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EPS 6000 UPS Shar ed Systems User’ s Guide.
IMPOR T ANT SAFETY INSTR UCTION SA VE THESE INSTRUCTIONS — This manual contains impor tant instr uctions for the EPS 6000 series UPS Systems that must be follo wed dur ing installation, operation and maintenance of the equipment.
For service call 1-800-438-7373 86-130034-00 B00 11/96 Cop yright © 1996 MGE UPS Systems, Inc.. All rights reser ved. Printed in U .S.A. MGE UPS Systems 1660 Scenic A venue Costa Mesa, CA 92626 (714).
W arranty Seller warrants to the Ultimate Purchaser (the purchaser who b uys for use , and not for resale) that all products furnished under this order and which are manufactured by Seller will conf o.
Section I Intr oduction 1.0 . . . . . . . . . . . . . . . Scope 1 — 1 1.1 . . . . . . . . . . . . . . . General Description 1 — 1 1.2 . . . . . . . . . . . . . . . Description of UPS Module Major Internal Components 1 — 4 1.2.1 Rectifier/Batter y Charger 1 — 4 1.
section description page number 2.4 . . . . . . . . . . . . . . . Normal Operating Procedures 2 — 29 2.4.1 Checks Bef ore Star t-up 2 — 29 2.4.2 Star t-up 2 — 30 2.4.3 Checks After Start-up 2 — 31 2.4.4 Shut-down 2 — 32 2.4.4.1 Emergency Shutdown Using EPO 2 — 32 2.
Illustrations figure descr iption page number 1-1 . . . . . . . . . . . . . . . Pictorial, T ypical EPS 6000 UPS Shared Installation (Shown With T wo 375 kV A UPS Modules) 1 — 3 1-2 . . . . . . . . . . . . . . . Single-Line Diagram, T ypical EPS 6000 UPS Shared Installation 1 — 3 1-3 .
2-9 . . . . . . . . . . . . . . . Single-Line Diagram, T ypical EPS 6000 UPS Shared Installation 2 — 14 2-10 . . . . . . . . . . . . . . EPS 6000 Major Internal Components, Shared 150 - 225 kV A UPS Module 2 — 15 2-11 . . . . . . . . . . . . . . EPS 6000 Major Internal Components, Shared 300 / 375 kV A UPS Module 2 — 16 2-12 .
T ables table description page number 1-1 . . . . . . . . . . . . . . . EPS 6000 Model Numbers, Shared System UPS Modules 1 — 2 1-2 . . . . . . . . .
This manual is designed f or ease of use and easy location of inf ormation. T o quickly find the meaning of terms used within the text, look in the Glossary .
This manual provides technical inf or mation required for operation and maintenance of the shared EPS 6000 uninterruptible pow er system (UPS). Please read this manual before oper ating the EPS 6000 equipment. Please retain this manual for future ref erence.
• EPS 6000 batter y cabinet Each of these cabinets is described below . Figure 1-1 shows a typical shared UPS installation, consisting of one static s witch cabinet (SSC), two UPS modules, and tw o adjacent batter y cabinets. Figure 1-2 shows a single-line diagr am of the same shared UPS installation.
Figure Pictorial, T ypical EPS 6000 UPS Shared Installation 1-1 (Shown With T wo 375 kV A UPS Modules) Figure Single-Line Diagram, T ypical EPS 6000 UPS Shared Installation 1-2 TO ATTACHED LOAD MAIN A.
F ollowing is a description of the EPS 6000 UPS major internal components. Refer to the single-line diagram provided in Figure 1-2, and the component locators provided in Figure 1-3 through Figure 1-1.
The static s witch cabinet (SSC) provides an electrical path between the output of the UPS modules and the load. When the UPS modules are off , the SSC provides pow er to the load from the bypass A C input source (mains 2). Up to six (6) modules can be connected to the SSC , suppor ting loads as great as 1,500 kV A.
Figure EPS 6000 Major Internal Components, 1-4 Shared 375 kV A UPS Modules FRONT VIEW, DOORS AND COVERS REMOVED TOP VIEW, COVER REMOVED INVERTERS (x6) OUTPUT CIRCUIT BREAKER NEUTRAL CONNECTION (BEHIND.
Figure EPS 6000 Major Internal Components, 1-5 Shared 500 kV A UPS I/O Cabinet Q1 A3 B3 C3 INPUT CONNECTIONS A4 B4 C4 OUTPUT CONNECTIONS BATTERY CONNECTIONS FRONT VIEW, DOORS AND COVERS REMOVED TOP VI.
Figure EPS 6000 Major Internal Components, 1-6 Shared 500 kV A UPS Cabinet FRONT VIEW, DOORS AND COVERS REMOVED TOP VIEW, COVER REMOVED AC CAP ASSY. K1 BATTERY CONNECTION (OPTIONAL) F10,F11,F18,F19 F1.
Figure EPS 6000 Major Internal Components, 1-7 Shared 750 kV A UPS Cabinet 1 Ground C apacitors C onnection Power Interconnect CT (6ea) ACPZ ARUZ Fuses Relay Battery Connections Output Connections Q5N.
Figure EPS 6000 Major Internal Components, 1-8 Shared 750 kV A UPS Cabinet 2 FRONT VIEW, DOORS AND COVERS REMOVED TOP VIEW, COVER REMOVED INVERTERS (x6) AC OUTPUT CAPACITORS ALBZ K3N K3NZ DC CAPACITOR.
Figure EPS 6000 Major Internal Components, 1-9 Shared 750 kV A UPS Cabinet 3 FRONT VIEW, DOORS AND COVERS REMOVED TOP VIEW, COVER REMOVED INVERTERS (x6) AC OUTPUT CAPACITOR ASSY ALBZ DOUZ RAUZ PCA DC .
Figure EPS 6000 Major Internal Components, 1-10 Static Switch Cabinet (SSC) UPS BYPASS UPS BYPASS FUSES (F1, F2, F3, & F4) ROTARY SWITCHES (SW1, & SW2) PCA (EPOZ) PCA (ACOZ) PCA (RAUZ) PCA (AC.
This section describes options av ailable f or the EPS 6000 UPS. Some configurations do not support some options. Most options must be specified at the time of equipment order; some options can be installed in the field. Contact your MGE dealer f or complete inf ormation.
A C output ratings V oltage: 480 V AC ± 0.5% (steady-state conditions) 480 V AC ± 5% (transient conditions from 0% to 100% or 100% to 0%) F requency: 60 Hz ± 0.1% (free-r unning) Phases: 3 Ø (phase sequence must be A, B , C) Wires: 4 wires plus ground Current: P ower f actor : 0.
Recommended environment: 20° to 25° C (68° to 77° F .); 50% relative humidity; computer room or other temperature- and humidity- controlled environment Operating temperature: 0° to 40° C (32° to 104° F .) e xcept batter y Storage: -20° to 50° C (-4° to 122° F .
Height: 1,981 mm/78 in. Depth: 1,219 mm/48 in. Width: 1,829 mm/72 in. W eight: 1,310 kg/2,900 lbs. (SSC) 1,091 kg/2,000 lbs. (MBC) Finish: MGE light gra y 1.
This section presents operating inf or mation for EPS 6000 UPS shared systems, including an o verview of the system, its components, and their function; a description of the indicators and controls and their function; and operational sequences to be f ollowed f or all conditions of nor mal, emergency , and maintenance operation.
During nor mal operation (as shown in Figure 2-1), pow er flows from the main A C input source (mains 1) into the UPS rectifier/batter y charger sections. The rectifier/battery chargers conv er t the AC v oltage to DC, maintain the charge on the batteries, and f eed the DC power to the in ver ters.
Figure P ower Flow , Bypass Operation 2-3 Indicators and controls are located in three places on the UPS module: on the front panel, behind a drop-down cov er just below the front panel, and inside the enclosure doors , as shown in Figure 2-4. In batter y cabinets and auxiliar y cabinets, the controls are located behind the cabinet doors .
Figure EPS 6000 Controls and Indicator s 2-4 Figure EPS 6000 Front P anel 2-5 Note: The SSC does not include inv er ter on or inverter off pushbuttons #6 and #7, or the batter y operation LED #4.
Emergency po wer off (EPO) On the left side of the front panel, an emergency power off (EPO) pushb utton is provided, with a protectiv e cover to guard against inadv er tent operation.
⁄ Operating prob lem LED (3) This orange LED turns on when an operating problem e xists, such as fan f ailure; static s witch power supply f ault; batter y temperature fault; ov erload fault; or bypass A C input (mains 2) out of tolerance. The UPS contin ues to protect the attached load.
Pushbuttons F ollowing are brief descriptions of the function of the alphanumeric display pushbuttons . Figure Alphanumeric Displa y and Controls 2-6 ø Settings pushbutton This pushbutton is used to select the displa y language and adjust the LCD screen contrast f or optimal viewing.
• Inv er ter current • Load current • P ercent current drawn b y the load relative to UPS module or SSC r ating • Crest f actor per phase „ Pushbutton This pushbutton pro vides access to pow.
Numbered lights The green light indicates the UPS module or SSC with which the displa y is currently communicating. A red light indicates that the corresponding UPS module or SSC has an anomaly or is not communicating with the displa y . Light #1 ref ers to the SSC; the UPS modules are numbered sequentially star ting at #2.
B: Rectifier/charger on This green LED indicates that the rectifier/battery charger is on. C: Rectifier/charger fault This red LED indicates an alarm condition within the rectifier/batter y charger.
J: In ver ter desynchronized This orange LED indicates that the in verter output frequency is not synchronized with the bypass A C input (mains 2). K: T ransfer fault This red LED indicates a transf e.
Figure Hidden P anel Pushbuttons 2-8 Battery charge cyc le (pushbutton #1) (applies to UPS module onl y) Pressing this pushbutton begins a battery charging cycle. After the cycle is complete, the rectifier/battery charger retur ns to float charge lev els on the batter y .
Forced b ypass to inverter (pushbutton #4) (applies to SSC only) Pressing and holding the “security key” while pressing this pushbutton f orces the transf er of the load to the inverter output when the bypass is out of tolerance.
attached load. Figure Single-Line Diagram, 2-9 T ypical EPS 6000 UPS Shared Installation TO ATTACHED LOAD MAIN AC INPUT/ MAINS 1 QF1 OUTPUT FUSES EPS 6000 UPS MODULE EPS 6000 BATTERY K3N Q1 INVERTER R.
Figure EPS 6000 Major Internal Components, 2-10 Shared 150 - 225 kV A UPS Module FRONT VIEW, DOORS AND COVERS REMOVED TOP VIEW, COVER REMOVED INVERTERS OUTPUT CIRCUIT BREAKER NEUTRAL CONNECTION (BEHIN.
Figure EPS 6000 Major Internal Components, 2-11 Shared 300 / 375 kV A UPS Module FRONT VIEW, DOORS AND COVERS REMOVED TOP VIEW, COVER REMOVED INVERTERS (x6) OUTPUT CIRCUIT BREAKER NEUTRAL CONNECTION (.
Figure EPS 6000 Major Internal Components, 2-12 Shared 500 kV A UPS Module I/O Cabinet Q1 A3 B3 C3 INPUT CONNECTIONS A4 B4 C4 OUTPUT CONNECTIONS BATTERY CONNECTIONS FRONT VIEW, DOORS AND COVERS REMOVE.
Figure EPS 6000 Major Internal Components, 2-13 Shared 500 kV A UPS Module UPS Cabinet FRONT VIEW, DOORS AND COVERS REMOVED TOP VIEW, COVER REMOVED AC CAP ASSY.
Figure EPS 6000 Major Internal Components, 2-14 Shared 750 kV A UPS Module UPS Cabinet 1 Ground Capacitors Connection Power Interconnect CT (6ea) ACPZ ARUZ Fuses Relay Battery Connections Output Conne.
Figure EPS 6000 Major Internal Components, 2-15 Shared 750 kV A UPS Module UPS Cabinet 2 FRONT VIEW, DOORS AND COVERS REMOVED TOP VIEW, COVER REMOVED INVERTERS (x6) AC OUTPUT CAPACITORS ALBZ K3N K3NZ .
Figure EPS 6000 Major Internal Components, 2-16 Shared 750 kV A UPS Module UPS Cabinet 3 FRONT VIEW, DOORS AND COVERS REMOVED TOP VIEW, COVER REMOVED INVERTERS (x6) AC OUTPUT CAPACITOR ASSY ALBZ DOUZ .
Figure EPS 6000 Major Internal Components, 2-17 Static Switch Cabinet (SSC) In the UPS modules: Q1 Input isolation circuit breaker , used to isolate the UPS module from the main A C input (mains 1) source and provide input current protection. Q5N UPS isolation circuit breaker , used to isolate the UPS module from he attached load.
This section describes operation and use of the alphanu- meric display in detail. The alphanumeric display inter acts with the user via the top half of the hidden panel (Figure 2-4). Figure 2-18 shows the general organization of the alphanumeric displa y .
Figure General Display Configuration 2-19 The settings selection screens allow the user to configure the displa y language and set the contrast of the LCD displa y . T o access the settings selection screen, press the settings pushbutton, and f ollow the steps as indicated in Figure 2-20.
In the e vent of an alarm condition, the general status screen shows an alarm message. T o deter mine the specific condition causing the alarm, press the alar m key on the front panel, as sho wn in Figure 2-21. If there is a flashing e xclamation mark (!) in the display ed message, there is additional inf ormation to be viewed.
The LCD can displa y comprehensive inf or mation about UPS perf ormance through its monitor ing functions. T o displa y voltage measurements , press the “V” key on the ke yboard, as shown in Figure 2-22.
T o displa y current measurements, press the “A” ke y on the ke yboard, as shown in Figure 2-23. Figure Current Measurements 2-23 Select current measurements by pressing the Å pushbutton INPUT I1 I2 I3 A RMS BYPASS I1 I2 I3 A RMS I LOAD / IN = Å Å Å Å Å Å Å INV.
T o displa y power or frequency measurements , press the “W .Hz” ke y on the keyboard, as shown in Figure 2-24. Figure P ower and Frequency Measurements 2-24 Select power and frequency measurements by pressing the „ pushbutton. FREQ. INP. BYP. INV.
T o displa y batter y voltage , current, ambient temperature, and time av ailable or remaining, press the batter y ke y on the ke yboard, as shown in Figure 2-25. Figure Battery Measurements 2-25 This section presents normal operating procedures for the EPS 6000 UPS.
In the individual UPS modules: • Input (isolation) circuit breaker Q1 is in the OFF (open) position. • Batter y disconnect circuit breaker QF1 is in the OFF (open) position.
d. Star t the UPS modules: 1. For each module, close the input isolation circuit break er Q1. V erify that the f ollowing conditions e xist: • The red “load not protected” LED is on • The rectifier/batter y charger automatically star ts If either condition is not present, there is a f ault.
• Remote emergency power off (REPO) test (if applicab le). • Inv er ter star t and stop (for each module). • Batter y transf er test. • Maintenance bypass procedure . This section presents procedures f or shutting down the system under normal, emergency , ov er load, and maintenance conditions.
T o shut down an individual UPS module , press the “in ver ter off ” pushbutton on the module front panel f or 3 seconds. T o restar t, press the “in ver ter on” pushbutton. Note that the transfer will occur only if the in ver ter is synchronized to the b ypass; otherwise, a f orced transfer is needed (see Section 2.
2. Open the UPS isolation circuit breaker Q5N. 3. Open the batter y disconnect circuit breaker(s) QF1. 4. Open the input isolation circuit breaker Q1. The UPS module is now isolated f or maintenance. For complete protection, the upstream circuit breaker supplying the UPS module should be opened, loc ked, and tagged while the UPS is being ser viced.
T o isolate the SSC f or maintenance, or to transf er the load to maintenance bypass input source (if present), f ollow the procedure that applies to your configur ation. This procedure assumes that the UPS system is operating normally , with the attached load supplied via the UPS modules.
The whole UPS system is now isolated f or maintenance. For complete protection, Q4S or the upstream circuit breaker supplying Q4S should be loc ked open and tagged while the UPS is being ser viced. T o restar t the UPS system after maintenance: 1. Close the upstream bypass circuit breaker Q4S .
This procedure assumes that the load is being supplied by the bypass A C input (mains 2) source via the SSC. Star t the UPS modules (refer to Section 2.
General alarms LOW LEVEL ALARM UPS OK ! This message indicates that a problem requiring action has occurred. The load is still supplied by the in ver ter . The problem is listed in the secondary alar m message (see below), as indicated by the flashing e xclamation mar k (!).
LOAD ON BYPASS ! This message indicates that the load has been transf erred to the bypass AC input (mains 2) source. The load is no longer protected. BYPASS PROBLEM CHECK FREQUENCY ! This message indicates that the bypass A C input (mains 2) source is out of frequency tolerance.
CHARGER SHUTDOWN COMMAND ON ! This message indicates that the rectifier/batter y charger has been instructed to shut down, f or example during progressiv e (stepped) transfer to a motor-gener ator set.
INVERTER OVERLOAD CHECK P.F. AND KW This message indicates that the inv er ter is in an overload condition, usually due to e xcessive real power (kW) being dr awn b y the load. The flashing “KW” indicates that the operator should check the load real po wer .
Q5N UPS OUTPUT ISOL. SWITCH OPEN ! On a UPS module, this message indicates that the UPS module isolation circuit break er Q5N is open, making it impossible f or that module to supply the load.
FAN FAILURE CALL SERVICE ! This message indicates that a f an has failed, and that service is required. Because the f ans of the rectifier/batter y charger and the inv er ter are redundant, the load is still supplied by the in ver ter .
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This section describes maintenance of the EPS 6000 UPS, including saf ety instructions, prev entive maintenance, descriptions of replacement par ts kits, and ser vice.
a. Isolate and de-energize all EPS 6000 UPS equipment for all maintenance operations. b . Ensure that all equipment is clean and free of loose dust, dir t, and debris. The e xterior of all enclosures may be cleaned with a mild solution of soap and water , lightly applied with a lint-free cloth.
Should you encounter a prob lem in the operation of a UPS module and need MGE UPS Systems, Inc. to ser vice your product, please tak e into account the f ollowing recommendations.
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Symbols ¶ Used to ref erence paragraph headings that are listed in the tab le 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.
B or B A T . or B A TT . Batter y . Breaker Circuit breaker . British Thermal Unit A unit of heat equal to 252 calories (see BTU). BTU or Btu Br itish ther mal unit. Defined as the amount of energy required to raise the temperature of 1 pound of water b y 1° F .
Free running Indicates that the inv er ter frequency is stable and independent of the bypass A C input (mains 2) frequency . FREQ F requency . Fusible Capab le of being melted with heat. GND Ground Hz Her tz, a measure of frequency; one cycle per second equals one Her tz.
MCM Thousand circular mil; standard wire sizes f or multiple stranded conductors ov er 4/0 AWG in diameter . M is from the Roman numeral system; it is the symbol f or 1,000. MG Motor-generator set. MGE MGE UPS Systems, Inc. module Ref ers to an EPS 6000 UPS module (rectifier/batter y charger , inverter , and attached batter y cabinet).
Remote emergency power off A switch used f or shutting down electrical equipment from a location awa y from the equipment. REPO Remote emergency power off . SCR Silicon-controlled rectifier . Security bypass (key) Pushb utton on the hidden panel (UPS modules and SSC) allowing f orced transf ers and other commands to be issued.
VDC V olts of direct current. Via By wa y of. VPC V olts per cell, the measure of the electrical potential of a storage cell, such as a batter y . XFMR T ransf or mer .
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, ommissions, or other prob lems you ha v e e xper ienced.
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