MGE UPS Systems S3 manual

T opaz S3 Inverters 0.5 kV A, 1 kV A, and 2 kV A Owner's Manual[...]

86-153061-00 ii IMPOR T ANT SAFETY INSTRUCTION SA VE THESE INSTRUCTIONS — This manual contains impor tant instructions for all in ver ters that must be f ollowed during installation, operation and maintenance of the equipment. W ARNING Opening enclosures e xpose hazardous v oltages. Alwa ys refer service to qualified personnel onl y . A TTENTION[...]

NO TE This equipment has been tested and found to compl y with the limits for a Class A digital de vice, pursuant to part 15 of the FCC Rules. These limits are designed to pro vide reasonable pr otection against harmful interference when the equipment is operated in a commer cial en vironment. This equipment generates, uses, and can radiate radio f[...]

iv 86-153061-00 T opaz S3 In ver ter s 0.5 kV A, 1 kV A, & 2 kV A[...]

86-153061-00 v For service call 1-800-523-0142 86-153061-00 B03 3/99 Cop yr ight © 1997 MGE UPS Systems, Inc. All rights reser ved. Printed in U.S .A. MGE UPS Systems, Inc. 1660 Scenic A ven ue Costa Mesa, CA 92626 (714) 557-1636 T opaz S3 Inverters 0.5KV A, 1 kV A, AND 2kV A Owner’ s Manual This manual cov ers these models: PRODUCTS MODEL RA TI[...]

vi 86-153061-00 W arranty MGE UPS Systems warranty: warr anties to distr ibutors and other commercial customers: MGE UPS Systems warrants equipment manuf actured by MGE UPS Systems to be free from defects in materials and workmanship for a period of one year from date of installation, b ut no longer than eighteen months from purchase by end user . [...]

Section . . . . . . . . . . . . Description P age Saf ety Information inside front cov er Ser vice and F actor y Repair vi W arranty vi T able of Contents vii How to Use This Manual xi Section I — Intr oduction 1.0 . . . . . . . . . . . . . . . Scope 1-1 1.1 . . . . . . . . . . . . . . . General Description 1-2 1.2 . . . . . . . . . . . . . . . O[...]

Section Description P age 1.7.1 Dimensions 1-15 1.7.2 W eight 1-15 1.8 . . . . . . . . . . . . . . . Environmental Specifications 1-15 1.8.1 Operating T emperature 1-15 1.8.2 Non-Operating T emperature 1-15 1.8.3 Operating Humidity 1-15 1.8.4 Operating Altitude 1-15 1.8.5 Audib le Noise 1-15 1.8.6 Cooling 1-15 Section II — Installation and Opera[...]

Section Description P age 3.1.3.1.1 Static T ransf er Switch 3-7 3.1.3.1.2 Star t Up Sequence 3-8 3.1.3.2 Off-Line Mode 3-8 3.1.4 Digital LCD 3-8 3.1.5 Status Indicators (LEDs) 3-8 3.1.5.1 "Bypass" 3-9 3.1.5.2 "Inv er ter" 3-9 3.1.6 P ower Supply 3-9 3.1.6.1 Supply Descr iption 3-9 3.1.6.2 Supply Operation 3-10 Section IV— Mai[...]

3-1 In verter Block Diagram 3-2 3-2 Hysteretic Booster Diag ram 3-4 3-3 Dual In verter and W a vef or m Diagram 3-5 T ables T able Description P age 1-1 Char acter istics of Inv er ter 1-3 1-2 LCD Readout Definitions 1-6 2-1 Recommended Input/Output Wir ing 2-4 4-1 Installation Chec klist 4-3 4-2 T roub leshooting Checklist 4-7 x 86-153061-00 T op[...]

How T o Use This Manual: This manual is designed f or ease of use and easy location of inf or mation. T o quickly find the meaning of terms used within the text, look to the Glossar y . The paragr aph symbol (¶) indicates numbered paragraphs that can be quickly f ound in the Contents on page iii. This manual uses Notebo xes to con ve y impor tant[...]

xii 86-153061-00 T opaz S3 In ver ter s 0.5 kV A, 1 kV A, & 2 kV A[...]

This manual provides technical inf ormation required for installation, operation and maintenance of the T opaz S3 inv er ters with power r atings of 0.5 kV A, 1.0 kV A, and 2kV A. Please read this manual bef ore operating the T opaz S3 equipment. Please retain this manual f or future reference . The manual is divided into f our sections: Section I [...]

Section IV — Maintenance and Service This section describes maintenance of the T opaz S3 inv erter, including saf ety instr uctions, pre ventiv e maintenance, and inf or mation about replacement par ts, and customer ser vice. A Glossar y in the rear of this manual pro vides definitions of terms used within the text. The sine wa ve inv er ter pro[...]

Ta b l e : Characteristics of In verter 1- 1 Model Output Nominal Input Max. Nominal Output A C Amperes at Number P ower Input V oltage Input DC Selectable Output V oltage of: Rating V oltage Range Current (V A/Watts) (Vdc)** (Vdc) Amperes 120V 220V 230V 240V 63204* 2000/1680 -48 42 to 57 60 16.6 8.4 8.4 8.4 63104* 1000/840 -48 40 to 60 30 8.3 4.2 [...]

Introduction Does not e xceed 3% for all linear and non-linear (computer) load conditions within the V A/Watt r ating. Inv er ter output RMS voltage will v ar y 1% maximum for line variations between lo w line and high line at any load betw een no load to rated load. Inv er ter output RMS v oltage will vary 1% maximum for load variations between no[...]

See Figure 2-1 on page 2-2 f or the location of indicators and controls. The LCD displa ys two lines of twenty characters. T wo types of messages are displa yed: system status or measurement. A system status message is the def ault at tur n-on, after a system f ailure or stop sequence. Each line consists of three columns that identify: 1) pow er so[...]

Ta b l e : LCD Readout Definitions 1- 2 Column 1 Column 2 Column 3 P ower Source Mode / Status Definition LED status P ower Source Source Source Mode Status SYSTEM SET TO THE ON-LINE Inverter (INVERTER) MODE. LED LINE 1 INV : on normal System is on the inv er ter delivers power to the load. Green LINE 1 INV : on dc low Input DC v oltage is less th[...]

The LCD can displa y a total of 10 different measurements, with tw o measurement values per line. The f ollowing is a list of measurements display ed: Load V olts (Vr ms) %Load (higher of watts/V A) Utility V olts (Vr ms) F requency (Hz) DC Input V olts (VDC) DC Input current (Amps) Load Watts Load Current (Arms) Inv er ter inter nal temperature (d[...]

Figure : Line 1 and 2 Measurement Readout, Status Indicator s 1- 1C T wo indicators are provided and identified as "ST A TUS". One indicator is labeled "BYP ASS", the other "INVERTER". In normal condition, if the OFF-LINE (bypass) mode has been selected, the "BYP ASS" LED will glow continuously and the "[...]

Three alarm relays are provided. 1) UTILITY F AILURE, 2) MINOR alarm, 3) MAJOR alar m. All relays are identical, howe ver the UTILITY and MINOR rela ys are wired as a SPDT units, whereas the MAJOR alarm relay is a DPDT unit. Rela ys are energized under nor mal operating condition. De- energizing of the rela ys results in an ALARM signal as shown in[...]

Alarm if Utility voltage is not within proper limits. Contacts are: TB2-1 = NC , TB2-2 - Common, TB2-3 = NO. A minor alarm will occur for any of the f ollowing: 1) inv erter output or static transfer s witch o v erload or shor t circuit. 2) thermal war ning or fault. 3) Input DC loss. 4) Static transf er switch f ailure. 5) 4 transf ers to bypass w[...]

A circuit breaker is located on the front panel and identified as "DC INPUT". T urning the breaker to the ON position will apply the input D .C. voltage to a capacitor bank through a resistor network to limit the inrush current. After a fe w seconds of dela y , the DC capacitor bank voltage will be within a f ew volts of the input. Then [...]

Figure : In verter Module Configuration for .5kV A and 1kV A 1- 3A 1 — 12 Introduction 86-153061-00 T opaz S3 In ver ter s 0.5 kV A, 1 kV A, & 2 kV A[...]

Figure : In verter Module Configuration for 2kV A 1- 3B 86-153061-00 1 — 13 Introduction Owner’ s Manual[...]

Selection of the A C output voltage is accomplished by moving a connector plug. The printed circuit board has a 10 pin connector (J3) and its mate is a 9 pin plug (P3). Moving this plug to the left (rear) position selects the 120V AC position (100, 110, 115, 120 V AC). Moving of the plug to the right (toward the front panel) connects the in verter [...]

These dimensions include both the receiver cabinet and the inv er ter module. Depth is inclusive of the in ver ter module thumb screws . 0.5 kV A, 1 kV A 2 kV A HEIGHT: 3.50 in (8.9 cm) 5.3 in (13.4 cm) WIDTH: 17.0 in (43.2 cm) 17.0 in (43.2 cm) DEPTH: 19.0 in (48.3 cm) 19.0 in (48.3 cm) 0.5 kV A & 1 kV A 2 kV A Receiver cabinet 8.0 lbs (3.63 K[...]

1 — 16 Introduction 86-153061-00 T opaz S3 In ver ter s 0.5 kV A, 1 kV A, & 2 kV A[...]

This section describes the installation of the T opaz S3 0.5 kV A, 1 kV A, & 2 kV A including receiving, handling, storage, and installation procedures. Bef ore accepting the shipment from the freight carr ier , inspect the e xter ior surfaces of all shipping containers or packaging used, and the equipment, f or damage that may hav e occurred d[...]

The equipment is designed f or installation in a protected environment. F actors to be considered in selecting a location include ventilation, en vironmental conditions, and accessibility . Optimum operation of the unit will be obtained by careful consider ation of its location. Install the unit in a clean, dr y location with an unrestricted air ?[...]

Figure : Outline and Mounting f or 2kV A 2- 1B The side mounting brac kets can be positioned f or either a 19 inch, 23 inch, or 25 inch rac k. The In verter can also be mounted either flush with the front panel or at the chassis midpoint. Prior to mounting the Inv er ter in the rack, determine the position of all input and output wir ing. NO TE In[...]

Ta b l e : Recommended Input/Output Wiring 2- 1 Model DC Input A C Output AC Input Current Current Current Max. Current 63054 16 AMPS 5 AMPS 5 AMPS Min. Wire Size (500V A) 12 A WG 14 A WG 14 A WG Max. Current 63104 30 AMPS 10 AMPS 10 AMPS Min. Wire Size (1kV A) 10 A WG 14 A WG 14 A WG Max. Current 63204 60 AMPS 17 AMPS 17 AMPS Min. Wire Size (2kV A[...]

F or safety and proper operation of the unit, including maximum attenuation of electrical noise, suitab le grounding is required. A separate grounding electrode conductor should be connected from the ground (GND) terminal to a nearby g rounding electrode, and should be sized per National Electrical Code Ar ticle 250-94. The grounding electrode shou[...]

Figure : Wiring Access and Connection for .5 kV A & 1 kV A 2- 2A 2 — 6 Installation and Operation 86-153061-00 T opaz S3 In ver ter s 0.5 kV A, 1 kV A, & 2 kV A[...]

Figure : Wiring Access and Connection for 2 kV A 2- 2B 86-153061-00 2 — 7 Installation and Operation Owner’ s Manual[...]

Remov e the cover plate on the rear of the in verter receiver cabinet to gain access to the wiring compar tment. Route the DC input, A C output, AC input (Static T ransfer Switch option), and alarm signal wires through the selected knock out holes, using the appropriate conduit b ushings. Use knock out cutters to obtain the proper conduit/bushing s[...]

F or optimum inv er ter performance, provide v entilation clearance from e xter ior surf aces as follows: T op and bottom: 0.25 inches [6.3 mm] F ront and sides: 1.50 inches [38.1 mm] • V erify the inv er ter module is NOT installed into its receiver cabinet. • After the receiv er cabinet has been wired, verify that a separate grounding electro[...]

View ed from the left side of the Inverter module, access holes can be seen f or selecting the AC output v oltage via a 120V AC/240V A C hard wired connector plug, and setting of the MICRO CONTR OL "DIP" switches . If low output v oltage is desired (100 to 120V AC) the jumper plug must be in the 120V AC position, to ward the rear of the u[...]

When all selections hav e been made, perf or m the follo wing steps to operate the in ver ter : A) Be sure that all loads are disconnected or tur ned OFF and A C input power to models with a Static T ransfer Switch is OFF . B) Refer to the installation chec klist in T ab le 2-1 (page 4-3)and be sure that all control settings and terminal bloc k scr[...]

K) T ur n the DC circuit breaker on the front panel to the OFF position. V erify that AC v oltage is still on the AC OUT terminal block TB3. L) Loosen the thumb screws securing the Inv er ter module into its receiver cabinet and remo ve the module. V er ify Utility voltage is still on the output terminal bloc k, TB3. M) T urn OFF all the AC and DC [...]

This section describes the theor y of operation of the T opaz S3 Inv er ter systems. The inv erter utilizes a "Fly-back" con v erter to boost the input voltage to tw o regulated +/- 200 volt outputs. T wo identical inv er ters are contained in the unit, both inv er ters controlled by a single PWM to gener ate sinusoidal A C outputs. The t[...]

Figure : In verter Block Diagram 3- 1 3 — 2 Theor y of Operation 86-153061-00 S3 Static In verters 1kV A[...]

The batter y booster is a "continuous" mode Fly-bac k conv er ter which takes the DC input v oltage and boost it to f our separate outputs of 200 volts. T wo of these outputs are connected in series to produce -200 VDC and +200 VDC and used by one of the In ver ters. The other two outputs are also connected in series to produce a second -[...]

Figure : Hystertic Booster Diagram 3- 2 3 — 4 Theor y of Operation 86-153061-00 S3 Static In verters 1kV A[...]

As indicated, two identical in ver ters are used to produce either 120 or 240V AC depending on parallel or series connection of their outputs. Each inverter is a conv entional half bridge, that is, only two FET s witches are used in each inv er ter . See Figure 3-3. The output of each in verter is applied to a coupled choke . Since the choke acts a[...]

A microprocessor is used in the Inv er ter system to generate a ref erence sine w a v e via one of its three PWM outputs . The PWM signal is filtered to make a clean sine w ave . This sine wa ve is applied to a v oltage error amplifier . The other input to the voltage error amplifier is the output of one of the inv er ters, called the master inv[...]

This is an optional f eature that is descr ibed below . The ON LINE mode is defined as allowing the load to operate from the In ver ter instead of the Utility power . If the Inv er ter should fault f or some reason (ov er load, shor t circuit, ov er temperature, DC v oltage not within specification, or Inv er ter failure) the system will transf e[...]

When the inv er ter is enabled (by turning ON the front panel DC circuit breaker) the microprocessor goes through its start up sequence, including phase loc king the reference sine wa ve to the Utility A C input. Then the maintenance bypass rela y is energized, opening its contacts. The inverter is turned ON to check its functional operation, then [...]

A blinking LED indicates that the load is po wered by the Inv er ter , not from the Utility . The "BYP ASS" LED will be illuminated Green if the Utility is within acceptable v oltage and frequency limits as specified by the 50/60 Hz DIP s witch setting. Y ellow indicates the Utility is not within proper limits. Red indicates the utility [...]

The duty cycle of the UC3842ANs oscillator is set up to be about 45%. The output of the chip drives the gate of an IRF840 FET . The "Drain" of the FET is connected to a "Flyback" tr ansformer (actually a coupled inductor of 50 uHy primar y inductance). At the beginning of the switching cycle , the FET is turned ON. Current start[...]

This section describes maintenance and ser vice of the T opaz S3 Inverters Systems, including saf ety instr uctions, pre ventive maintenance , descriptions of replacement par ts kits, and service. IMPORT ANT SAFETY INSTR UCTIONS FOR SER VICING INVERTER SER VICING SHOULD BE PERFORMED OR SUPER VISED BY QU ALIFIED PERSONNEL ONL Y . The f ollowing prev[...]

a. Ensure that all equipment is clean and free of loose dust, dir t, and debris. The exterior of all enclosures ma y be cleaned with a mild solution of soap and water , lightly applied with a lint-free cloth. b . Inspect the air intak e and exhaust openings and clean as required. V erify that air flows freely through the equipment. Clean the air i[...]

Many operation prob lems are due to incorrect installation or setup . Before turning the unit on, revie w Section 2 for instructions per taining to your par ticular system. Use the checklist in T able 4-1 in this re view . If the system f ails to operate properly after being tur ned on, the T able 4-1 checklist should be re verified. Ta b l e : In[...]

Bef ore the inverter system can be tur ned on with the DC circuit breaker on the front panel, the DC po wer source must be energized. Upon tur ning the DC circuit breaker ON, a rela y will energize and the cooling fan will start to operate after a shor t delay of less than one second. The Inv er ter ST A TUS indicator will go through a RED , YELLOW[...]

As soon as power is applied to the unit, either from the A C power source or the DC is applied b y closing the DC circuit breaker , the unit will star t up as indicated abov e for the basic unit. During the lamp test sequence, both ST A TUS indicators will go through the RED , YELLOW , GREEN lamp test sequence. ST A TUS indication star ts to differ[...]

If A C has been applied to the Inverter and is within proper limits (120V AC or 230V A C, +/- 10% maximum) the In ver ter ST A TUS indicator should turn YELLOW and then after a shor t delay , it will tur n GREEN, indicating power is being supplied to the load. If the Inv er ter ST A TUS indicator remains illuminated either YELLOW or RED , f ollow t[...]

Ta b l e :T r oubleshooting Checklist 4- 2 SYMPT OM POSSIBLE CA USE RECOMMENDED PROCEDURE No response when DC circuit Polarity re versed on DC Input Chec k input connections and rev erse breaker is turned ON. connections. If this is the if wrong. Remo ve the inv er ter module Inv er ter ST A TUS indicator case, the internal Soft Star t from the rec[...]

SYMPT OM POSSIBLE CA USE RECOMMENDED PROCEDURE terminals and that the proper AC output voltage e xist on the A C output ter minal bloc k. If 100-120 V AC or 200-240 V AC e xist on the AC input terminal block, Maintenance Bypass rela y is defectiv e, replace A C EMI filter board. Inv er ter will not star t. DC input v oltage is too high or Measure [...]

Symbols ¶ Used to ref erence paragraph headings that are listed in the table of contents. / Used to represent “and/or. ” % P ercent; of each hundred. ° F . Deg rees F ahrenheit. ° C Degrees Celsius. @ At. ± Plus or minus. # Number . Ø Phase. Ω Ohms. 2nd Second. A C or ac Alternating current. Ambient air temperature The temperature of the[...]

C Common. CB Circuit breaker . Conduit A fle xible or rigid tube surrounding electr ical conductors. C .S.S. Customer Suppor t Ser vices. Current rating The maxim um current that a piece of electr ical equipment is designed to carr y . dBA Decibels adjusted. dBrnC Decibels abov e reference noise . DC or dc Direct current. Digital Meter The LCD dis[...]

Input branch circuit The input circuit from the building power panel to the equipment. Inv er ter An electrical circuit that generates an AC sine wav e output from a DC input. kV A Kilov olt-Ampere; a measure of apparent power . L Line. LCD Liquid-crystal display . LED Light-emitting diode. Mains or mains 1 Main A C input source. Mains 2 Bypass A C[...]

SCR Silicon-controlled rectifier . Shipping damage Any damage done to an article while it is in transit. SPDT Single P ole Double Throw . Static T ransfer Switch An electronic or solid state s witching mechanism electronically controlled to pass A C power directly from the utility to an output load. T echnician Refers to an electronic technician q[...]

Reor der f orm 1660 Scenic A v enue Costa Mesa, CA 92626 to order additional copies of this document, or to repor t any errors, omissions, or other prob lems you ha ve e xper ienced. NAME __________________________________________________________ COMP ANY ______________________________________________________ STREET ADDRESS ________________________[...]

Nothing will stop you now ™ 1660 Scenic Avenue, Costa Mesa, California 92626 • (714) 557-1636 • www .mgeups.com[...]