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MGE UPS Systems POWER-SURE 700 manual

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Table of contents for the manual

  • Page 1

    Three Phase Power Conditioners Installation and User Manual www .mgeups.com Po w e r - Sure ™[...]

  • Page 2

    IMPORT ANT SAFETY INSTRUCTIONS SA VE THESE INSTRUCTIONS – This manual contains important instructions for Power-Sure™ 700 that must be followed during operation of the equipment. W ARNING Opening enclosures expose hazardous voltages. Always refer service to qualified personnel only . A TTENTION L'ouverture des cabinets expose des tensions [...]

  • Page 3

    86-108814-00 B01 W ARNING T o reduce the risk of fire or electric shock, install in a temperature and humidity controlled indoor area free of conductive contaminants. This equipment is intended only for installations in a RESTRICTED ACCESS LOCA TION. A TTENTION Pour réduire le riske d'inccendie ou d'électrocution, installer dans une enc[...]

  • Page 4

    86-108814-00 B01 Power-Sure™ 700 — Three Phase Power Conditioners iv CAUTION: Record All Serial Numbers CAUTION: Record All Serial Numbers! RECORD ALL SERIAL NUMBERS FOR THE POWER-SURE™ 700 AND COMPONENTS. THESE SERIAL NUMBERS WILL BE REQUIRED IF YOUR SYSTEM NEEDS SERVICE. KEEP THIS MANUAL IN A PLACE WHERE YOU CAN REFERENCE THE SERIAL NUMBERS[...]

  • Page 5

    v Installation and User Manual 86-108814-00 B01 Power-Sure™ 700 Thr ee Phase Power Conditioners Installation and User Manual Revision History Power-Sure™ 700 Three Phase Power Conditioners Installation and User Manual 86-108814-00 Revision: A00 Initial Release 09/2003 A01 ECN#: 003787 02/2004 B00 ECN#: 004681 08/2006 B01 ECN#: 005088 12/2006 Fo[...]

  • Page 6

    (This page left blank intentionally) Power-Sure™ 700 — Three Phase Power Conditioners vi 86-108814-00 B01[...]

  • Page 7

    86-108814-00 B01 c i Installation and User Manual Contents section description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page IMPORT ANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .ii Certification Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii Ho[...]

  • Page 8

    Section 3 Maintenance section description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3.0 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 1 3.1 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 1 Power-Sure?[...]

  • Page 9

    Contents c iii Installation and User Manual Figures figure description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-1: Power-Sure™ 700 — 10-15kV A Mechanical Cabinet Measurements . . .2 — 2 2-2: Power-Sure™ 700 — 25-30kV A Mechanical Cabinet Measurements . . .2 — 3 2-3: Power-Su[...]

  • Page 10

    (This page left blank intentionally) Power-Sure™ 700 — Three Phase Power Conditioners c iv 86-108814-00 B01[...]

  • Page 11

    1.0 Scope This section is a general description of the Power-Sure™ 700 Three Phase Power Conditioners. Includes receiving, location and storage, electrical, mechanical specifications, monitoring, and internal protection for components. 1.1 Reference Manuals N/A 1.2 Section Descriptions This manual is divided into three sections: Section 1: Introd[...]

  • Page 12

    1.3 Receiving and Inspection Notes Before accepting the shipment from the freight carrier , inspect the exterior surfaces of all shipping containers or packaging used, and the equipment, for damage that may have occurred during transit. If the shipping containers or equipment shows evidence of damage, note the damage on the receiving document (bill[...]

  • Page 13

    Introduction - Specifications 1 — 3 Installation and User Manual 1.4.1 Electrical and Performance Specifications * Output Maintained to within ± 3% of nominal. * Input +10% to -20% of the nominal rated input. * Frequency 60 Hertz ± 3 Hertz. Efficiency 95% Minimum. Line Regulation Output is ± 3% of nominal for input variations of +10% to -20% o[...]

  • Page 14

    1.4.3 Input Breaker Main input molded case circuit breaker , rated at 125% of full load input current. 1.5 Monitoring the Power-Sure™ 700 Monitoring of the Power-Sure™ 700 is simple, clean, and effective. Three green light indicators are utilized to display “POWER ON” (output line to neutral for each phase) and one red light indicator to di[...]

  • Page 15

    2.0 Scope This section describes installation requirements, system dimensions, cable connections, and start-up procedures for the Power-Sure™ 700 Three Phase Power Conditioners. W ARNING: HIGH VOL T AGE, ONL Y QUALIFIED ELECTRICIANS SHOULD INST ALL OR PERFORM MAINTENANCE. 2.1 Installation Notes ◗ The Power-Sure™ 700 requires ventilation. Refe[...]

  • Page 16

    2.3 Power-Sure™ 700 Installation Drawings and Cabinet Dimensions When sizing the Power-Sure™ 700, be sure to take into consideration all loads and circuits the Power-Sure™ 700 is to supply . Figure 2-1: Power-Sure™ 700 — 10-15kV A Mechanical Cabinet Measurements. 24" (609.60m) CLEARANCE FOR SERVICEABILITY 30" (762m) 21.5" ([...]

  • Page 17

    Figure 2-2: Power-Sure™ 700 — 25-30kV A Mechanical Cabinet Measurements. 24" (609.6m) CLEARANCE FOR SERVICEABILITY 44" (1 1 17.6m) 21.5" (546.1m) POWER ON ALERT INPUT CIRCUIT BREAKER BYP ASS SWITCH (OPTIONAL) INPUT TERMINALS ALLEN BRADLEY 31492 -CE2 #12-I/O WIRE INPUT GROUND TERMINAL ILSCD #T A-2 #2-#14 WIRE HOLE PROVIDED FOR 1 I[...]

  • Page 18

    Installation and Operation Power-Sure™ 700 — Three Phase Power Conditioners 2 — 4 86-108814-00 B01 Figure 2-3: Power-Sure™ 700 — 45-150kV A Mechanical Cabinet Measurements. COOLING F ANS 29.000 44.000 45.000 27.000 3.500 9.000 5.500 12.000 PREFERED OUTPUT CONDUIT LOCA TION PREFERED INPUT CONDUIT LOCA TION FRONT VIEW A OUTPUT BC CONDITIONE[...]

  • Page 19

    86-108814-00 B01 Installation and Operation 2 — 5 Installation and User Manual Figure 2-4: Power-Sure™ 700 — 225-300kV A Mechanical Cabinet Measurements. 2.4 General Operation Notes The Power-Sure™ 700 Power Conditioners provides the triple function of isolation, noise attenuation and voltage regulation. The first two functions are provided[...]

  • Page 20

    Installation and Operation Power-Sure™ 700 — Three Phase Power Conditioners 2 — 6 86-108814-00 B01 As the input voltage (building power) varies, the voltage available at each tap of the transformer will also change. The amount of variation is dependent upon the input sag or surge, turns ratio and transformer losses. By selecting a particular [...]

  • Page 21

    Installation and Operation T able 2-1: 480 V AC Input and 208 V AC Output Wire Size Chart. Unit Size Input Input Minimum Maximum in kV A Breaker Wire Ground Wire Output Size Size Size Current 10 15 Amp #10 #10 28 15 25 Amp #10 #8 42 25 50 Amp #8 #4 70 30 50 Amp #8 #4 83 45 80 Amp #6 #2 125 50 80 Amp #6 #2 139 75 125 Amp #1 #6 208 100 150 Amp 1/0 4/[...]

  • Page 22

    2.6 Start-Up Sequence W ARNING: THERE ARE DANGEROUSL Y HIGH VOL T AGES PRESENT WITHIN THE ENCLOSURE OF THE POWER SUPPL Y SYSTEM. CAUTION MUST BE T AKEN WHEN WORKING WITH THE ENCLOSURE. IT IS RECOMMENDED THA T ALL WORK BE PERFORMED BY QUALIFIED ELECTRICAL PERSONNEL ONL Y . NOTE: INITIAL ST AR T -UP SHOULD BE PERFORMED WITH NO-LOAD ON THE SYSTEM. 1. [...]

  • Page 23

    3.0 Scope This section contains preventive maintenance for the Power-Sure™ 700, electrical connection troubleshooting, checking power modules (SCR), voltage adjustments, and PCB card troubleshooting to assist the user with commu- nication and configuration connections. W ARNING: HIGH VOL T AGE DANGER OF ELECTRICAL SHOCK, TURN OFF ALL POWER SUPPLI[...]

  • Page 24

    Maintenance Power-Sure™ 700 — Three Phase Power Conditioners 3 —2 86-108814-00 B01 Power-Sure ™ 700 Performance Checklist Company : ____________________________________________________________________________________ Model #:_________________________________________ Serial #: ______________________________________ 1. Customer Comments or Pr[...]

  • Page 25

    Maintenance 3 —3 Installation and User Manual 86-108814-00 B01 Power-Sure ™ 700 Performance Checklist (Continued) 9. Input/Output V oltage Checks (Adjust as needed): No Load Input No Load Output A-B____________V AC AN____________V AC A-B____________V AC B-C____________V AC BN____________V AC B-C____________V AC A-C____________V AC CN___________[...]

  • Page 26

    3.2 T roubleshooting Guide SYMPTOM PROBABLE CAUSES 1. No Output on One or More Phases. A. Blown Fuse. B. Defective SCR or Power Module C. Defective Control Card. D. Defective Sense Card. E. No Input. 2. Output is to High or to Low . A. Control Card Adjustment. B. Defective Control Card. C. Defective Sense Card. D. Defective SCR or Power Module E. I[...]

  • Page 27

    Maintenance 3 —5 Installation and User Manual 3.3.1 Step 1. Disassembling the Power Conditioners 1. T urn off the power to the conditioner at its source. 2. T urn off the input circuit breaker on the unit and the output circuit breakers to all loads. (Remove all loads from unit). 3. Remove the top and side covers to the conditioner . 3.3.2 Step 2[...]

  • Page 28

    NOTE: When checking the power module assembly , if more than one defective power module is present it will appear as if all the power modules are defective. The individual power module must be isolated from the power transformer: ◗ K1-1 to K2-1 thru K1-7 to K2-7 = High resistance, 1 Meg Ohm. ◗ K1-1 to G1-1 thru K1-7 to G1-7 = 10 to 90 Ohms. ◗[...]

  • Page 29

    Maintenance 3 —7 Installation and User Manual RE-CONNECT SEMI-CONDUCTOR FUSE, AND ALL WIRES AND F ANS. DOUBLE CHECK THA T ALL CONNEC- TIONS ARE SECURE. NOTE: Control board #49120 is for 10kV A to 50kV A units. Control board #407415 is for 75kV A and larger . DO NOT CONNECT TB1, TB2, and TB3 CONNECTORS FROM THE CONTROL CARDS #49120/407415 YET! 3.5[...]

  • Page 30

    FORMULA AC Input x 2.47 = V olts DC at TP2 480 (Nominal) Example: 475 V olts AC Input x 2.47 = 2.44 V olts DC at TP2 480 (Nominal) 8. After calculations are complete, place DC voltmeter on the 20 volt scale and check between TP2 and TP GND on control card. Adjust pot P1 so meter reads DC level calculated in Step 7 of Section 3.5.1 for all three pha[...]

  • Page 31

    Maintenance 3 —9 Installation and User Manual 5. T urn the input circuit breaker off. 6. Connect customers equipment. 7. Energize system. 8. Repeat Step #4 and adjust as needed. 9. Be sure over/under detect is connected and if input breaker trips or there is no output voltage, re-calibrate the detect board or replace board if defective. 3.7 Unit [...]

  • Page 32

    Figure 3-5: Power-Sure™ 700 — 45-150kV A Major Components (Rear View). SENSE CARD CONTROL CARD HEA TSINK REGULA TOR ASSEMBL Y COOLING F AN OUTPUT TERMINAL P ADS MUL TI-SHIELDED ISOLA TION TRANSFORMER OUTPUT FIL TERING INPUT TERMINAL P ADS SEMI-CONDUCTOR FUSES SCR POWER MODULE SNUBBER CARD Maintenance Power-Sure™ 700 — Three Phase Power Cond[...]

  • Page 33

    Maintenance 3 —11 Installation and User Manual Figure 3-6: Power-Sure™ 700 — 225-300kV A Cable Connections, Input Output Locations. 41.5" (1054.1m) 77.207" (159.9m) 35" (889m) 2.75" (69.85m) 56" (1422.4m) 50.5" (1282.7m) 2.75" (69.85m) 32" (1812.80m) POWER ON ALERT INPUT CIRCUIT BREAKER (TERMINA TE INPU[...]

  • Page 34

    3.8 SCR Heat Sink Assemblies Figure 3-7: Power-Sure™ 700 — 10-30kV A SCR Heatsink Assembly . SHUNT GA TE CONNECTIONS G1 - 1 THROUGH G1 - 7, G2 - 1 THROUGH G2 - 7 (TYPICAL) FUSIBLE LINK THERMAL SENSOR T AP WIRES FROM POWER TRANSFORMER (K2-1 THROUGH K2-7 CONNECTIONS, TYPICAL) CABLE TO TRANSFORMER SEMI-CONDUCTOR FUSE POWER MODULE Maintenance Power[...]

  • Page 35

    Maintenance 3 —13 Installation and User Manual Figure 3-8: Power-Sure™ 700 — 45-50kV A SCR Heatsink Assembly . SHUNT GA TE CONNECTIONS G1 - 1 THROUGH G1 - 7, G2 - 1 THROUGH G2 - 7 (TYPICAL) FUSIBLE LINK THERMAL SENSOR T AP WIRES FROM POWER TRANSFORMER (K2-1 THROUGH K2-7 CONNECTIONS, TYPICAL) CABLE TO TRANSFORMER SEMI-CONDUCTOR FUSE POWER MODU[...]

  • Page 36

    Figure 3-9: Power-Sure™ 700 — 75-150kV A SCR Heatsink Assembly . GA TE CONNECTIONS G1 - 1 THROUGH G1 - 7, G2 - 1 THROUGH G2 - 7 (TYPICAL) FUSIBLE LINK (CONTINUOUS THROUGH EACH POWER MODULE) THERMAL SENSOR T AP WIRES FROM POWER TRANSFORMER (K2-1 THROUGH K2-7 CONNECTIONS, TYPICAL) INPUT CABLE POWER MODULE HEA TSINK DIODE Maintenance Power-Sure™[...]

  • Page 37

    Maintenance 3 —15 Installation and User Manual Figure 3-10: Power-Sure™ 700 — 225-300kV A SCR Heatsink Assembly . 3.9 Field Adjustments of Circuit Cards 3.9.1 Power-Sure™ 700 Control Card #49120/407415 W ARNING: ALL SERVICE T O THIS PIECE OF EQUIPMENT MUST BY PERFORMED BY QUALIFIED PERSONNEL. GA TE LEADS (TYPICAL) FUSIBLE LINK (CONTINUOUS T[...]

  • Page 38

    CAUTION: THE CONTROL BOARD (#49120/407415) IS ELECTRICALL Y REFERENCED TO HIGH VOL T AGE, NOT EARTH OR CHASSIS GROUND. EXTREME CARE MUST BE USED WHEN T AKING MEASUREMENTS ON THE CONTROL BOARD. ANY AC POWERED INSTRUMENTS MUST BE GROUND ISOLA TED PRIOR T O T AKING MEASUREMENTS. A GROUND ISOLA TED INSTRUMENT CASE WILL BE A T THE HIGH VOL T AGE LINE PO[...]

  • Page 39

    Maintenance 3 —17 Installation and User Manual FORMULA X AC Input x 2.47 = V olts DC at TP2 480 (Nominal) Example: 475 V olts AC Input x 2.47 = 2.44 V olts DC at TP2 480 (Nominal) NOTE: Be sure AC input is stable when making this adjustment. If the input changes, you must re-calculate. 7. After calculations are complete, place DC voltmeter on 20 [...]

  • Page 40

    2. P1 will adjust the overvoltage set point. One turn on P1 will change the voltage level approximately 1 volt. Clockwise = Decrease Sensitivity . Counter-clockwise = Increase Sensitivity . 3.9.3.3 Delay Adjustment 1. The delay adjustment can be adjusted for a minimum of 5 cycles to a maximum of 15 seconds. The standard set point is 6 seconds. 2. P[...]

  • Page 41

    Maintenance 3 —19 Installation and User Manual 3.1 1 Replacement Parts Individual components are available upon request. Please contact MGE for specific part numbers and prices. See Section 3.7 in this manual for component location and description. When contacting MGE Service at 1-800-523-0142, please have the unit’s full model number and seria[...]

  • Page 42

    T able 3-1: Power-Sure™ 700 Power Conditioners Part Numbers (Continued). Part Number kV A Input V oltage Output V oltage Hz TDL-010K-6 10 TDL-015K-6 15 TDL-025K-6 25 TDL-030K-6 30 TDL-045K-6 45 TDL-050K-6 50 480 208/120 60 TDL-075K-6 75 TDL-100K-6 100 TDL-125K-6 125 TDL-150K-6 150 TDL-225K-6 225 TDL-300K-6 300 TDN-010K-6 10 TDN-015K-6 15 TDN-025K[...]

  • Page 43

    Figure A-1: 10-50kV A W iring Diagram. 86-108814-00 B01 TDL-010K-6 TCL-010K-6 TBL-010K-6 8DLX-10K-7A 8CLX-10K-7A 8BLX-10K-7A 7 (E) OUTPUT CONDITIONED POWER C B A OUTPUT TERMINALS G G G OUTPUT FIL TER ASSEMBLY 32(B) 33(B) 34(B) 7(B) 35(B) 36(B) 37(B) L1 L2 L3 N G 10(A) 32(E) 33(E) 34(E) BLACK/WHITE TWIST 18 GAGE (T YP .) 7 (E) 28 (E) 27 (E) 26 (E) 2[...]

  • Page 44

    86-108814-00 B01 FWH-600 FWH-600 FWH-200 #1/0 #1/0 #1/0 #1/0 225A 200A 125A 8DNX-150K-7A 8DNX-125K-7A 8DNX-75K-7A TDN-150K-6 TDN-125K-6 TDN-075K-6 480V AC 480V AC 480V AC 75,125,150KV A 480V 40(A) 39(A) 38(A) 4(A) G G G A B C OUTPUT CONDITIONED POWER Z2 Z3 Z4 Z5 Z6 OUTPUT SURGE PROTECTION 80 (A) 73 (A) 47 (A) 48 (A) OPTIONAL THREE PHASE SEQUENCE &a[...]

  • Page 45

    480V 40(A) 39(A) 38(A) #1/O #1/O #1/O 225A 200A 125A 8DNX-150K-7A 8DNX-125K-7A 8DNX-75K-7A 480V AC 480V AC 480V AC 28 (**) 21(**) 14 (**) 9(**) 8(**) 7(**) 2 1 10 12 5 7 8 6 9 11 3 4 NORMAL BY-P ASS 4(A) G G G A B C OUTPUT CONDITIONED POWER Z1 Z2 Z3 Z4 Z5 Z6 OUTPUT SURGE PROTECTION INPUT SURGE PROTECTION 80 (A) 73 (A) 47 (A) 48 (A) OPTIONAL THREE P[...]

  • Page 46

    (This page left blank intentionally) Power-Sure™ 700 — Three Phase Power Conditioners A —4 86-108814-00 B01[...]

  • Page 47

    MGE W arranty & Proprietary Rights Statement for Three Phase Products (Applicable within the United States, Canada and Mexico) MGE Standard Three Phase W arranty MGE UPS SYSTEMS, INC. (“MGE”) warrants three phase products it manufactures to be free from defects in materials and workmanship for a period of three hundred sixty five (365) days[...]

  • Page 48

    MGE Customer Care Center — Three Phase Products T echnical Support and Product Services T echnical questions? If you encounter a problem while following the instructions in this manual, or have question the operation, repair , or servicing of your equipment, please direct calls to MGE UPS SYSTEMS, INC. Customer Care Center or visit our web site w[...]

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    1660 Scenic Avenue, Costa Mesa, California 92626 • (714) 557-1636 www .mgeups.com Contact MGE United States MGE UPS SYSTEMS 1660 Scenic Ave. Costa Mesa, CA 92626 T el: (714) 557-1636 CCC: (800) 438-7373 Fax: (714) 557-9788 email: info@mgeups.com www: mgeups.com Canada MGE UPS SYSTEMS #9, 2789 Thamesgate Drive Mississauga, ON L4T 4E8 T el: (905) 6[...]