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MGE UPS Systems STS 200A manual

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Table of contents for the manual

  • Page 1

    Epsilon STS TM 200A and 400A/600A Static T ransfer Switch Installation and User Manual 86-504004-00 B03 www .mgeups.com Standard Features ◗ Epsilon 200A System ◗ Epsilon 400A/600A System[...]

  • Page 2

    [...]

  • Page 3

    Installation and User Manual Chaptername i 86-504004-00 B03 Epsilon STS TM 200A and 400A/600A Static T ransfer Switch Installation and User manual Revision History Epsilon STS 200A and 400A/600A STS, Installation and User Manual 86-12345-00 B02 Revision: A00 Initial Release 06/2002 B00 ECN: 002866 09/2002 B01 ECN:#003777 03/2004 B02 ECN:#004471 07/[...]

  • Page 4

    Epilson STS TM ii 86-504004-00 B03 IMPORT ANT SAFETY INSTRUCTIONS SA VE THESE INSTRUCTIONS – This manual contains important instructions for the Epsilon STS TM 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'ouvertu[...]

  • Page 5

    Installation and User Manual iii 86-504004-00 B03 How T o Use This Manual and Symbol Usage W ARNING T o reduce the risk of fire or electric shock, install in a temperature and humidity controlled indoor area free of conductive contaminant’ s. This equipment is intended only for installations in a RESTRICTED ACCESS LOCA TION. A TTENTION Pour rédu[...]

  • Page 6

    Epilson STS TM iv 86-504004-00 B03 CAUTION: Record All Serial Numbers CAUTION: Record All Serial Numbers! RECORD ALL SERIAL NUMBERS FOR THE Epilson STS TM AND COMPONENTS. THESE SERIAL NUMBERS WILL BE REQUIRED IF YOUR SYSTEM NEEDS SER VICE. KEEP THIS MANUAL IN A PLACE WHERE YOU CAN REFERENCE THE SERIAL NUMBERS IF SERVICE IS REQUIRED! UPS SERIAL NUMB[...]

  • Page 7

    Contents Contents c i 86-504004-00 B03 section description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i IMPORT ANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .ii Certification Standa[...]

  • Page 8

    Epilson STS TM Contents c ii 86-504004-00 B03 Section 2 Setup and Installation section description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2.0 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 1 First steps by an on-site qualified T echnical Enginee[...]

  • Page 9

    Installation and User Manual Section 3 Operation (continued) section description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3.4.6 EPO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 —6 3.5 Preferred Source Selection (Symmetrical Operation) . . . . . . . [...]

  • Page 10

    Figures figure description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page QS-1 Positioning of 200A Epsilon STS™. . . . . . . . . . . . . . . . . . . . . .QS —2 QS-2 Positioning of 400/600A Epsilon STS™ . . . . . . . . . . . . . . . . . .QS —3 QS-3 200A STS Input/Output Power Connections. . . . . . [...]

  • Page 11

    Quick Start QS —1 86-504004-00 B03 On-Site Quick Start CAUTION 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 for assistance. Final installation[...]

  • Page 12

    Step 1 Unpacking Once the Epsilon STS TM UPS System has been inspected and received from the shipping courier , the unit should be moved with the use of a fork lift or pallet jack to a position as close to the final installation location as possible. Prior to any installation, the following items should be observed upon receipt of the Epsilon STSTM[...]

  • Page 13

    Installation and User Manual Figure QS-2 Positioning of 400/600A Epsilon STS™ Quick Start QS —3 86-504004-00 B03 CASTERS LEVELING JA CKS OPTIONAL SEISMIC BRA CKETS SECURED USING 3/8 BOL T[...]

  • Page 14

    Step 2 Connection of Utility Power Inputs Connect Input Power from T wo Sources The Epsilon STS™ systems provides for either top or bottom cable entry . Connections are to be made with 75°C copper wire cables and using the lugs supplied with the STS unit. Refer to section 2.0 Installation and/or the system installation drawing(s) for more detail[...]

  • Page 15

    Installation and User Manual Figure QS-4 400/600A STS Input/Output Power Connections. Step 4 Arrival of MGE Field Engineer The MGE Field Engineer will finalize the initial Epsilon STS™ start-up. T o insure a successful installation and reliable STS service, the MGE Field Engineer will verify all of the installation connections, fusing, and then w[...]

  • Page 16

    Optional Steps Should you require AC power on site prior to the arrival of the MGE Field Engineer , the following procedure will provide the AC power in the bypass mode. Should you have any questions about this procedure, do not hesitate to contact MGE Customer Support. A. Ensure that all switches, CB1-5 in the STS are open (off). B. Apply input po[...]

  • Page 17

    Introduction 1.0 Scope Introduction is a general description of system characteristics of Epsilon STS TM , its intended use and applicable electrical, mechanical and environmental specifications. 1.1 Reference Manuals 160304-00 C00 JBUS/RS232, Installation and User manual. 1.2 Section Descriptions Quick Start This Quick Start will guide qualified e[...]

  • Page 18

    1.3 General Description The Epsilon STS™ system is available in two different cabinet sizes . Dimensions for the cabinets are: ◗ 200A cabinet: 72”H x 24”W x 30”D ◗ 400A/600A cabinet: 72”H x 38”W x 30”D Both cabinets are designed to provide for top and/or bottom entry of input and output power feeds. The Epsilon STS™ system can b[...]

  • Page 19

    Installation and User Manual 1.4 Epsilon STS TM System Characteristics The Epsilon digital Static T ransfer Switch (STS) is a solid state, three-phase, break-before-make, dual position switch designed to connect a critical three-phase load to one of two separate, independent, synchronized sources of three-phase power . The STS consists of six pairs[...]

  • Page 20

    1.4.1 PMM 2 Plus and PMM 2 Ultra In the PMM 2 Plus configuration, the input of the PMM 2 cabinet is supplied by the output of the STS. The dual input distribution system accepts two independent AC input sources feeding to the STS. If the preferred input source power is not available, the STS will transfer to the alternate input source, avoiding int[...]

  • Page 21

    Installation and User Manual 1.5 System Major Components Source #1 CB1 Input isolation molded case switch with magnetic trip for isolating SCR static switch #1 and associated components from source S1. Source #2 CB2 Input isolation molded case switch with magnetic trip for isolating SCR static switch #2 and associated components from source S2. Out[...]

  • Page 22

    Front Display Panel Comprised of a 4.7” x 3.6” LCD with associated “soft” keys for monitoring status, alarms, changing certain settings and performing certain operations; an LED “mimic” diagram display for indicating switch status and power flow; and manual control pushbuttons for manual transfer functions. Hard Keys Manual, dedicated k[...]

  • Page 23

    Installation and User Manual 1.6 Single Line Diagram During normal operation, CB1, 2, 3A and 3B (if installed) are closed and the load receives power from the designated preferred source through either SW1 or SW2 SCR switch. In the event of a preferred source failure, the STS will transfer the load to the alternate source in a fraction of a cycle. [...]

  • Page 24

    1.7 System Specifications Recommended environment 20° to 25°C (68° to 77°F); 50% relative humidity; computer room or other temperature and humidity-controlled environment. Operating temperature 10° to 40°C (50° to 104°F). Storage -10° to 60°C (-14° to 140°F). Humidity up to 95% non-condensing (operating). Altitude sea level to 8,500 fee[...]

  • Page 25

    Installation and User Manual 1.72 Electrical Cable Access and Connections Electrical connections and other cabinet interconnection will vary depending upon the configuration and options selected with your Epsilon STS™ system. Refer to the installation drawings supplied with your equipment. CAUTION: Before making any electrical connections, verify[...]

  • Page 26

    1.7.4 Accessing Electrical Connections CAUTION: Only an authorized electrical professional should access electrical con- nections. A severe shock hazard exists. The ONL Y user serviceable items in the Epsilon STS™ unit are: A. The input power connections B. The load connection C. Any wire connections to the customer control terminal block. D. The[...]

  • Page 27

    Installation and User Manual Figure 1-6: 400/600 STS Power and Control Wire Connections. T able 1-2: Input/Output Power Connections. STS # OF CABLES PER MINIMUM CABLE LUG CONDUIT RA TING PHASE N GND CABLE SIZE (SUPPLIED) HOLE (AMPS) (75°C, CU) DIA. (QTY .) 400 2 4 1 # 250 MCM # 250 MCM, 3/8” STUD 4” (3) (T&B M973 OR EQUIV .) 600 3 5 1 # 25[...]

  • Page 28

    (This page left blank intentionally) Epilson STS TM 1 — 12 86-504004-00 B02[...]

  • Page 29

    Setup and Installation 2.0 Scope Setup and Installation guides the User through tools and equipment required for making hardwire connections. Included are power cable connections with wire diagrams for configuring the product to specifications, and obtaining MGE field service assistance for final installation and startup. Final installation and sta[...]

  • Page 30

    2.1 Cabinet Placement and Environment The complete STS system may consist of more than one cabinet depending on whether the STS is a stand-alone unit or it is used in conjunction with input isolation or output distribution cabinets such as the Power Management Module 2 (PMM 2 ) cabinets. Cabinets must be arranged in the required positions to ensure[...]

  • Page 31

    Installation and User Manual 2.2.1 Conduit Plate Location (bottom entry) Cable entry through the bottom is the standard preferred design for the Epsilon STS™ cabinet. Please see the following figure for the location of the bottom entry conduit plate. Figure 2-2: 200A /400/600A STS Cabinet Footprint and T op View . 2.3 Source #1 AC Input Connectio[...]

  • Page 32

    They should not pass near interference-emitting equipment or sensitive loads. Complete wiring instructions for your installation are provided on the installation drawings supplied with the equipment. 2.3.3 Remote Emergency Power Off (REPO) Cable Connections Control connections are available for “Remote Emergency Power Off” (REPO) through a cust[...]

  • Page 33

    Installation and User Manual 2.3.5 Connection of the Relay Communication Card The relay communications card contains six programmable dry contact outputs and two programmable dry contact inputs, and is standard on the Epsilon STS™. The inputs and outputs are factory programmed according to functions listed in T able 2-2. T able 2-2: Relay Contact[...]

  • Page 34

    2.3.6 Characteristics of the Output Contacts Relay type Normally Open. Max. voltage 250V AC, 30VDC. Max. current 2A. Cable 4 x 18 A WG, cover plate hole diameter 0.26 inch ± 0.01 inch Figure 2-4: Output Contacts. 2.3.7 Characteristics of the Input Contacts Switched voltage 5 VDC. Consumption 10 mA. Cable 4 x 22 A WG, hole diameter 0.2 inch ± 0.02[...]

  • Page 35

    Installation and User Manual 2.3.8 Removing the Communications Card Cover a) Remove the cover “3” secured by the screws “1”. b) Run the communications cables through the cable entry holes “4”. c) Connect the conductors to the input “6” and output “5” terminal blocks (see connection example in diagram below). Figure 2-5: Removing[...]

  • Page 36

    2.4 Setting Operation Mode Set DIP switch SA1 for one of the following configuration modes: First Card Second Card (optional) Standard Mode (default) Standard Mode (default) All switches OFF SA1 switch 1 ON First Card Second Card (optional) Programmable Mode Programmable Mode SA1 switch 3 ON SA1 switches 1 & 3 ON Figure 2-7: SA2 and Dip switch [...]

  • Page 37

    2.5 Setting the Output Relay Contacts and Input Switching States Set DIP switch SA2 for one of the following configuration modes: N.O. Setting (default) All switches OFF N.C. Setting All switches ON It is possible to individually set each relay and input to N.O. or N.C. mode by setting each switch on SA2 individu- ally . The parameters for relays 1[...]

  • Page 38

    2.5.1 Connection of the JBUS Communication Card The JBUS communications card provides two DB-9 ports (RS232 and RS485 communications). Only one commu- nication port may be used at a time. For information on using the communication card, see the JBUS communication card manual. Figure 2-8: JBUS Communication Card. 2.6 Check Points Before and After St[...]

  • Page 39

    Operation 3.0 Scope Operation describes Epsilon STS TM system characteristics of indicators and controls, startup and shutdown proce- dures, safety checklists, modes and specifications and theory of operating the Epsilon STS TM system. 3.1 Preparation for Operation Several items must be considered when preparing the Epsilon STS™ system for operat[...]

  • Page 40

    3.2.1 Normal Start Up Procedure With all of the initial safety check points verified, the Epsilon STS™ system can now be powered. The following procedure should be used after the Epsilon STS™ system has been commissioned (typically by an MGE Field Service Engineer). 1. Ensure that all switches, CB1, 2, 3A, 3B(if installed), 4 and 5 in the STS a[...]

  • Page 41

    Installation and User Manual 3.2.2 Post Start Up Safety Check List After initial start up of the system, normal operation of the STS should be verified. At the minimum, the following should be checked as applicable to your installation: ◗ Remote emergency power off (REPO) operation (all switches in the STS should trip of f). After this test, rese[...]

  • Page 42

    3.3 T ransfer Operations 3.3.1 Automatic T ransfers Automatic transfer of the load from one source to the other is accomplished by turning off the active source SCR's and turning on the inactive source SCR's in a sequence and timing that allows a combined sense and on transfer time of less than one quarter cycle (4.17ms). Automatic transf[...]

  • Page 43

    Installation and User Manual 3.3.4 T ransfer Authorization/Prohibition T ransfer is prohibited under the following conditions: a) Transfer Prohibit Input from the operator control panel, control contact input, or communications port. b) Peak Current Overload. c) External Power Fault (peak current overload caused by undervoltage) - Memorized. d) Ove[...]

  • Page 44

    3.4.5 Live System T est (Except with 4-Interlock System) While in maintenance bypass, and with the STS output isolation switch off, the STS can be tested with both sources connected to the STS through the input isolation switches (using the SCR's to make actual transfers). 3.4.6 EPO In the event of an Emergency Power Off (EPO) condition, all s[...]

  • Page 45

    Installation and User Manual 3.9 Open SCR Protection The STS design includes sensing circuits to detect an open SCR and in addition to the following actions, will initiate audible and visual alarms: In the event of an open SCR in the active source powering the load, the unit will alarm and immediately transfer to the inactive source. Then the SCR i[...]

  • Page 46

    Bypass Load to Source #2 1. The Source #2 SCR Switch #2 must be indicated closed on the display panel. If not, transfer the load to Source #2 by turning the Manual Control key switch on the front display panel to the “ON” position and pressing the Change Preferred Source Pushbutton. The STS should transfer to Source #2. 2. Open Source #1 isolat[...]

  • Page 47

    Installation and User Manual 3.12 Front Panel The Epsilon STS™ system is simple to operate and yet provides a wealth of continuous monitoring and diagnostic features to insure the proper operation of the unit. Operators gain access to information in the Epsilon STS™ system through the operator interface. This display panel and keyboard is conve[...]

  • Page 48

    3.13 Front Display Interface Panel Figure 3-1: Front Display Interface Panel. Epilson STS TM Operation 3 —10 86-504004-00 B03 HELP MAIN MENU ALARM SILENCE LAMP TEST RETURN TO PREFERRED SOURCE CHANGE PREFERRED SOURCE OVERRIDE LIMITS SOURCE S1 AVAILABLE PREFERED SOURCE IN SYNC ALARM SWITCH 1 SWITCH 2 SOURCE S2 AVAILABLE ? ON CB4 CB3 CB5 CB1 S1 S2 C[...]

  • Page 49

    Installation and User Manual Figure 3-2: LCD Normal Operation Screen Operation 3 —11 86-504004-00 B03 NORMAL OPERATION A 200A B 200A C 200A 133 KW 166 KVA 0. 8 PF Preferred Source S1 V1 480V V2 480V V3 480V Synchro 60.0 HZ =0 ° 60.0 HZ Source S2 Source S2 Meters -Voltage (Ø's A-B, B-C, C-A) -Frequency (Hz) Current Flow Indication for Sourc[...]

  • Page 50

    Figure 3-3: Manual Operation Pushbuttons. Epilson STS TM Operation 3 —12 86-504004-00 B03 Manual Control keyed switch- The "Return to Preferred Source", "Change Preferred Source" and "Override Limits" manual control pushbuttons are active (enabled) in the "ON" position, and inactive (disabled) in the "[...]

  • Page 51

    Installation and User Manual Operation 3 —13 86-504004-00 B03 Figure 3-4: LED Mimic Diagram. SOURCE #1 AVAILABLE GREEN LED-LIT WHEN SOURCE #1 POWER IS APPLIED TO SOURCE S1 INPUT SOURCE #2 AVAILABLE GREEN LED-LIT WHEN SOURCE #2 POWER IS APPLIED TO SOURCE S2 INPUT OUTPUT POWER TO LOAD GREEN LED-LIT WHEN OUTPUT POWER IS ON STS OUTPUT ISOLATION C.B. [...]

  • Page 52

    Epilson STS TM Operation 3 —14 86-504004-00 B03 3.14 Operator Interface Screens The screen displays contained on the Epsilon STS™ Operator Interface provide an easy to use method to access and control the STS features. A screen saver feature will blank out the LCD screen after the Epsilon STS™ has been in continuous operation for a while. Fig[...]

  • Page 53

    Installation and User Manual Operation 3 —15 86-504004-00 B03 3.15 Epsilon STS™ Customization Certain parameters can be customized as follows: 1. Press the <Menu> button. 2. Select <Setup>, then <Customization> using the function buttons marked or . 3. Confirm by pressing the function button marked  ❚ 4. Enter the passwor[...]

  • Page 54

    (This page left blank intentionally) Product Name 3 —16 86-504004-00 B02[...]

  • Page 55

    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 56

    W arranty 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 r[...]

  • Page 57

    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 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 s[...]

  • Page 58

    (This page left blank intentionally) Product Name W—4 86-504004-00 B02[...]

  • Page 59

    Glossary T erm 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. ® T rade Mark. 2nd Second. AC or ac Alternating current, also implies root-mean-square (rms). Ambient T emp. T emperature of surrounding air . Ambi[...]

  • Page 60

    Current rating The maximum current that a conductor or equipment can carry reliably without damage. dBA Decibel Adjusted. dBrnC Decibel above reference noise. DC or dc Direct current, or voltage. Digital Meter The LCD display on the front panel of inverter system. Earth ground A ground circuit that has contact with the earth. Electrician Refers to [...]

  • Page 61

    Glossary G — 3 86-504004-00 B03 NFP A National Fire Protection Association. NO. or No. Part number . On-line mode Inverter output power is the primary energy source to load. Off-line 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 [...]

  • Page 62

    (This page left blank intentionally) Epilson STS TM G — 4 86-504004-00 B03[...]

  • Page 63

    Reorder Form 1660 Scenic A venue 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[...]

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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 (800) 523-0142 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) 672-09[...]