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3.5 to 21 kVA N+1 Inverter IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS – This manual contains important instructions for the S4 Inverter Plant that must be followed during operation of the equipment. WARNING: page ii Opening enclosures expose hazardous voltages. Always refer service to qualified personnel only. ATTENTION: L'ouverture des cabinets expose des tensions dangereuses. Assurez-vous toujours que le service ne soit fait que par des personnes qualifiees.
Owner’s Manual NOTE: 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.
3.5 to 21 kVA N+1 Inverter This manual covers these models: Product: Rating: 64074 64144 64214 7.0 kVA 120/240 Line to Neutral only 14.0 kVA 120/240 Line to Neutral only 21.0 kVA 120/240 Line to Neutral only 64074H 64144H 64214H 7.0 kVA 208/240 Line to Line only 14.0 kVA 208/240 Line to Line only 21.0 kVA 208/240 Line to Line only 3.5 kVA to 21 kVA Inverter Owner's Manual For service call 1-800-523-0142 86-153460-01 C00 06/2003 Copyright © 2003 MGE UPS SYSTEMS, Inc. All rights reserved.
Owner’s Manual 3.5 to 21 kVA N+1 Inverter Owner ’s Manual Warranty The liability of MGE UPS SYSTEMS, Inc. hereunder is limited to replacing or repairing at MGE UPS SYSTEMS, Inc.’s factory or on the job site at MGE UPS SYSTEMS, Inc.’s option, any part or parts which are defective, including labor, for a period of 12 months from the date of purchase. The MGE UPS SYSTEMS, Inc.
3.5 to 21 kVA N+1 Inverter How To Use This Manual: This manual is designed for ease of use and easy location of information. To quickly find the meaning of terms used within the text, look to the Glossary. To quickly find a specific topic, look at the Table of Contents. This manual uses Note lines and icons to convey important information. Note lines and icons come in four varieties.
Owner’s Manual CAUTION RECORD ALL SERIAL NUMBERS FOR THE S4 INVERTER AND COMPONENTS. THESE SERIAL NUMBERS WILL BE REQUIRED IF YOUR SYSTEM NEEDS SERVICE.
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Owner’s Manual Contents description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page IMPORTANT SAFETY INSTRUCTIONS . . . . . .Inside Front Cover Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi CAUTION: Record all Serial Numbers . . . . . . . . . . . . . .
3.5 to 21 kVA N+1 Inverter Section 2 Installation and Operation (continued) section 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6 2.6 2.6.1 2.6.2 2.6.3 2.6.4 2.6.5 2.7 DC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 DC Input Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 AC Input/Output Voltage Selection . . . . . . . . . . . . . . . . . . . . .
Owner’s Manual Section 3 Maintenance Adjustment and Troubleshooting section description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Instructions for Servicing . . . . . . . Preventative Maintenance . . . . . . . . . . . Equipment Adjustment and Calibration . . Air Intake Cleaning . . . . . . . . . . . . . . . . AC Fan Replacement . . . . . . . . . . . . . .
3.5 to 21 kVA N+1 Inverter Figures figure description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-1 System Configurations. (N+1 = added redundancy) . . . . . . . . . . . 1-2 2-1 2-2 2-3 2-3a 2-4 2-5 2-6 2-6a 2-7 2-8 Installation Drawing, 7 kVA Inverter System . . . . . . . . . . . . . . . . .2-2 Front View, 7 kVA, System Component Description . . . . . . . . . . . .2-3 Line To Neutral Inverter Receiver Junction Box . . . . . . . . . . . . . . .
Owner’s Manual Introduction 1.0 WARNING: An AC output will be present at the output terminals immediately when AC input is energized. ATTENTION: La tension alternative de sortie appara ît dès la mise sous tension de l'entrée. WARNUNG! Eine Ausgangsspannung liegt an den Ausgangsklemmen, sobald der Netzeingang angeschlossen wird. Scope This manual provides technical information for installation, operation, and maintenance of MGE inverter systems series ranging from 3.5 kVA to 21 kVA.
3.5 to 21 kVA N+1 Inverter 1.1 General Description This static, modular inverter system series provide stable, distortion-free AC power from a DC input source at a selectable output voltage and frequency prior to shipment, for sensitive equipment. With a built-in static transfer switch, the inverter also forms a reliable and economical part of uninterruptible power supply systems in either online or off-line mode.
Owner’s Manual Table 1-2: Inverter Module Dimensions. Inverter Module HEIGHT (in/cm) DEPTH (in/cm) WIDTH (in/cm) WEIGHT (lb/kg) 5.18 / 13.16 15.12 / 38.4 15.76 / 40.03 46 / 20.86 64004-9MSK1 Note: Weight: Six-mod receiver = 135 lbs. (61.2 kg) 1 UPS Module = 46 lbs. (20.09 kg) Total System Weight, 21 kVA system = 411 lbs. (186.4 kg) 1.3 Electrical Specifications Electrical Specifications are subject to revision without notice. 1.3.1 DC Input Nominal: -48Vdc; Operating Range: -39.
3.5 to 21 kVA N+1 Inverter Efficiency 85% minimum, 88% typical (on-line mode); 97% typical (off-line mode) at full kVA/Watt load. Power Factor Rated kVA is available over a power factor range of 0.6 lagging to 0.6 leading at nominal voltage. Watt rating should not be exceeded. Total Harmonic Distortion Less than 1% for linear load conditions, 3% maximum for crest factor loads up to 3:1. Line Regulation System output voltage variation, less than 1% over the DC voltage range.
Owner’s Manual 1.5 1.5.1 Environmental Specifications Operating Temperature All models operate to specifications from -5°C to +50°C (+23°F to +122°F) for altitude up to 3,300 feet (1006 Meters), and -5°C to 35°C (+23°F to + 95°F) for up to 13,300 feet (4054 Meters). Shipping Temperature -40°C to +75°C (-40°F to +192°F) for shipping; Not recommended for storage. Storage Temperature -40°C to +60°C (-40°F to +166°F). Operating Humidity 0 to 90% relative, without condensation.
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Owner’s Manual Installation and Operation IMPORTANT: 2.0 Equipment is factory set to operate at 120VAC for Line to Neutral and 240VAC for Line to Line units. Please read installation procedure to configure for Line to Neutral and 240VAC for Line to Line units other configurations. Scope This section describes installation of the inverters, including receiving, handling, and storage procedures, prerequisites to the installation, installation procedures, and start-up procedures. 2.
3.5 to 21 kVA N+1 Inverter 2.3 Mechanical Mounting The equipment can be floor mounted or rack mounted in a 19” (48.3 cm), 23” (58.4 cm), or 25” (63.5 cm) rack. Optional mounting bracket kits can be ordered for rack mounting in a 25” (63.5 cm) or 26” (66.0 cm) rack. All receivers and inverter power modules are shipped separately from the factory. Receivers will be shipped on a pallet.
Owner’s Manual Figure 2-2: Front View, 7 kVA, System Component Description. Inverter on/Stand by WARNING: Communications Port Controller Status LEDs Redundant Microcontroller Panel Disconnect AC (Mains) and DC supply before removing this cover.
3.5 to 21 kVA N+1 Inverter 2.4 Wiring Connections Line to Neutral Units Note: For Line to Line units please skip to section 2.7, page 2—10. 2.4.1 Grounding For safety and proper operation of the unit, including maximum attenuation of electrical noise, suitable grounding is required. A separate grounding electrode conductor should be connected from the safety ground (GND) terminal to a nearby grounding electrode, and should be sized per National Electrical Code Article 250-94.
Owner’s Manual 2.5.2 DC Input Normal: -48VDC Operating Range: -39.5 VDC to -57VDC This system is designed for battery systems with the positive terminal Earth Ground. All DC breakers are in the negative DC lines. The system DC terminals are isolated from Earth Ground. 2.5.
3.5 to 21 kVA N+1 Inverter Figure 2-3a: Static Switch Section - Input and Output Wiring.
Owner’s Manual 2.5.4 Connections All DC input connections are made through the knock-outs, located in the top or left side panel. Refer to Figure 21. Make sure that the upstream source DC circuit breaker and AC circuit breaker (if applicable) supplying the inverter are in the off (or open) position. DC input power cables should be sized such that the maximum voltage drop between inverter busbar terminals and battery terminals is less than 1.0 volt at the breaker current rating.
3.5 to 21 kVA N+1 Inverter The utility input and output cables are connected to a screw type terminal block. Connect the ground wires first, then the neutral wires, then connect the AC input wire (if applicable) and the AC output wire. A separate, optional Maintenance Bypass unit and a Power Distribution panel (200A Square D “QO” type of circuit breakers) are available. 2.5.5 AC Input/Output Voltage Selection The inverter is preset at the factory for 120VAC input, ON-LINE, 120VAC, 60 Hz output.
Owner’s Manual 2.6 Software Configuration Set-Up The factory default configurations of the inverter plant is: 120V, 60Hz, Utility voltage connected and Mode of operation is Online. If the factory configuration is different, the inverter will ship with marking that will describe the inverter plant configuration. Use the configuration setup program when a different configuration is required or when a new processor is installed.
3.5 to 21 kVA N+1 Inverter 2.6.3 Unit kVA Rating ID Label For kVA rating see the inverter ID label. Use the label kVA rating, regardless of the number of inverter modules installed. The processor will detect and display the number of modules installed and the number of modules that are “ON” and operating without fault. MGE is offering the 7, 14, and 21 kVA rating. 2.6.4 On-Line Mode On-line mode is the mode in which the load is powered by the inverter system, not the utility.
Owner’s Manual 2.7 Wiring Connections Line to Line Units Note: For Line to Neutral units continue to section 2.11, page 2—17. 2.7.1 Grounding For safety and proper operation of the unit, including maximum attenuation of electrical noise, suitable grounding is required. A separate grounding electrode conductor should be connected from the safety ground (GND) terminal to a nearby grounding electrode, and should be sized per National Electrical Code Article 250-94.
3.5 to 21 kVA N+1 Inverter 2.8.3 DC Input Circuit Breaker Due to tremendous amounts of short circuit current available (in excess of 1000A for as long as several minutes!) from bank(s) of batteries, that supply electrical power to inverter systems, it is extremely important to connect a properly sized DC circuit breaker at the DC input cable that feeds the inverter system. The following table is provided as a guide for selecting the proper circuit breaker.
Owner’s Manual Figure 2-6a: Static Switch Section - Input and Output Wiring.
3.5 to 21 kVA N+1 Inverter 2.8.4 Connections All DC input connections are made through the knock-outs, located in the top or left side panel. Refer to Figure 21. Make sure that the upstream source DC circuit breaker and AC circuit breaker (if applicable) supplying the inverter are in the off (or open) position. DC input power cables should be sized such that the maximum voltage drop between inverter busbar terminals and battery terminals is less than 1.0 volt at the breaker current rating.
Owner’s Manual Figure 2-7: Line To Line Setup Screen. Line To Line Inverter Configuration ? Rack kVA rating Utility 7.0 14.0 Voltage connected 21.0 AC tree Inverter voltage 208 x Mode 220 230 240 On-line Off-line Inverter frequency 50 hz 60 hz DC fail auto restart Save Cancel After the selections are complete, click on the Save button. The data will be sent to the appropriate address in the controllers “EEROM”.
3.5 to 21 kVA N+1 Inverter 2.10 Redundant Controller Set-Up After making sure the 48VDC power has been removed from the unit, remove the two Phillips head screws from the display panel as above. Re-install the top controller printed board that was previously partially removed. Using the circuit board retaining bracket, disengage the bottom controller board from its connector. Replace the display panel and secure it with the two Phillips head screws previously removed.
Owner’s Manual 2.11 Indicators and Controls There are six LED indicators divided into three groups – DS1 and DS2, DS3 and DS4, DS5 and DS6 - on the display front panel. DS1 and DS2 are indicators of controller A; DS3 and DS4 are indicators for controller B; DS5 and DS6 are for output capacitors fuse indicators. Failure of output capacitors will trip output fuses, and will activate DS5 and/or DS6 indicators. See Figure 2-9.
3.5 to 21 kVA N+1 Inverter Figure 2-9: S4 Inverter Components. Inverter on/Stand by WARNING: Communications Port Controller Status LEDs Redundant Microcontroller Panel Disconnect AC (Mains) and DC supply before removing this cover.
Owner’s Manual 2.12 Remote Alarm The system provides three alarm signals, namely, Utility alarm, Minor alarm, and Major alarm. ◗ Utility alarm – Utility alarm is ON when utility input voltage is lost/out of tolerance. ◗ Minor alarm – The system sends out this signal to indicate something is not functioning properly, but inverter can still maintain the load. ◗ Major alarm – Whenever load is lost power and the system is energized. For alarm connection, see Table 2-5. 2.12.
3.5 to 21 kVA N+1 Inverter 2.13 Start-Up Sequence Confirm that all power modules’ ON/OFF circuit breakers are set to the OFF position. On the LCD “Display” panel, be sure inverter switch SW1 is set at STANDBY position. 2.13.1 Power-Up Procedure Turn the main source DC input circuit breaker ON to apply 48VC to the system. The “controller” boards and LCD “Display” panels are now energized. The following message will be displayed. See Figure 2-9.
Owner’s Manual M a i n t e n a n c e A d j u s t m e n t a n d Tr o u b l e s h o o t i n g CAUTION: ATTENTION VORSICHT Troubleshooting the static inverter should be done only by qualified electronic technicians. Connecting and disconnecting the input and output power conductors in the course of troubleshooting should be done in accordance with the installation instructions in Section 2 of this document.
3.5 to 21 kVA N+1 Inverter 3.0 Scope This section describes the maintenance and service of the S4 Inverter, including safety instructions, preventive maintenance, descriptions of replacement kits, and a troubleshooting table. 3.1 Safety Instructions for Servicing IMPORTANT SAFETY INSTRUCTIONS FOR INVERTER SERVICING SHOULD BE PERFORMED OR SUPERVISED BY QUALIFIED PERSONNEL ONLY. 3.
Owner’s Manual 3.3 Equipment Adjustment and Calibration The equipment is factory adjusted and, normally, no further adjustments and calibration are required. However, in the course of repair, components may have to be changed that will require configuration of the equipment. These configurations should only be made by a qualified technician. 3.4 Air Intake Cleaning Inspect the air intake and exhaust openings for blockage. Verify that air flows freely through the equipment.
3.5 to 21 kVA N+1 Inverter 3.7 Replacement Parts MGE offers a complete spare parts kit for each model number. Spare parts kits include the inverter modules. Parts (those included in the spare parts kit) can be ordered individually or as a complete parts kit. To order on individual part, give the full description along with the complete model number and serial number of the inverter. Table 3-1: Spare Parts and Kits.
Owner’s Manual 3.8 Redundant Microprocessor (72-153588-00) Installation/Configuration Follow this procedure to replace or add a microprocessor board to the S4 Inverter. Only one microprocessor can be configured at a time. To configure a microprocessor, install only that microprocessor board in the inverter receiver. The redundant microprocessor board is factory calibrated and pre-configured. Please see the configuration on the label. If this is the desired configuration, skip steps 6 to 10.
3.5 to 21 kVA N+1 Inverter 3.9 Troubleshooting and Servicing Should you encounter a problem in the operation of the inverter and need MGE Systems to service your equipment, it is recommended to leave the unit in its current state. Record message (if any) and color signals on the LCD display and LED indicators on the display panel, then call MGE Customer Support Services at 1-800-523-0142 for assistance.
Owner’s Manual 3.11 Troubleshooting Guide After having thoroughly reexamined the installation and setup of the system, and still found it un-operational, user can follow Table 3-2 to identify a problem, its cause, and recommendations for fixing it. Table 3-2: Troubleshooting table. Problem Possible Cause Possible Solution Display panel not illuminated No power to system Check AC & DC power sources.
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Owner’s Manual Glossary Symbols 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. ABC Normal sequence of phase (clockwise) in three-phase power. AC or ac Alternating current, also implies root-mean-square (rms). Ambient Temp. Temperature of surrounding air. Ambient noise Acoustical noise of surrounding environment.
3.5 to 21 kVA N+1 Inverter BYPASS See “Static Transfer switch”. Bypass Maintenance bypass; wrap-around manual maintenance bypass using the optional bypass circuit breaker Q3BP in conjunction with circuit breaker Q4S and isolation circuit breaker Q5N. Bypass AC Input Mains 2. BYPASS mode See “off-line mode”. Carrier The company or individual responsible for delivering goods from one location to another. C Common. CB Circuit breaker. cm Centimeter. Comm. Communication.
Owner’s Manual 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 An electrical circuit that generates an AC voltage source from a DC voltage source.
3.5 to 21 kVA N+1 Inverter NO. or No. Part number. NO Normally open. Online mode Inverter output power is the primary energy source to load. Offline mode Inverter output is off, and the load connected at the inverter output receives power from utility line via a static transfer switch or maintenance bypass relay. OSHA Occupational Safety and Health Agency. PCA Printed circuit assembly. PCB Printed circuit board. P.F. Power Factor. PWM Pulse Width Modulation.
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