC
5 — 2
Appendix
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Installation and User Manual
Table 5-3: Battery Recharge time to recover 90% of the rated backup time after discharge at full load.
Configuration for
2 hours backup time
Configuration for
4 hours backup time
Configuration for
8 hours backup time
EX 5RT
EX 7RT
EX 11RT
7 hours
5 hours
7 hours
15 hours
12 hours
15 hours
24 hours
20 hours
24 hours
Table 5-4: Efficiency online (RL load) and batteries fully charged.
kVA / kW
25% 50%
75% 100% Output load percentage
90
89
91
90
91
91
91
91
Output: 220 / 230 / 240 Volts
Output: 200 / 208 / 250 Volts
5kVA /
4kWatts
7kVA /
4.9kWatts
90
89
91
90
91
91
91
90
Output: 220 / 230 / 240 Volts
Output: 200 / 208 / 250 Volts
11kVA /
8kWatts
90
89
91
90
90
90
90
89
Output: 220 / 230 / 240 Volts
Output: 200 / 208 / 250 Volts
Table 5-5: Efficiency online (RCD load) and batteries fully charged.
kVA / kW
25% 50%
75% 100% Output load percentage
90
89
91
91
91
91
92
91
Output: 220 / 230 / 240 Volts
Output: 200 / 208 / 250 Volts
5kVA /
4kWatts
7kVA /
4.9kWatts
90
89
91
91
91
91
92
91
Output: 220 / 230 / 240 Volts
Output: 200 / 208 / 250 Volts
11kVA /
8kWatts
90
89
92
91
91
90
91
90
Output: 220 / 230 / 240 Volts
Output: 200 / 208 / 250 Volts
Table 5-6: Efficiency on battery (RCD load).
kVA / kW
25% 50%
75% 100% Output load percentage
87
87
89
88
89
89
88
88
Output: 220 / 230 / 240 Volts
Output: 200 / 208 / 250 Volts
5kVA /
4kWatts
7kVA /
4.9kWatts
87
87
89
88
89
89
88
88
Output: 220 / 230 / 240 Volts
Output: 200 / 208 / 250 Volts
11kVA /
8kWatts
89
88
90
90
89
89
87
88
Output: 220 / 230 / 240 Volts
Output: 200 / 208 / 250 Volts
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Appendix
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EX 5/7/11RT Systems
Table 5-7: Efficiency on ECO mode (all kinds of load) and batteries fully charged.
kVA / kW
25% 50%
75% 100% Output load percentage
96
95
97
96
96
96
97
96
Output: 220 / 230 / 240 Volts
Output: 200 / 208 / 250 Volts
5kVA /
4kWatts
7kVA /
4.9kWatts
96
95
97
96
96
96
97
96
Output: 220 / 230 / 240 Volts
Output: 200 / 208 / 250 Volts
11kVA /
8kWatts
96
95
97
96
96
96
97
96
Output: 220 / 230 / 240 Volts
Output: 200 / 208 / 250 Volts
5.6
Heat Rejection
Table 5-8: Full load heat rejection in BTU’s/hr.
System
Operation Mode
On-line
On Battery
5kVA
7kVA
11kVA
1350
1654
3033
1861
2280
3723
5.7
Environmental Characteristics
◗
The operating temperature is 0 to 40°C (8 hours at 45°C), however optimum operation is within the +20 to
+25°C range and at 5-95% humidity, non-condensing at altitude up to 3280ft without de-rating.
◗
◗
The storage temperature: -20 to 40°C. Humidity: 5-95%, non condensing.
Battery backup time is adversely affected by high and low temperatures. It is significantly reduced at tempera-
tures under 10°C. Above 25°C, battery service life is cut in half every 10°C. Above 40°C, battery manufacturers
no longer guarantee operation due to the risk of thermal runaway.
◗
Air enters through the front air vent grills and exits through the back. Always keep air vent grills unobstructed.
5 — 4
Appendix
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MGE Warranty & Proprietary Rights for Single Phase Products
Standard Warranty Form (Applicable within the United States, Canada and Mexico)
MGE Standard Single Phrase Warranty
MGE UPS SYSTEMS, INC. (“MGE”) warrants single phase products manufactured by MGE to be free from defects in materials and
workmanship for the following applicable time periods beginning with the date of purchase by or for the first end user (“Purchaser”):
The following products are covered by a one (1) year warranty period:
◗ Topaz 700 Power Conditioners and Topaz S3 Inverters. Topaz S4 Inverter (parts only), but includes parts and
labor when service startup is purchased (extended warranty available).
The following products are covered by a two (2) year warranty period:
◗ Pulsar STS, Pulsar Ellipse, Pulsar Evolution, Pulsar EX, Pulsar EXRT, EXRT and Comet Extreme.
The following products are covered by a three (3) year warranty period:
◗ Eclipse Personal.
The following products are covered by a five (5) year warranty period:
◗ Topaz T100 and Topaz T7 Ultra-Isolator Noise Suppressors and Topaz 800 Power Conditioners.
The following products are covered by a ten (10) year warranty period:
◗ Eclipse Pro and Eclipse Protel.
Any defects in materials or workmanship must be reported to MGE within the applicable warranty period. Where labor is not
included in the warranty, any labor performed by MGE shall be billed to Purchaser at, and Purchaser agrees to pay, MGE’s
standard labor rates then in effect for all warranty work performed hereunder. MGE shall have the sole right to determine if any
defective parts are to be repaired at the job site or whether they are to be returned to the factory for repair or replacement. All
items returned to MGE for repair or replacement must be sent freight prepaid to its factory. Purchaser must obtain MGE’s Return
Goods Authorization (“RGA”) prior to returning items. The conditions stated herein must be met for MGE’s warranty to be valid.
MGE will not be liable for any damage done by unauthorized repair work, unauthorized replacement parts, from any misapplica-
tion of the subject product, for damage due to accident, abuse, or act of God (such as earthquake, flood, inclement weather, rain
or fire), or relating to Purchaser’s failure to follow proper environmental conditions for the product.
In no event shall MGE be liable for loss, damage, or expense directly or indirectly arising from the use of or any defects in the
subject product, or from any other cause, except as expressly stated in this warranty. EXCEPT AS EXPRESSLY STATED IN THIS
WARRANTY, MGE UPS SYSTEMS, INC. MAKES NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY AS
TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE OR NON-INFRINGEMENT. MGE is not liable for
and Purchaser waives any right of action it has or may have against MGE for any consequential or special damages arising out
of any breach of warranty, and for any damages Purchaser may claim for damage to any property or injury or death to any person
arising out of its purchase or the use, operation or maintenance of the subject product. In no event will MGE be liable for any
labor subcontracted or performed by Purchaser for preparation of the warranted item for return to MGE’s factory or for prepara-
tion work for field repair or replacement, and MGE will not be responsible to pay any invoice therefore.
This warranty shall be exclusive of any and all other warranties express or implied and may be modified only by a writing signed
by an authorized officer of MGE UPS SYSTEMS, INC. This warranty shall extend to the Purchaser but to no one else.
Accessories supplied by MGE, but manufactured by others, carry any warranty the manufacturers have made to MGE, and which
can be passed on to Purchaser.
MGE UPS SYSTEMS, INC. makes no warranty with respect to whether the products sold hereunder infringe any patent, U.S. or
foreign, and Purchaser represents that any specially ordered products do not infringe any patent. Purchaser agrees to indemnify
and hold MGE UPS SYSTEMS, INC. harmless from any liability by virtue of any patent claims where Purchaser has ordered a
product conforming to Purchaser’s specifications, or conforming to Purchaser’s specific design.
Purchaser has not relied and shall not rely on any oral representation regarding any products sold hereunder and any oral
representation shall not bind MGE UPS SYSTEMS, INC. and shall not be part of any warranty
There are no warranties which extend beyond the description on the face hereof. In no event shall MGE UPS SYSTEMS, INC. be
responsible for consequential damages or for any other damages except as expressly stated herein.
Proprietary Rights Statement
The information in this manual is the property of MGE UPS SYSTEMS, INC., and represents a proprietary article in which MGE
UPS SYSTEMS, INC. retains any and all intellectual property rights, including exclusive rights of use and/or manufacture and/or
sale. Possession of this information does not convey any permission to reproduce, print, manufacture or have made the article
or articles shown herein. Such permission may be granted only by specific written authorization signed by an authorized officer
of MGE UPS SYSTEMS, INC.
IBM, PC-AT, ES/9000, and AS/400 are trademarks of International Business Machines Corporation. MGE and MGE UPS
SYSTEMS are trademarks of MGE UPS SYSTEMS, INC. Other trademarks that may be used herein are owned by their respec-
tive companies and are referred to in an editorial fashion only.
For Single Phase Warranty applicable outside of the United States, Canada and Mexico, refer to Single Phase International
Warranty.
January 2005 Rev C00
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Warranty and Product Registration
Thank you for choosing MGE UPS SYSTEMS, INC. for your power protection, distribution, and quality
requirements. We are pleased to have you join our increasing family of users.
In order to maximize the value you receive from this product, and to ensure that you are kept informed of
product or software updates, we recommend that you take a few minutes to register your new purchase.
You may register online at the URL noted below. Should you not have Internet access, you may mail or fax
this form back (attn: Warranty Registration) as indicated at the bottom of the page.
Please be prepared with the following information to register and validate your UPS warranty, keep
informed on software and product updates, and register your extension "Warranty+" if purchased with the
UPS.
User Information
Last name
First name
Company name
Address
Zip code
City
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
State/Province
Country
Tel
Fax *
Email*
Product information
Model
________________________________________
________________________________________
Serial Number
Date of purchase ________________________________________
Warranty Extension (Warranty+) not available on products
I have purchased a warranty extension (Warranty+)
Reference: _____________________ Contract Number: _________________
Thank you from all of us at MGE.
MGE UPS SYSTEMS, INC., 1660 Scenic Avenue, Costa Mesa, CA 92626, USA
Tel: 714-557-1636
Fax: 714-557-9788
41-000154-53 Rev B00 9/2003
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MGE Customer Care Center - Single Phase Products
Technical Support and Product Services
Technical questions? If you encounter a problem while following the instructions in this manual, or have
?
questions about the operation, repair, or servicing of your equipment, please direct calls to MGE UPS
SYSTEMS, INC. Customer Care Center or visit our web site www.mgeups.com for complete service information.
To insure that your questions are correctly answered, please obtain the part number, assembly number, and serial
number of the unit and include them in any discussions or correspondence.
Part Number:
_____________________________________________________________________
Assembly Number: _____________________________________________________________________
Serial number:
_____________________________________________________________________
Who To Contact
Technical Support:
1-800-523-0142 (during business hours)
Customer Care Center:
1-800-438-7373 (Hours: 24/7)
Customer FAQ
or International calls:
1-714-557-1636
Commitment: MGE UPS SYSTEMS, INC. is committed to providing easy to access factory trained experts that will
provide responses to any questions that you might have.
Scheduling Field Service Engineer Support
Scheduling of the MGE 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 call the MGE
toll free telephone number at 1-800-438-7373, to insure a safe installation and startup that will maintain
the MGE warranty and insure smooth performance
Return Policy for Repair of Single Phase Products (RGA)
Should you require factory service for your equipment, contact MGE Customer Care Center and obtain a Return Goods
Authorization (RGA) prior to shipping your unit. Never ship equipment to MGE without first obtaining an RGA number.
Date:
______________________________________________________
RGA Number: ______________________________________________________
Contact Name: ______________________________________________________
Rev A00 5/2005
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EX 5/7/11RT Systems
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Glossary
Term used
Definition/Meaning
@
At.
/
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.
®
2nd
Second.
AC or ac
Ambient Temp.
Ambient noise
ANSI
Alternating current, also implies root-mean-square (rms).
Temperature of surrounding air.
Acoustical noise of surrounding environment.
American National Standard Institute.
American Wire Gauge.
Electrical circuit interrupter.
AWG
Breaker
BTU or Btu
British thermal unit. Defined as the amount of heat required to raise the temperature
of one pound of water by 1°F.
Carrier
C
The company or individual responsible for delivering goods from one location to another.
Common.
CB
Circuit breaker.
cm
Centimeter.
Conduit
C.S.S.
Current rating
dBA
A flexible or rigid tube enclosing electrical conductors.
Customer Support Service.
The maximum current that a conductor or equipment can carry reliably without damage.
Decibel Adjusted.
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Glossary
G — 1
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EX 5/7/11RT Systems
dBrnC
Decibel above reference noise.
DC or dc
Earth ground
Electrician
Direct current, or voltage.
A ground circuit that has contact with the earth.
Refers to an installation electrician qualified to install heavy-duty electrical components in
accordance with local codes and regulations. Not necessarily qualified to maintain or repair
electrical or electronic equipment.
FET
Field effect transistor.
Freq.
Frequency.
Frequency slew rate
The change in frequency per unit of time. Given in term of Hz per second (Hz/sec.).
GND
Ground (safety).
Hz
Hertz, frequency measurement unit, 1Hz is one cycle per second.
Inverter mode
See “on-line” mode.
I
Current.
IEC
International Electrotechnical Commission.
IEEE
Institute of Electrical and Electronic Engineers.
Input branch circuit
The input circuit from the building power panel to the equipment.
Inverter
IGBT
I/O
An electrical circuit that generates an AC voltage source from a DC voltage source.
Insulated gate bipolar transistors.
Input/Output.
I/T or IT
kVA
Information Technology.
KiloVolt-Ampere; is equal to 1000 Volt-Ampere.
Line.
L
LCD
Liquid-Crystal Display unit.
Light Emitting Diode.
Main AC input source.
Bypass AC input source.
Milliampere.
LED
Mains or Mains 1
Mains 2
mA
MAX.
MCM
Maximum.
Thousand circular mil; standard wire sizes for multiple stranded conductors over 4/0 AWG
in diameter. M is from Roman numerical system indicating 1000.
N
Neutral.
NC
Normally closed.
NO
Normally open.
NEC
NFPA
National Electrical Code.
National Fire Protection Association.
G — 2
Glossary
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Installation and User Manual
OSHA
PCA
Occupational Safety and Health Agency.
Printed circuit assembly.
Printed circuit board.
PCB
PN
Part number.
PWM
RCD Load
Pulse Width Modulation.
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. A fan or a drill is considered a RL
load.
SCR
Silicon controlled rectifier.
Shipping damage
SPDT
Any damage done to an article while it is in transit.
Single Pole Double Throw.
Static Transfer
An solid state switching mechanism electronically controlled to pass AC power
directly from the utility to an output load.
Technician
Refers to an electronic technician qualified to maintain and repair electronic
equipment. Not necessarily qualified to install electrical wiring.
V
Volts
VA
Volt amperes
VA
Volt-amps, unit for apparent power measurement, equal V x I.
VAC or Vac
VDC or Vdc
ve
Voltage of AC type.
Voltage of DC type.
Battery voltage.
By way of.
Via
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Reorder Form
1660 Scenic Avenue
Costa Mesa, CA 92626
Use this form
to report any errors, omissions, or other problems you have experienced, or to order additional
hardcopies of this document. A free copy of this document may be downloaded from the proprietary MGE Rep Web
site. Please contact your MGE UPS SYSTEMS, INC. Representative for assistance.
NAME _____________________________________________________________________________________
COMPANY ___________________________________________________________________________________
STREET ADDRESS ____________________________________________________________________________
CITY ________________________________________ STATE __________________ ZIP ___________________
I would like to order______ (quantity @ $75.00 each) additional copies of the:
EX 5/7/11RT Systems
Installation and User Manual
86-86000-00 B00
I would like to report the following problems with this document:
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w w w. m g e u p s . c o m
Contact MGE
United States
MGE UPS SYSTEMS
1660 Scenic Ave.
Costa Mesa, CA 92626
Tel: (714) 557-1636
(800) 523-0142
Fax: (714) 557-9788
email: [email protected]
www: mgeups.com
Canada
MGE UPS SYSTEMS
#9, 2789 Thamesgate Drive
Mississauga, ON L4T 4E8
Tel: (905) 672-0990
(877) 672-0990
Fax: (905) 672-7667
email: [email protected]
www: mgeups.com
Latin America and
Other International
MGE UPS SYSTEMS
1660 Scenic Ave.
Costa Mesa, CA 92626
Tel: (714) 513-7831
(800) 523-0142 ext. 7831
Fax: (714) 434-0199
email: [email protected]
www: mgeups.com
1660 Scenic Avenue, Costa Mesa, California 92626 • (714) 557-1636
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