EXL 1000
Uninterruptible
Power System
Installation and
User’s Guide
IMPORTANT SAFETY INSTRUCTION
SAVE THESE INSTRUCTIONS — This manual contains
important instructions for models EXL 1050 (PNs 891050-44,
891050-84), EXL 1075 (PNs 891075-44, 891075-84) and
EXL 1100 (PNs 891100-44, 891100-84) that must be
followed during installation, operation and maintenance of
the UPS and batteries.
Tightening torque for all input and output terminal blocks
shall be 10.6 - 12.3 in-lbs (1.2 - 1.4 Nm).
The nominal battery voltage ratings are:
EXL 1050 - 180 Vdc
EXL 1075 - 180 Vdc
EXL 1100 - 240 Vdc.
A power output disconnect switch must be provided by the
user if the EXL 1000 distribution cabinet is not installed.
Input power cables and output power cables for the 5 kVA
model shall be rated for 10 AWG, 75°C or 10 AWG, 90°C.
Input power cables and output power cables for 7.5 kVA and
10 kVA models shall be rated for 6 AWG, 75°C or 6 AWG,
90°C copper wire.
The EXL 1000 series UPS is intended for installation in a
temperature controlled, indoor area free of conductive contaminants.
Servicing of batteries should be performed or supervised by
personnel knowledgeable of batteries and the required
precautions.
When replacing batteries, replace with the same number of
batteries. Use Yuasa NP7-12 FR
CAUTION - Do not dispose of battery or batteries in a fire.
The battery may explode.
CAUTION - Do not dispose or mutilate the battery or
batteries. Released electrolyte is harmful to the skin and
eyes. It may be toxic.
CAUTION - A battery can present a risk of electrical shock
and high short circuit current. The following precautions
should be observed when working on batteries.
Remove watches, rings, or other metal objects.
Use tools with insulated handles.
Wear rubber gloves and boots.
Do not lay tools or metal parts on top of batteries.
Important Safety Instructions
86-891000-00
Installation and User’s Manual
Disconnect charging source prior to connecting or
disconnecting battery terminals (if applicable).
Determine if the battery is inadvertently grounded. If inadvertently grounded, remove source of a ground. Contact with
any part of a grounded battery can result in electrical shock.
The likelihood of such shock will be reduced if such grounds
are removed during installation and maintenance.
Interconnecting cables - Flexible cord or flexible cable
assemblies used for external interconnection between parts
of equipment or between components of a system are not
provided.
Internal Wiring - (AVLV2), Style Nos. 1015, 1061, 2464, 2690,
2768, type SIS.
Building wire type THHN and XHHW and ribbon cable style
2651. All wiring is routed away from sharp edges and moving
parts. Smooth and well-rounded surfaces are provided for
wiring to bear upon when passing through sheet metal walls.
Where wires are bundled or run in ducts, 300 V insulated
wires are bundled and physically separated from 600 V rated
wire or occupy separate ducts. All multi-conductor style 2464
wires are rated 300 V.
Size of Branch Circuit Overcurrent Protection - CAUTION To reduce the risk of fire, connect only to a circuit provided
with 60 amperes maximum branch circuit overprotection in
accordance with the National Electrical Code, ANSI/NFPA
70.
Operating temperature - 0° - 30°C at rated output. 40°C for 8
hours max.
WARNING
High voltages are present inside the EXL 1000 system. Any servicing
requiring removal of the protective covers may be undertaken only by
qualified personnel certified by MGE UPS Systems.
WARNING
OPENING ENCLOSURES EXPOSES HAZARDOUS VOLTAGES.
ALWAYS REFER SERVICE TO QUALIFIED PERSONNEL ONLY.
86-891000-00
Important Safety Instructions
EXL 1000 Uninterruptible Power System
NOTE
As standards, specifications and designs are subject to change,
please ask for confirmation of the information given in this publication.
This manual is a controlled document. Pages should not be removed
individually from this binder.
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. Operation of this equipment in a residential area is likely to
cause harmful interference in which case the user will be required to
correct the interference at his own expense.
Important Safety Instructions
86-891000-00
prepared for:
EXL 1000
Uninterruptible Power System
Installation and User’s Guide
For service call
1-800-438-7373
86-891000-00 C01 06/98
Copyright © 1997 MGE UPS Systems, Inc..
All rights reserved. Printed in U.S.A.
MGE UPS Systems
1660 Scenic Avenue
Costa Mesa, CA 92626
(714) 557-1636
86-891000-00
EXL 1000
Uninterruptible Power System
Installation and User’s Guide
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 24 months from the date of purchase. MGE UPS Systems, Inc. shall have the sole right to determine if the parts
are to be repaired at the job site or whether they are to be returned to the factory for repair or replacement. All items
returned to MGE UPS Systems, Inc. for repair or replacement must be sent freight prepaid to its factory. Purchaser must
obtain MGE UPS Systems, Inc.’s Return Materials Authorization prior to returning items. The above conditions must be
met if warranty is to be valid. MGE UPS Systems, Inc. will not be liable for any damage done by unauthorized repair work,
unauthorized replacement parts, from any misapplication of the item, or for damage due to accident, abuse, or Act of
God.
In no event shall MGE UPS Systems, Inc. be liable for loss, damage, or expense directly or indirectly arising from the
use of the units, or from any other cause, except as expressly stated in this warranty. MGE UPS Systems, Inc. makes no
warranties, express or implied, including any warranty as to merchantability or fitness for a particular purpose or use.
MGE UPS Systems, Inc. is not liable for and Purchaser waives any right of action it has or may have against MGE UPS
Systems, Inc. for any consequential or special damages arising out of any breach of warranty, and for any damages
Purchaser may claim for damage to any property or injury or death to any person arising out of its purchase of, or the
use, operation or maintenance of the product. MGE UPS Systems, Inc. will not be liable for any labor subcontracted or
performed by Purchaser for preparation of warranted item for return to MGE UPS Systems, Inc.’s factory or for
preparation work for field repair or replacement. Invoicing of MGE UPS Systems, Inc. for labor either performed or
subcontracted by Purchaser will not be considered as a liability by MGE UPS Systems, Inc.
This warranty shall be exclusive of any and all other warranties express or implied and may be modified only by a
writing signed by an officer of MGE UPS Systems, Inc. This warranty shall extend to the Purchaser but to no one else.
Accessories supplied by MGE Systems, Inc., but manufactured by others, carry any warranty the manufacturers have
made to MGE UPS Systems, Inc. and which can be passed on to Purchaser.
MGE UPS Systems, Inc. makes no warranty with respect to whether the products sold hereunder infringe any patent,
U.S. or foreign, and Purchaser represents that any specially ordered products do not infringe any patent. Purchaser
agrees to indemnify and hold MGE UPS Systems, Inc. harmless from any liability by virtue of any patent claims where
Purchaser has ordered a product conforming to Purchaser’s specifications, or conforming to Purchaser’s specific design.
Purchaser has not relied and shall not rely on any oral representation regarding the Product sold hereunder and any
oral representation shall not bind MGE UPS Systems, Inc. and shall not be part of any warranty.
There are no warranties which extend beyond the description on the face hereof. In no event shall MGE UPS
Systems, Inc. be responsible for consequential damages or for any damages except as expressly stated herein.
Service and Factory Repair - Call 1 - 800 - 523 - 0142
Direct questions about the operation, repair, or servicing of this equipment to MGE UPS Systems, Inc. Technical
Support Services. Include the part number and serial number of the unit in any correspondence. Should you require
factory service for your equipment, contact MGE UPS Systems, Inc. Technical Support Services and obtain a Return
Materials Authorization (RMA) prior to shipping your unit. Never ship equipment to MGE UPS Systems, Inc. without first
obtaining an RMA.
Proprietary Rights Statement
The information in this manual is the property of MGE UPS Systems, Inc., and represents a proprietary article in
which MGE UPS Systems, Inc. retains any and all patent rights, including exclusive rights of use and/or manufacture
and/or sale. Possession of this information does not convey any permission to reproduce, print, or manufacture the article
or articles shown herein. Such permission may be granted only by specific written authorization, signed by an officer of
MGE UPS Systems, Inc.
IBM, PC-AT, ES/9000, and AS/400 are trademarks of International Business Machines Corporation. MGE and MGE
UPS Systems are trademarks of MGE UPS Systems, Inc. Other trademarks that may be used herein are owned by their
respective companies and are referred to in an editorial fashion only.
Revision History
EXL 1000 Uninteruptible Power System Installation and User’s Guide
86-891000-00
Copyright © 1997 MGE UPS Systems. All rights reserved. Printed in U.S.A.
Revision:
A00
New Release
01/97
B00
ECN 289-93
10/97
C00
ECN 291-79
2/98
C01
ECN 293-49
06/98
86-891000-00
Contents
Introduction
1.0 . . . . . . . . . . . . . . . Scope
1.1 . . . . . . . . . . . . . . . General Description
1.1.1
Description of UPS Module
1.2 . . . . . . . . . . . . . . . Configuration
1
1
1
1
—
—
—
—
1
2
2
4
2
2
2
2
2
2
2
—
—
—
—
—
—
—
1
1
1
4
4
5
5
Installation
2.0
2.1
2.2
2.3
2.4
2.5
2.6
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2.6.1
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Scope
Storage
Unpacking
General
Final positioning
Special Precautions
Connections
Electrical Diagram for
Power Connections
2—5
Operation
3.1 . . . . . . .
3.1.1
3.1.2
3.2 . . . . . . .
3.3 . . . . . . .
3.4 . . . . . . .
3.5 . . . . . . .
3.6 . . . . . . .
3.7 . . . . . . .
3.8 . . . . . . .
3.9 . . . . . . .
3.10 . . . . . .
3.11 . . . . . .
3.12 . . . . . .
3.13 . . . . . .
3.14 . . . . . .
3.15 . . . . . .
. . . . . . . . Controls and indicators
3—1
Basic controls and indicators
3—1
Controls and Diagnostic Display
3—4
. . . . . . . . Checks before Start-up
3—5
. . . . . . . . Powering up the EXL 1000
3—6
. . . . . . . . Manual Inverter Start-up
3—6
. . . . . . . . Shutting down the inverter
3—6
. . . . . . . . Powering down the inverter
3—7
. . . . . . . . Normal Operation
3—7
. . . . . . . . Operation on battery power
3—8
. . . . . . . . Battery duration
3—8
. . . . . . . . Return of AC input power
3—9
. . . . . . . . Battery Monitoring Tests
3—9
. . . . . . . . Overload
3—9
. . . . . . . . Alarms
3 — 10
. . . . . . . . Diagnostics display messages
3 — 11
. . . . . . . . Manual Bypass
3 — 14
Communications
4.0 . . . . . . . . . . . . . . . Standard Functions
4.1 . . . . . . . . . . . . . . . Options
86-891000-00
4—1
4—2
iii
EXL 1000 Uninterruptible Power System
Maintenance and Service
5.0 . . . . . . . . . . . . . . . Scope
5.1 . . . . . . . . . . . . . . . User Preventive Maintenance
5.2 . . . . . . . . . . . . . . . Maintenance by
Certified MGE Representatives
5.2.1
Battery Maintenance
5.2.2
Environmental Protection
5.2.3
Annual Check
5.2.4
Customer Training
5.2.5
Maintenance Contracts
5—1
5—1
5
5
5
5
5
5
—
—
—
—
—
—
1
1
2
2
2
2
Options
6.1 . . . . . . . . . . . . . . . Extended battery cabinet
6.2 . . . . . . . . . . . . . . . Connection of an
additional battery cabinet
6.3 . . . . . . . . . . . . . . . Emergency Power Off (EPO)
6.4 . . . . . . . . . . . . . . . Battery circuit breaker
shunt trip connection
6.5 . . . . . . . . . . . . . . . Combined options
6—1
7.1 . . . . . . . . . . . . . . . Introduction
7.1.1
Storage
7.1.2
Safety Recommendation
7.2 . . . . . . . . . . . . . . . Installation of the U-Talk board
7.2.1
Powering down the
EXL 1000 UPS
7.2.2
Installing the U-Talk
RS232 board
7.2.3
Returning power to the
EXL 1000 UPS
7.3 . . . . . . . . . . . . . . . Description of RS232 board
7.3.1
Function
7.3.2
Configuring the RS232 board
7.4 . . . . . . . . . . . . . . . Configuration for
UPS Manager software
7.5 . . . . . . . . . . . . . . . U-Talk data format
7
7
7
7
6—2
6—4
6—4
6—5
U-Talk
iv
Contents
—
—
—
—
1
1
1
2
7—2
7—2
7
7
7
7
—
—
—
—
3
3
3
3
7—4
7—5
86-891000-00
Installation and User’s Manual
Appendices
A.0 . . . . . . . . . . . . . . . General Characteristics
A.1 . . . . . . . . . . . . . . . Range Characteristics
a—1
a—1
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . g — 1
Illustrations
figure
description
page number
1-1 . . . . . . . . . . . . . . . Identification Plate
1—4
1-2 . . . . . . . . . . . . . . . EXL 1000 5kVA
front and rear view
1—5
1-3 . . . . . . . . . . . . . . . EXL 1000 7.5 & 10 kVA
front and rear view
1—5
1-4 . . . . . . . . . . . . . . . Functional diagram
1—6
2-1 . . . . . . . . . . . . . . . Unpacking the EXL 1000 UPS
2—2
2-2 . . . . . . . . . . . . . . . Removing stabilizing material
from under EXL 1000 UPS
2—3
2-3 . . . . . . . . . . . . . . . Using supplied ramp
to bring EXL 1000
off of shipping base
2—3
2-4 . . . . . . . . . . . . . . . Installation clearanc
es as seen from above
2—4
2-5 . . . . . . . . . . . . . . . Connection diagram
for a single AC input
2—5
2-6 . . . . . . . . . . . . . . . Removal of
conduit landing cover panel
(5 kVA)
2—7
2-7 . . . . . . . . . . . . . . . Cable connections (5 kVA)
2—7
2-8 . . . . . . . . . . . . . . . Removal of
maintenance bypass switch knob
and conduit landing cover panel
(7.5 & 10 kVA)
2—8
2-9 . . . . . . . . . . . . . . . Cable Connections
(7.5 & 10 kVA)
2—8
3-1 . . . . . . . . . . . . . . . Location of Controls and
indicators on cabinet
3—1
3-2 . . . . . . . . . . . . . . . Close-up of
Controls and indicators
3—2
3-3 . . . . . . . . . . . . . . . “Load protected” LED
3—2
3-4 . . . . . . . . . . . . . . . “Battery Status” LED
3—2
3-5 . . . . . . . . . . . . . . . “Fault” LED
3—3
3-6 . . . . . . . . . . . . . . . “Load Not Protected” LED
3—3
3-7 . . . . . . . . . . . . . . . Audible Alarm
3—3
3-8 . . . . . . . . . . . . . . . “Inverter On” button
3—3
3-9 . . . . . . . . . . . . . . . “Inverter Off” button
3—4
3-10 . . . . . . . . . . . . . . Controls and
Diagnostics Display
3—4
3-11 . . . . . . . . . . . . . . Manual Maintenance Bypass
circuit breaker
3—5
3-12 . . . . . . . . . . . . . . EXL 1000 power-up
3—6
86-891000-00
Contents
v
EXL 1000 Uninterruptible Power System
figure
description
page
3-13 . . . . . . . . . . . . . . Indicators during
normal operation
3-14 . . . . . . . . . . . . . . Diagram of normal operation
on utility power
3-15 . . . . . . . . . . . . . . Indicators when on
battery power
3-16 . . . . . . . . . . . . . . Diagram of operation
on battery power
3-17 . . . . . . . . . . . . . . Inverter overload curve
3-18 . . . . . . . . . . . . . . Static Bypass overload curve
3-19 . . . . . . . . . . . . . . Relationship of fault codes
to EXL 1000 subsystems
3-20 . . . . . . . . . . . . . . Manual Bypass Switch
4-1 . . . . . . . . . . . . . . . Electrical connections of
15 pin D connector
4-2 . . . . . . . . . . . . . . . 15 pin D connector
6-1 . . . . . . . . . . . . . . . Connection of an additional
battery cabinet (5kVA Model)
Covers Removed
6-2 . . . . . . . . . . . . . . . Connection of an
additional battery cabinet
(7.5 & 10 kVA Models)
6-3 . . . . . . . . . . . . . . . Connection diagram for
battery circuit breaker
shunt trip on terminal block XR3
6-4 . . . . . . . . . . . . . . . XR3 terminal block for
EXL 1050, EXL 1075
and EXL 1100
7-1 . . . . . . . . . . . . . . . Inserting the U-Talk board
into the groove
7-2 . . . . . . . . . . . . . . . Overview of RS232 board
7-3 . . . . . . . . . . . . . . . Close-up of
figure 7-2, section A
7-4 . . . . . . . . . . . . . . . Factory settings of
U-Talk board jumpers
7-5 . . . . . . . . . . . . . . . Configuring the
Transmission Speed
7-6 . . . . . . . . . . . . . . . Configuring the
Transmission Format
7-7 . . . . . . . . . . . . . . . Configuring the
Hx and Ix Signals Format
vi
Contents
number
3—7
3—7
3—8
3—8
3 — 10
3 — 10
3 — 13
3 — 14
4—1
4—1
6—3
6—3
6—5
6—5
7—2
7—3
7—3
7—4
7—4
7—5
7—5
86-891000-00
Installation and User’s Manual
Tables
table
description
page number
1-1 . . . . . . . . . . . . . . . Model and Part numbers
for installation of 5 kVA,
7.5kVA and 10kVA
1—2
2-1 . . . . . . . . . . . . . . . Battery cabinet for an
overall operating time
of 30 minutes (7.5 & 10 kVA)
or 24 minutes (5 kVA)
at rated output power
with a power factor of 0.6
6—1
2-2 . . . . . . . . . . . . . . . Battery cabinet for an
overall operating time of
50 minutes (7.5 & 10 kVA)
or 40 minutes (5 kVA)
at rated output power
with a power factor of 0.6
6—2
3-1 . . . . . . . . . . . . . . . Maximum current ratings
a—4
3-2 . . . . . . . . . . . . . . . Minimum cable size
a—4
86-891000-00
Contents
vii
EXL 1000 Uninterruptible Power System
This manual has been designed to provide you with all the
information you need to install and use your EXL 1000 UPS
system.
How to use this manual
This manual is designed for ease of use and easy
location of information.
This manual uses Noteboxes to convey
information. Noteboxes come in four varieties:
WARNING
CAUTION
A WA R N I N G n o t e b ox
indicates information
p rov i d e d t o p ro t e c t
the user and service
personnel against safety
hazards and/or possible
equipment damage .
A C AU T I O N n o t e b ox
indicates information
provided to protect
the user and ser vice
personnel against
possible equipment
damage .
IMPORTANT
NOTE
An IMPORTANT notebox
indicates information
provided as an operating
instruction or as an
operating tip.
A
N OT E
n o t e b ox
indicates information
provided as an operating
tip or an equipment
feature.
Safety
Recommendations
viii
important
If you encounter a problem while following the instructions in
this manual, we recommend that you contact our Customer
Support Services. On request, our customer support
personnel can carry out the complete installation of your
equipment.
86-891000-00
Introduction
1.0
Scope
This manual provides technical information required for
operation and maintenance of the EXL 1000 series uninterruptible power system (UPS). Please read this manual
before operating the EXL 1000 equipment. Please retain this
manual for future reference.
The manual is divided into seven100 sections:
Section I — General Description
This section introduces the EXL1000 family of uninterruptible power systems, including a general description
of the system and its internal components, a description
of available options, and system specifications.
Section II — Installation
This section describes the installation procedures for
the EXL 1000.
Section III — Operation
This section describes operating information for EXL
1000 UPS single-module systems, including an
overview of the system, its components, and their
functions; a description of the indicators and controls
and their functions; and operational sequences to be
followed for all conditions of normal, emergency, and
maintenance operation.
Section IV — Communication
This section describes communication options availabel
for the EXL 1000.
Section V — Maintenance and Service
This section describes user level maintenance and
service practices for the EXL 1000.
Section VI — Options
This section describes available add on options for the
EXL1000.
Section VII — U-Talk
This section describes installation and usage of the
optional U-Talk board which allows computer systems to
monitor and controll the EXL 1000 remotely.
An appendix near the rear of this manual provides
information on specifications of the EXL 1000.
86-891000-00
1—1
EXL 1000 Uninterruptible Power System
A Glossary in the rear of this manual provides definitions of
terms used within the text.
1.1
General Description
The EXL1000 series are a family of Uninterruptible Power
Supplies (UPS) designed for safe reliable VAC backup power
for the computer room, office or industrial environments.
This manual describes the function and installation of the
5kVA, 7.5kVA, and 10kVA members of the EXL1000 UPS
family. The following are the model numbers and part
numbers respectively:
Table
1-1
1.1.1
M o d e l a n d Pa r t n u m b e rs fo r i n s t a l l a t i o n
o f 5 k VA , 7 . 5 k VA a n d 1 0 k VA
Description
Model Number
Part Number
UPS 4.7 kVA/3.8 kw, 208 VAC in/out
EXL 1050
891050-84
UPS 5 kVA/4 kw, 240 VAC in/out
EXL 1050
891050-44
UPS 7.1 kVA/5.7 kw, 208 VAC in/out
EXL 1075
891075-84
UPS 7.5 kVA/6 kw, 240 VAC in/out
EXL 1075
891075-44
UPS 9.5 kVA/7.6 kw, 208 VAC in/out
EXL 1100
891100-84
UPS 10 kVA/8kw, 240 VAC in/out
EXL 1100
891100-44
Description of
There are 7 major components within the EXL1000 UPS and
they are as follows:
UPS Module
1.
Input EMI filter - This is an electonic filter which
prevents electrical noise (EMI) generated by the UPS
from conducting or radiating back onto the AC input
power lines. It also incorporates lightning strike
protection for the UPS.
2.
Input rectifier - This module takes AC input line to line
voltage and converts it to a rectified DC voltage which is
fed to the input of the “chopper” module.
3
Chopper - The chopper module has two voltage inputs.
A rectified AC input and a battery DC voltage. The
chopper module outputs + and - 385 Vdc which is fed to
the inverter module.
When AC input is present the chopper takes power from
this input. When the AC input fails or is removed the
chopper automatically will transfer to battery and take
power from the battery source in order to continue to
power the inverter module.
4.
1—2
Battery - A 180 Vdc (5 or 7.5 kVA models) or 240Vdc
(10 kVA model) source is used to power the chopper
Introduction
86-891000-00
Installation and User’s manual
module which powers the inverter module which powers
a user’s output load. This happens only when the AC
input fails, is out of tolorance or is removed.
86-891000-00
5.
Inverter - This power module converts the + and 385Vdc output from the chopper to 208 or 240VAC line
to line which continually outputs and powers the user’s
load.
6.
Static bypass switch - Solid state switch. When the
inverter is overloaded, fails or is turned off, the UPS
automatically transfers it’s output load to the AC input of
the UPS via this solid state switch called the static
bypass switch. This automatic power transfer
mechanism allows for no loss of output power to the
user’s load. The load’s power is never interrupted with
this type of power transfer. The inverter output,
although off or disabled, is still physically connected to
the load.
7.
Maintenance bypass switch - A manual hard switch.
This switch is used when maintenance is required on
the UPS without interrupting power to the load. Turning
this switch to “bypass” internally connects the AC input
directly to the AC output of the UPS, while at the same
time physically disconnecting the inverter output from
the load. By also turning off the input circuit breaker,
the internal electronics are now physically isolated from
input and output, enabling a service technician to open
the UPS and service it without fear of electrocution. At
the same time, the load is still being powered directly by
the AC input via the maintenance bypass switch.
Introduction
1—3
EXL 1000 Uninterruptible Power System
Figure
1-1
Identification Plate
PULSAR EXL 1000
Article - Article - Artikel
NT
6762690
01
N° Série - Serial Number - Artikel
+
-
PB02
CEAC
Volt :
Ah :
YUA
Model Number
Serial Number
Sales Order No.
AC Input:
891100-84
L1 L2 + GND
Input Voltage:
Input Current:
208V
47
Frequency:
60 Hz
AC Output:
Vrms L — L
Arms
L1 L2 + GND
Output Voltage:
Output Current:
208V
46
Frequency:
60 Hz
Vrms L — L
Arms
Output Power: 9.5KVA/7.6KW
Batt Voltage: 240VDC
Batt Current: 46 Adc

LISTED
55K6

E87247
UNINTERRUPTIBLE POWER SUPPLY
1.2
1—4
Configuration
The configuration sheet, included with the UPS, indicates all
the factory settings. Keep the sheet in a safe place as it may
be required by the after-sales support technicians if you wish
to modify parameters.
Introduction
86-891000-00
Installation and User’s Manual
Figure
1-2
E X L 1 0 0 0 5 k VA f ro n t a n d r e a r v i ew
!
Basic control and
indication panel
Location of optional
communications ports
Special command and
diagnostic display
Diagnostics and
configuration connector
(reserved for after-sales support)
Standard communication port
!
fault
Input circuit breaker
"manual maintenance
bypass" switch
Utility connection cover panel
Figure
1-3
Battery connection panel
Fan
E X L 1 0 0 0 7 . 5 & 1 0 k VA f ro n t a n d r e a r v i ew
Basic control and
indication panel
!
Special command and
diagnostic display
!
Location of optional
communications ports
Battery circuit breaker
fault
Diagnostics and
configuration connector
(reserved for after-sales support)
Standard communication port
Fans
"manual maintenance
bypass" switch
Input circuit breaker
Connection cover panel
86-891000-00
Introduction
1—5
EXL 1000 Uninterruptible Power System
Figure
1-4
Functional diagram
"static bypass" module
AC input
load
Input circuit breaker
"manual maintenance bypass" switch
Rectifier module
Inverter module
Battery circuit breaker
Charger module
Battery
1—6
Introduction
86-891000-00
Installation
2.0
Scope
This section describes installation of the EXL 1000 UPS.
2.1
Storage
The equipment must always be stored in its original
packaging.
IMPORTANT
The battery is of the sealed type. Battery storage or prolonged
shutdown of EXL 1000 should never exceed 6 months at 68°F (20°C)
without recharging, for a battery initially at 100% charge. Battery
recharge requires system start-up. The battery warranty is void if the 6
month recharge interval is not respected.
2.2
Unpacking
The equipment must be unpacked close to the installation
location.
NOTE
After unpacking, check the overturn indicator at the back of the device.
If it is red (or otherwise indicates that the unit has been tipped over
during shipping), contact the after-sales department.
86-891000-00
2—1
EXL 1000 Uninterruptible Power System
Figure
2-1
U n p a ck i n g t h e E X L 1 0 0 0 U P S
remove
ramp
ramp for 7.5 & 10 kVA UPS
ramp for 5kVA UPS
remove
packing
corners
remove box
unbolt
from
base
2—2
Installation
86-891000-00
Installation and User’s manual
Figure
2-2
R e m ov e s t a b i l i z i n g m a t e r i a l f ro m u n d e r E X L 1 0 0 0 U P S
Figure
2-3
Use supplied ramp to bring EXL 1000 off of shipping base
levelling screws in
the raised position
ramp (7.5/10kVA)
ramp (5kVA)
86-891000-00
Installation
2—3
EXL 1000 Uninterruptible Power System
2.3
General
EXL 1000 cabinets are equipped with 4 wheels for moving
over short distances and with jacks to immobilize the unit.
The jacks must be raised prior to repositioning the unit.
Since operating temperature range is 32°F to 86°F (0°C to
30°C) at rated output, a location with appropriate ventillation
and cooling should be chosen for installation. Battery life is
extended when it is installed in a room with an ambient
temperature of 59°F to 77°F (15°C to 25°C). Above 77°F
(25°C), battery life is reduced by 50% for every additional
18°F (10°C). Heat generatedfrom EXL 1000 operation must
be taken into account when sizing the ventilation system.
See the Appendices.
Power cable connections are made through the bottom
section in the back of the EXL 1000.
2.4
Final positioning
Figure
2-4
I n s t a l l a t i o n cl e a r a n c e s a s s e e n f ro m a b ov e
Ensure that service clearance to the left of EXL 1000 is
greater than 16 inches (400 mm) for side access to the
battery cells. Ensure that there is greater than 4 inches (100
mm) on the left for ventilation. Ensure that front clearance is
greater than 22 inches (550 mm) for servicing. Ensure that
there is at least 4 inches (100 mm) behind the cabinet for
ventilation.
4 inches minimum
(for ventilation)
12 in. min.
15.75 inches
service clearance
10.5
inches
15.75 inches
4 in.
ventilation
clearance
4 in.
air exhaust
ventilation clearance
P
EXL1000
transformer/
distribution
cabinet
extended battery
option
other option
22 in. min.
service clearance
Additional cabinets (extended battery, distribution/
transformer, etc.) must be placed to the right of EXL 1000. If
the above installation conditions are not respected,
maintenance and servicing of the unit may require system
shutdown.
2—4
Installation
86-891000-00
Installation and User’s manual
2.5
Special Precautions
Load cables must be run separately from all other cables
(power supply or computer system interconnection cables).
They should not pass near interference-emitting equipment
or sensitive loads.
2.6
Connections
Connection cables should enter at the bottom rear of the
7.5/10kVA. Connection cables for the 5kVA model must be
10 AWG 75°C minimum. Connection cables for the 7.5 kVA
and 10 kVA must be 6 AWG 75°C minimum. Cables must be
enclosed in a .75 inch flexible conduit. Cables should be sufficiently long to enable forward movement of EXL 1000 without
disconnection. Allow an extra 5 feet (1.5 meters) slack in the
cables. Conduit shall be terminated to a conduit landing via a
3/4 inch flexible metal conduit fitting.
2.6.1
Electrical Diagram for
Figure 2-5 shows a single-line electrical diagram for a typical
installation. The power cables requiring connection are
shown as bold lines (see the appendices for information on
selecting cable gauges).
Power Connections
Figure
2-5
C o n n e c t i o n d i a g r a m fo r a s i n g l e AC i n p u t
EXL1000
AC input
XR1
XR2
load
XR3
XR3
extended battery
cabinets (optional)
Make sure the unit is powered down and disconnected from
all input power before making connections to the terminal
blocks at the back of the cabinet. For protection of life and
property, ground wires should always be connected first.
Neutral system: identical upstream and downstream neutral
systems (no galvanic isolation). EXL 1000 can be used with
all types of neutral systems, on the condition that standard
practices be respected.
Check that AC input power circuit breaker, installed upstream
on the low voltage switchboard, is in off (O) position;
Check that the input circuit breaker and the battery circuit
breaker are in off (O) position.
86-891000-00
Installation
2—5
EXL 1000 Uninterruptible Power System
Connection sequence:
•
Remove maintenance bypass switch knob using
a narrow flathead screwdriver (7.5 & 10 kVA
models only).
•
Remove the conduit landing cover panel that is secured
with six torx screws.
•
Connect flexible conduit to conduit landing.
•
Connect the AC input cables to Mains 1 terminal block
XR1. Observe phase 1 (L1), phase 2 (L2) and ground
correspondence as indicated on the label (figure 2-7 for
5 kVA and figure 2-9 for 7.5 & 10 kVA).
NOTE
There are two phases and one ground. There is no neutral connection.
•
Connect the AC load cables to terminal block XR2.
Observe phase 1 (L1), phase 2 (L2) and ground correspondence as indicated on the label (figure 2-7 for 5
kVA and figure 2-9 for 7.5 & 10 kVA).
•
Connect the various options as indicated in the corresponding sections of this manual.
•
Reattach the conduit landing cover panel and
maintenance bypass switch knob (7.5 & 10 kVA
models).
NOTE
5 kVA UPS conduit landings are shipped loose. Installation should be
done by authorized personnel only.
2—6
Installation
86-891000-00
Installation and User’s Manual
Figure
2-6
R e m ova l o f c o n d u i t l a n d i n g c ov e r p a n e l ( 5 k VA )
Figure
2-7
C a b l e c o n n e c t i o n s ( 5 k VA )
detail of connection
terminal blocks
L- L+
to load
(two-phase + ground)
L2
L1
XR3
battery
XR2
load
L2
L1
XR1
Mains 1
from LV switchboard
(two-phase + ground)
86-891000-00
Installation
2—7
EXL 1000 Uninterruptible Power System
Figure
2-8
R e m ova l o f m a i n t e n a n c e by p a s s sw i t c h k n o b a n d
c o n d u i t l a n d i n g c ov e r p a n e l ( 7 . 5 & 1 0 k VA )
maintenance bypass
switch knob
conduit landing
cover panel
Figure
2-9
C a b l e C o n n e c t i o n s ( 7 . 5 & 1 0 k VA )
L– L+ 1 2 3 4
L1 L2
XR1
Mains 1
XR3
battery
EPO
connector
(optional)
from LV switchboard
(two-phase + ground)
2—8
L1 L2
Installation
XR2
load
to load
(two-phase + ground)
86-891000-00
Operation
3.1
Controls and
EXL 1000 operating controls include basic controls and
indicators (figure 3-1), concerning the overall operating
status of the UPS and the special command and diagnostic
display panel (figure 3-10), which includes specific controls
and a 2-digit display for the UPS fault numbers. These
numbers provide UPS diagnostics.
indicators
Figure
3-1
L o c a t i o n o f C o n t ro l s a n d i n d i c a t o rs o n c a b i n e t
basic controls
and indicators
panel
!
!
!
!
fault
fault
special
command and
diagnostic
display
3.1.1
Basic controls
and indicators
The basic controls and indicators are located in the upper
left-hand corner of the front panel. This panel provides
information on the operating status of the system (see figure
3-2). Interpretation of the LEDs is very easy and requires no
special training.
The LEDs indicate normal operation (load protected), UPS
fault, load not protected and operation on battery power.
86-891000-00
3—1
EXL 1000 Uninterruptible Power System
Figure
3-2
C l o s e - u p o f C o n t ro l s a n d i n d i c a t o rs
!
!
I
+–
O
audible alarm
"load not protected" light
"fault" light
"battery status or
operation on battery power"
light
"load protected" light
"inverter on" button
"inverter off" button
The “Load protected” LED indicates that the EXL 1000 is
operating normally. The load is supplied by the inverter
output. This LED also goes on during normal start-up of EXL
1000.
Figure
3-3
“ L o a d p ro t e c t e d ” L E D
!
!
+–
I
O
“Load Protected” LED
The “Battery Status” LED can be on continuously or may
flash repeatedly. If continuously lit, the “Battery Status” LED
indicates that the inverter is operating on battery power
following an AC input failure or detection of an AC input
voltage outside tolerances. When flashing, it indicates that
the low battery shutdown warning level has been reached. If
the LED flashes when the battery is not in self-operating
phase, this indicates that the battery status should be
checked by an After-Sales representative.
Figure
3-4
“Battery Status” LED
!
!
+–
I
O
“Battery Status” LED
Continuously on — Inverter on battery power
Flashing —
low battery shutdown
or check batteries
3—2
Operation
86-891000-00
Installation and User’s manual
The “Fault” LED indicates an operating fault or an
environment fault. However, the load continues to be
supplied by the inverter.
Figure
3-5
“ Fa u l t ” L E D
!
!
I
+ –
O
“Fault” LED
The “Load Not Protected” LED indicates that the load is
supplied through the "static bypass" because of inverter
shutdown (voluntary or following an overload or an internal
fault), or that battery power is not available because the
battery circuit breaker is in "off" position.
Figure
3-6
“ L o a d N o t P ro t e c t e d ” L E D
!
!
I
+–
O
“Load Not Protected” LED
The audible alarm is activated when the load is supplied
directly by AC input power via the “static bypass,” the inverter
is operating on battery power, or when there is an operating
fault. It beeps softly and slowly for minor faults and during
inverter operation on battery power. When the low battery
shutdown warning level has been reached, the beeps get
louder and more frequent. In the event of an inverter
shutdown, a continuous loud alarm is emitted.
An audible alarm reset button is provided on the controls and
diagnostics display panel. Detection of a new fault will
reactivate audible alarm.
Figure
3-7
Au d i b l e A l a r m
beep...beep...
!
!
+–
I
O
“Audible alarm” LED
The green “inverter on” button is used to start the inverter.
Figure
3-8
“ I nv e r t e r O n ” bu t t o n
!
!
+–
I
O
“Inverter on” button
86-891000-00
Operation
3—3
EXL 1000 Uninterruptible Power System
The grey “inverter off” button is used to stop the inverter.
Figure
3-9
“ I nv e r t e r O f f ” bu t t o n
!
!
+–
I
O
“Inverter off” button
3.1.2
Controls and
Diagnostic Display
Figure
3-10
The controls and diagnostics display panel (figure 3-10)
includes an LED display for environment and subassembly
faults and buttons for specific controls. Faults are displayed
only when the user presses (once) one of the control buttons.
C o n t ro l s a n d D i a g n o s t i c s D i s p l ay
fault
diagnostics display
fault reset
security button
audible alarm reset
The audible alarm reset button enables the user to quiet the
audible alarm. Detection of a new alarm will set the audible
alarm off again.
The fault reset button clears the faults stored in memory.
Clearing of alarms in memory is accepted only if the alarm
conditions themselves have been cleared.
The security button authorizes forced operation or shutdown
of the inverter. There are three tasks that can be done using
the security button.
Forced shutdown
Forced operation
Battery manual test
3—4
press the security button and the "inverter off" button
(figure 3-9) simultaneously for three seconds.
press the security button and the "inverter on" button
(figure 3-8) simultaneously for three seconds.
press the security button and the audible alarm reset button
simultaneously for three seconds.
Operation
86-891000-00
Installation and User’s manual
IMPORTANT
The batery manual test function causes the battery to discharge completely in order to update the battery monitoring parameters. Do not
enable test during normal work hours because battery back-up will be
lessened or unavailable during this test. In the event of a network
power cut, the uninterrupted battery power supply returns to normal
operation. The self-operating time is thus reduced.
Alarm, fault and status messages are displayed as numerical
codes. See section 3.14 for the meaning of the codes. The
alarm-code equivalence table is also displayed at the back of
EXL 1000.
3.2
Check the settings of the protection devices:
Start-up
•
Input circuit breaker is in the off (O) position.
•
Battery circuit breaker is in the off (O) position,
•
"Manual bypass" circuit breaker is set to "NORMAL"
position (see figure 3-11)
•
Check that nothing is blocking the ventilation system
(air entry through the bottom and, where applicable,
through the side vents)
•
Check that there is a minimum of 4 inches (100mm)
clearance at the back for ventilation
•
Check that the EXL 1000 no longer rests on its 4
wheels (leveling screws in place)
•
Check that the load-circuit circuit breakers (where
applicable) are in the off (O) position.
M a n u a l M a i n t e n a n c e B y p a s s c i rc u i t b r e a k e r
BY-PASS
TEST 1
NORMAL
Figure
3-11
Checks before
TEST 2
86-891000-00
Operation
3—5
EXL 1000 Uninterruptible Power System
3.3
Powering up the
EXL 1000
First put the input circuit breaker in the “on” position, then put
the battery circuit breaker in the "on" position. The audible
alarm will sound and the green “load protected” LED will light.
The rectifier and the battery charger will start up. If the
transfer conditions (AC input power within tolerances) are
correct, the inverter comes on line and supplies the load
unless the system is in "manual start-up" mode (optional,
section 3.4).
The green "load protected" LED will now be on.
Figure
3-12
E X L 1 0 0 0 p ow e r- u p
beep...beep
!
!
+ –
I
O
"load protected" LED
"inverter on" button
In the event of a fault, the red "load not protected" light goes
on. See the Alarms section (section 3.13).
3.4
Manual Inverter
To manually start the inverter,use the following steps:
Start-up
Press the green "inverter on" button
The green "load protected" LED will flash
The inverter will start and if the transfer conditions are
correct, the load will be transferred to the inverter. The red
"load not protected" LED will go off and the green "load
protected" LED will light.
3.5
Shutting down
the inverter
Press and hold the "inverter off" button for three seconds.
The green "load protected" LED will go off and the red "load
not protected" LED will light. The audible alarm will sound. If
the transfer conditions are correct, the inverter will stop and
the load will be supplied directly by AC input power via the
"static bypass."
In the event of fault, see the Alarms section (section 3.13).
3—6
Operation
86-891000-00
Installation and User’s manual
3.6
Powering down
Powering down the EXL 1000 for long periods is not
recommended because the battery should remain charged.
However, to carry out a power down, proceed as follows:
the inverter
•
Shutdown the inverter (section 3.5)
•
Put the battery circuit breaker in the "off" position;
•
Turn off the input circuit breaker
All the LEDs on the control panel will go off.
WARNING
The load is still supplied by AC input power via the "static bypass".
•
3.7
Normal Operation
Put the upstream circuit breaker(s) on the low voltage
switchboard in "off" position.
The AC input power supply is present:
the green "load protected" light (figure 3-13) is on;
the power drawn by the load is supplied by AC input power
via the rectifier and inverter modules. The battery charger
float charges or recharges the battery. The DC output
voltage of the battery charger is temperature regulated to
ensure an optimal charge voltage.
Figure
3-13
I n d i c a t o rs d u r i n g n o r m a l o p e r a t i o n
!
!
+–
I
O
“Load Protected” LED
Figure
3-14
Diagram of normal operation on utility power
AC input
load
inverter
rectifier
charger
86-891000-00
battery
Operation
3—7
EXL 1000 Uninterruptible Power System
3.8
Operation on
When AC input power fails or exceeds tolerances, the
rectifier and the battery charger shut down. The battery
supplies the power required by the inverter to supply the
load.
battery power
The battery discharges.
The green "load protected" light is on.
The user is warned of operation on battery power by the
audible alarm and by the orange "battery status" light (figure
3-15). This information is also available via the standard
communication connector.
Figure
3-15
I n d i c a t o rs w h e n o n b a t t e r y p ow e r
beep...beep...
!
!
I
+–
O
audible alarm
"battery status" LED
"load protected" LED
Figure
3-16
D i a g r a m o f o p e r a t i o n o n b a t t e r y p ow e r
static bypass
AC input
load
rectifier
inverter
charger
3.9
Battery duration
battery
EXL 1000 has a battery monitoring function that calculates
the remaining backup time. This function may be
implemented with a communications option.
A low battery shutdown warning signal is available via the
standard communication connector for remote indications. It
warns the user of upcoming battery shutdown at a userdetermined level of remaining power.
On the UPS itself, the audible alarm beeps louder and more
rapidly, and the orange "battery status" light flashes.
3—8
Operation
86-891000-00
Installation and User’s manual
The end of battery power occurs when the battery is fully
discharged. At this point, the inverter shuts down.
The recharge time required to restore the battery of a 5 kVA
model to its rated backup power is 12 hours maximum. The
recharge time required to restore the battery of a 7.5 kVA or
10 kVA model is 5 hours maximum.
3.10
Return of
AC input power
If the end of battery backup power was not reached when the
AC input power failure ends or power returns to within
tolerances; EXL 1000 returns to normal operating status
where the inverter will receive power from the rectifier and
not the battery.
If the end of battery backup power was reached, the rectifier,
the battery charger and the inverter automatically start up
(the inverter must be manually started if the system is in
manual start mode).
3.11
Battery Monitoring
Tests
The battery is automatically checked every month. The
message "17" on the diagnostics display (figure 3-10) tells
the user that the battery is in this operating mode.
It is recommended to carry out a complete discharge test on
the battery once a year in order to update the battery
monitoring parameters. This test is activated by the "battery
manual test" control. See section 3.1.2. The message "18" on
the diagnostics display tells the user that the battery is in this
operating mode.
In these operating modes, total battery failure is indicated by
the alarm message "15" on the diagnostics display.
3.12
Overload
During a major temporary overload (greater than 150%), the
load is supplied by AC input power via the static bypass.
Return to the inverter is automatic, following elimination of
the overload. The inverter can handle a minor overload for a
given duration depending on the size of the overload (see
figure 3-17).
When an overload occurs, the audible alarm sounds, the
orange "fault" LED goes on, and the inverter shuts down at
the end of its corresponding overload time. When the inverter
shuts down, the load receives its AC input power via the
static bypass.
To indicate that the inverter is no longer protecting the load,
the green "load protected" light goes off and the red "load
not protected" light goes on.
86-891000-00
Operation
3—9
EXL 1000 Uninterruptible Power System
If the overload continues during operation via the static
bypass, the supply of power to the load is interrupted after a
specified time. See figure 3-18.
When the EXL 1000 has shut down because of an overload,
the fault reset button must be pressed prior to return to
normal operation.
Figure
3-17
I nv e r t e r ov e r l o a d c u r v e
time
10 min
1 min
10 sec
1 sec
rated load
current In
0.15 sec
1.05 1.1
Figure
3-18
1.3
1.5
1.7
1.9
2
S t a t i c B y p a s s ov e r l o a d c u r v e
time
10 mn
1 mn
10 sec
1 sec
rated load
current In
0.15 sec
1.05 1.1
3.13
Alarms
1.3
1.5
1.7
1.9
2
The status of the EXL 1000 can be determined by the status
LEDs and the audible alarm (see section 3.14). Any state
other than normal operation (green “load protected” LED on)
is considered a fault by the diagnostics system.
Before undertaking any servicing or other action, note the
status of the LEDs and the number(s) of the fault(s) indicated
on the diagnostics display. If the "Monitor Plus" option is
installed, also note the messages in the list on the screen.
Certain faults may result in the display not functioning.
If the load still functions, it is supplied via the "static bypass;"
it is not protected by the inverter.
3 — 10
Operation
86-891000-00
Installation and User’s manual
3.14
Diagnostics display
messages
86-891000-00
The diagnostics display shows numeric codes for alarms,
faults and status messages. Following is a list of the numeric
codes and their meanings. Figure 3-19 is a diagram of the
EXL 1000’s major components and shows which subsystems
are responsible or affected by various fault codes.
11
battery circuit breaker in "off" position
indicates that the battery circuit is open (battery circuit
breaker is in "off" position). The load is no longer protected
because battery power is no longer available in the event of
an AC input power failure. In the case of the "battery-free
frequency converter" option, it is normal for the "11"
message to remain on.
12
check battery
indicates that the battery should be checked (see Battery
maintenance section 5.2.1).
13
low battery shutdown warning
indicates that battery power will end after a user-set time
period. The user must take the required measures to secure
the load (load shedding, file saving and system shutdown,
etc.).
14
end of battery power
15
battery fault
indicates a problem with the battery (see "battery
maintenance" in the "maintenance and servicing" section.
16
ambient temperature fault
this display indicates that the ambient temperature is outside
the tolerance range (<0°C or > 40°C).
17
battery periodic test
this message indicates that the battery is in the process of
being checked.
18
battery manual test
this message indicates that the battery is in the process of
being completely discharged in order to update the battery
monitoring parameters.
21
inverter fault
indicates a fault in the inverter module; contact the aftersales support department.
Operation
3 — 11
EXL 1000 Uninterruptible Power System
3 — 12
22
inverter overtemperature
indicates overheating inside the UPS; check that the EXL
1000 ventilation system is working and that the ambient
temperature is within tolerances (see "appendices").
25
inverter overload
indicates an overload when the load is being supplied via the
inverter. Reduce the load.
31
Mains 2 (bypass) voltage outside tolerance range
this display indicates that the Mains 2 power supply voltage
of the "static bypass" is outside the tolerance range.
32
phase shift outside tolerance range
this display indicates that the phase between the Mains 2
power supply of the "static bypass" and the "inverter module"
is outside the tolerance range
34
frequency of Mains 2 (bypass) power supply to
"static bypass" outside tolerances
the output inverter voltage is no longer synchronized with
Mains 2. To force transfer of the load to the inverter, simultaniously press the security button and the green "inverter
on" button and hold for three seconds. Transfer results in a
0.5 second break in the supply of power to the load.
To force transfer of the load to the "static bypass", simultaniously press the security button and the grey "inverter off"
button. Transfer results in a 0.5 second break in the supply of
power to the load.
35
"static bypass" overload
indicates an overload when the load is being supplied via the
"static bypass". Reduce the load.
37
Mains 1 voltage outside tolerance range
this display indicates that the voltage of the Mains 1 power
supply of the "rectifier module" is outside the tolerance
range.
39
installation fault
indicates an incorrect connection at the frequency converter
input; check the connection of the Mains 1 input source to
terminal block XR1.
41
load supplied via "static bypass"
this display indicates that the load is powered by the Mains 2
via the "static bypass"
51
battery charger fault
indicates a fault in the battery charger module; contact the
after-sales support department
Operation
86-891000-00
Installation and User’s manual
Figure
3-19
rectifier or chopper fault
indicates a fault in the rectifier module; contact the after-sales
support department
62
chopper overtemperature
see fault "22".
63
fuse blown on Mains 1 input
indicates that the fuse has blown in the rectifier module;
contact the after-sales support department.
65
chopper overload
indicates that the active power consumed is too high. Reduce
the load
71
internal communication fault
indicates an EXL 1000 internal fault; contact the after-sales
support department
72
internal communication self-test fault
see fault "71".
73
CPU board self-test fault
see fault "71".
Relationship of fault codes to EXL 1000 subsystems
35
31
33
34
41
39
61
16
37
63
Ambient
Temp.
51
12
86-891000-00
61
62
65
32
21
22
25
71
72
73
11
13
14
15
17
18
Operation
3 — 13
EXL 1000 Uninterruptible Power System
3.15
Manual Bypass
If the load is no longer supplied, a manual bypass operation
enabling supply is possible, while waiting for the after-sales
support personnel.
Proceed as follows:
Switch the input circuit breaker to the "off" position.
•
Switch the battery circuit breaker to "off" position.
•
Check that all lights are off.
•
Turn the "manual bypass" switch as indicated in figure
3-20 from the
"NORMAL" position to the "BYPASS" position.
Manual Bypass Switch
BY-PASS
TEST 1
NORMAL
Figure
3-20
•
TEST 2
IMPORTANT
The TEST 1 and TEST 2 positions are reserved for the after-sales support personnel. Leave the switch set to the "BYPASS" position until the
arrival of the after-sales support personnel.
Use of the switch other than as indicated above may damage EXL 1000
and void the warranty.
3 — 14
Operation
86-891000-00
Communication
4.0
Standard Functions
The communication connector, positioned on the back for
EXL 1000 5/7.5/10kVA, supplies the following information:
•
operation on the "static bypass".
•
low battery shutdown warning.
•
load supplied by the inverter.
•
operation on battery power.
This connector enables communication with the most
common computer systems (AS400, NOVELL, etc.).
Figure 4-1 indicates the pin-outs for the SUB-D 15-pin female
connector (front view).
Figure
4-1
Electrical connections of 15 pin D connector
very low safety
voltage signals:
PIJO PC board
5
operation on inverter
NO
8
NC
NO
contact
switching
capacities:
P = 2.5VA
V = 30V max.
I = 0.1A max.
NC
6
operation on
"static bypass"
10
NO
9
NC
operation on battery
connector
SUB-D
15-pin
11
13
NO
7
NC
12
14
4
Figure
4-2
UPS remote
shutdown
(signal between
3 and 15V DC)
15 pin D connector
8
7
6
5
4
3
15 14 13 12 11 10
86-891000-00
low battery
shutdown warning
1
2
9
4—1
EXL 1000 Uninterruptible Power System
NOTE
The remote UPS shutdown command is valid when the inverter is supplied by the AC input source or the battery. The inverter shuts down
after a two minute delay.
4.1
Options
Three options may be used simultaneously on the EXL 1000,
thus enabling communication with a wide number of
computers and control devices.
Monitor Plus
Monitor Plus is a mini terminal for control and display of AC
input power and system parameters. The Monitor Plus can
be installed locally or remotely. This option, the U-Talk option
and the JBUS option can be used with the battery monitoring
function to provide information on available battery power
during normal operation and remaining battery power during
operation on battery power.
Contact 5
This option offers communication of five different signals via
dry relay contacts:
•
operation on battery
•
operation on "static bypass"
•
low battery shutdown warning
•
load supplied by the inverter
•
general alarm
Relay-contact breaking capacities: 250V AC, 125V DC, 1A.
4—2
Communication
86-891000-00
Installation and User’s Manual
U-Talk
This option manages an RS232 serial interface using an
ASCII protocol. This option is supplied with the "Solution
Pac"™ CD-ROM which integrates a range of management
software for MGE Uninterruptible Power Supplies under
SNMP. Like the Monitor Plus and JBUS options, this option
can be used with the battery monitoring function to provide
information on available battery power during normal
operation and remaining battery power during operation on
battery power.
More complete information on the U-Talk option can be found
in chapter 6 of this manual.
JBUS/RS232 and JBUS/RS485
These options enable remote monitoring of the EXL 1000.
Like the Monitor Plus and U-Talk options, this option can be
used with the battery monitoring function to provide
information on available battery power during normal
operation and remaining battery power during operation on
battery power.
86-891000-00
Communication
4—3
EXL 1000 Uninterruptible Power System
(this page left blank intentionally)
4—4
Communication
86-891000-00
Maintenance and Service
5.0
Scope
Preventive maintenance for the EXL 1000 is limited to the
strict minimum. However, this chapter indicates important
procedures to ensure continuous and correct operation.
WARNING
High voltages are present inside the EXL 1000 system. Any servicing
requiring removal of the protective covers may be undertaken only by
qualified personnel certified by MGE UPS Systems.
5.1
User Preventive
User maintenance of the EXL 1000 is limited. The following
items may be checked to insure safe, efficient operation.
Maintenance
Check the installation and operating conditions:
5.2
Maintenance by
Certified MGE
•
Distance from wall
•
Ventilation inlet and outlet vents unobstructed
•
Operating temperature, particularly for the batteries
•
No faults signalled by the LEDs
Consult the after-sales support department for further
information concerning the services presented below
requiring special tools, in particular the "Soft Tunor" software.
Representatives
5.2.1
Battery
Maintenance
Battery status is monitored by EXL 1000 When the orange
"operation on battery" light flashes and fault number. “12” is
indicated on the diagnostics display, the battery should be
checked.
When the red "load not protected" light flashes and fault
number “15” is indicated on the diagnostics display, a battery
fault is present.
To clear these alarms, press the "security" and "fault reset"
buttons at the same time.
86-891000-00
5—1
EXL 1000 Uninterruptible Power System
CAUTION
Clearing the alarms by pressing "security" and "fault reset" disables
the battery monitoring and backup time calculation functions (Monitor
Plus option); contact the after-sales support department to check the
condition of the battery and replace it if necessary. The after-sales
support technician will reactivate the battery monitoring and backup
time calculation functions.
5.2.2
Environmental
The battery cells contain substances which are dangerous to
the environment. Following replacement, the after-sales
support department forwards old batteries to special organizations for recycling and disposal.
Protection
5.2.3
Annual Check
This complete check-up can be run only by qualified
personnel certified by MGE UPS Systems.
5.2.4
Customer Training
Training courses are offered by MGE UPS Systems which
enable personnel to monitor the system and undertake basic
maintenance. Contact your MGE UPS Systems distributor for
the list of courses offered.
5.2.5
Maintenance
Your MGE UPS Systems contact can supply you with the
catalogue of maintenance contracts that indicate how you
can transfer responsibility for maintenance to qualified
technicians always on call.
Contracts
5—2
Maintenance and Service
86-891000-00
Options
6.1
Extended battery
cabinet
As standard equipment, EXL 1000 comes with an internal
240 volt battery for the 10 kVA EXL 1100 and 180 volts for
the 5 kVA EXL 1050 and 7.5 kVA EXL 1075. These provide a
backup time (at full rated load and a power factor of 0.6) of
10 minutes for 7.5 kVA and 10 kVA models or 8 minutes for
5 kVA model. The backup time can be increased to 30
minutes or up to 50 minutes for the 7.5 kVA or 10 kVA
models, 24 minutes or up to 40 minutes for the 5 kVA model,
by the addition of an optional auxiliary battery cabinet.
If EXL 1000 was not factory-set for the additional cabinets,
the new configuration must be entered by an MGE UPS
Systems after-sales support technician.
Table
2-1
B a t t e r y c a b i n e t fo r a n ov e r a l l o p e r a t i n g t i m e o f
3 0 m i n u t e s ( 7 . 5 & 1 0 k VA ) o r 2 4 m i n u t e s ( 5 k VA )
a t r a t e d o u t p u t p ow e r w i t h a p ow e r f a c t o r o f 0 . 6
model number of UPS
EXL1050
EXL1075
EXL1100
model number
EXL 5-24
EXL 7.5-30
EXL10-30
891056
891076
891101
height (in/mm)
28.7/730
35.8/910
35.8/910
width (in/mm)
14.17/360
15.75/400
15.75/400
depth (in/mm)
16.5/420
21.65/550
21.65/550
weight (lb/kg)
147/66
262/118
331/149
part number
Battery
cabinet
dimensions
86-891000-00
6—1
EXL 1000 Uninterruptible Power System
Table
2-2
B a t t e r y c a b i n e t fo r a n ov e r a l l o p e r a t i n g t i m e o f
5 0 m i n u t e s ( 7 . 5 & 1 0 k VA ) o r 4 0 m i n u t e s ( 5 k VA )
a t r a t e d o u t p u t p ow e r w i t h a p ow e r f a c t o r o f 0 . 6
model number of UPS
EXL1050
EXL1075
EXL1100
model number
EXL 5-40
EXL 7.5-50
EXL10-50
891057
891077
891102
height (in/mm)
28.7/730
35.8/910
35.8/910
width (in/mm)
14.17/360
15.75/400
15.75/400
depth (in/mm)
16.5/420
21.65/550
21.65/550
weight (lb/kg)
242/109
477/215
613/276
part number
Battery
cabinet
dimensions
6.2
Connection of
Prior to installation of additional battery cabinets, check that
the protection devices are in the following positions:
an additional
battery cabinet
•
upstream circuit breaker off
•
input circuit breaker off
•
battery circuit breaker off
•
"manual bypass" switch set to the "NORMAL" position
Position the battery cabinet on the right side of EXL 1000.
Connect the terminal block in the battery cabinet to the XR3
terminal block in EXL 1000 as follows:
6—2
•
yellow/green cable (ground) to the yellow/green terminal
on XR3
•
red cable (+ pole) to the L+ terminal on XR3
•
black cable (– pole) to the L– terminal on XR3
•
position the two cabinets with the front panels aligned
•
turn on the circuit breaker in the battery cabinet
Options
86-891000-00
Installation and User’s manual
Figure
6-1
Connection of an additional battery cabinet
( 5 k VA M o d e l ) C ov e rs R e m ov e d
connection terminal blocks of EXL 1000 5kVA
battery cabinet terminal block
L L+
L L+
flexible conduit from EXL 1000
to battery cabinet
Figure
6-2
to a secondary
battery cabinet
(if available)
Connection of an additional battery cabinet
( 7 . 5 & 1 0 k VA M o d e l s )
connection terminal blocks of EXL 1000 7.5 and 10 kVA
XR1
Mains
XR3
battery
battery cabinet terminal block
XR2
load
XR3
battery
L L+
L L+
flexible conduit from EXL 1000
to battery cabinet
86-891000-00
Options
to a second
battery cabinet
(if applicable)
6—3
EXL 1000 Uninterruptible Power System
6.3
Emergency Power
Off (EPO)
The end user is responsible for the installation of an
emergeny power off function. Installation must be carried out
in compliance with local code regulations.
To power down the entire installation via an emergency
power off function, the action should perform the following via
a single device:
•
sever the AC input power to the EXL 1000
•
remotely trip off the battery circuit breaker on the EXL
1000
•
remotely trip off the circuit breaker for the additional
battery cabinet(s), if applicable
CAUTION
After the EPO function is activated, the UPS output remains live for
approximately 3 seconds.
6.4
Battery circuit
breaker shunt trip
connection
6—4
To accomodate the EPO function, the EXL 1000 UPS and
battery cabinets come equipped with battery circuit breakers
with shunt trip mechanisms. By applying 24 Vdc or 24 VAC
across the shunt trip coil, the circuit breaker will trip off,
thereby disconnecting battery input to the inverter.
•
Check that the upstream circuit breaker on the low
voltage switchboard, the input circuit breaker, and the
battery circuit breaker are all in "off" position
•
Remove the connection cover panel from the EXL 1000
•
Connect the 24Vdc or 24 VAC output of the EPO circuit
to the shunt trip coil across terminals 1 and 4
•
Once the connections are made, reposition the
connection cover panel and reset all circuit breakers
Options
86-891000-00
Installation and User’s Manual
Figure
6-3
C o n n e c t i o n d i a g r a m fo r b a t t e r y c i rc u i t b r e a k e r
s h u n t t r i p o n t e r m i n a l b l o ck X R 3
EXL 1000
1
4
2
3
not used
not used
emergency
off button
+
–
24 VDC/VAC
Figure
6-4
X R 3 t e r m i n a l b l o ck fo r E X L 1 0 5 0 , E X L 1 0 7 5 a n d E X L 1 1 0 0
battery
L– L+
emergency
off
1234
Secure the shielding of the cable to the stud provided on the
connection cover panel (see appendicies.)
6.5
86-891000-00
Combined options
If several option cabinets are combined, they must be placed
to the right of the UPS cabinet.
•
distribution cabinet (including full galvanic isolation
transformer)
•
battery cabinet(s)
Options
6—5
EXL 1000 Uninterruptible Power System
(this page left blank intentionally)
6—6
Options
86-891000-00
U-Talk
7.1
Introduction
This chapter describes all the information you need to install
and use your EXL 1000 U-TALK communications system.
If you have purchased the UPS Manager 3.0 option, this
chapter will give you the information required to install your
board (ignore the "EXL 1000 U-TALK protocol" section).
Feel free to contact us for any further information you may
require concerning special applications beyond the scope of
this chapter.
7.1.1
Storage
If the U-Talk board must be stored prior to installation, leave
your RS232 interface board in its original packaging in a dry
location.
7.1.2
Safety
If you encounter a problem while following the instructions in
this chapter, we recommend that you contact our after-sales
support service. On request, our after-sales support
personnel can carry out the complete installation of your
equipment.
Recommendation
IMPORTANT
Instructions in this chapter must be followed strictly. Not adhering to
these instructions may endanger personnel, result in damage to the
EXL 1000 and render the manufacturer's warranty void.
NOTE
All repair or maintenance operations must be carried out by MGE aftersales support personnel.
The U-TALK option may be installed and operated by any
person as long as the indications presented in this chapter
are complied with.
86-891000-00
7—1
EXL 1000 Uninterruptible Power System
7.2
Installation of the
The EXL 1000 UPS includes the U-Talk communications
board. Installation must be done by the user.
U-Talk board
7.2.1
Powering down the
EXL 1000 UPS
7.2.2
Installing the U-Talk
RS232 board
Powering down is necessary to avoid any danger during
operations in the boards and/or communication cables area
(installation and configuration).
•
press the "inverter off" button for three seconds
•
the inverter shuts down if the transfer conditions are
correct
•
the "load protected" light goes off
•
the "load not protected" light goes on
•
the load is supplied by the mains via the "static bypass"
•
switch maintenance bypass switch to “bypass”
•
turn off input circuit breaker
•
load is now supplied by the mains via the maintenance
bypass switch
To locate the EXL 1000 UPSs communications ports for
board installation, access the rear panel. The EXL 1000
communications port is located in the rear panel, along the
top edge. Two torque screws hold each board or rear cover
on. Next, insert the RS232 board into grooves.
The EXL 1000 UPS can be equipped with up to three
optional boards. It is immaterial which board is in which slot.
Figure
7-1
7—2
Inserting the U-Talk board into the groove
U-Talk
86-891000-00
Installation and User’s manual
7.2.3
Returning power to
The system must be powered up following installation and
connection of the RS232 board option and prior to any tests
the EXL 1000 UPS
Turn the manual bypass switch from the "By-pass" position to
the "Normal" position.
7.3
Description of
RS232 board
O v e r v i ew o f R S 2 3 2 b o a rd
XM2
RS
232C
B
XM1
Figure
7-2
A
Close-up of figure 7-2, section A
OFF
XM5
XM3
ON
XM4
D2
D3
Figure
7-3
7.3.1
Function
The RS232 communications board enables data concerning
EXL 1000’s operating status to be sent to a computer.
The system provides a communications channel with an
RS232 interface.
7.3.2
Configuring the
The D2 and D3 jumpers on the board must be positioned as
in figure 7-3.
RS232 board
86-891000-00
U-Talk
7—3
EXL 1000 Uninterruptible Power System
7.4
Configuration for
When using UPS Manager software, and unless otherwise
indicated in the software instruction manual, check that the
positions of jumpers D1 to D8 of the RS232 board conform
to figure 7-4.
UPS Manager
software
Figure
7-4
Fa c t o r y s e t t i n g s o f U - Ta l k b o a rd j u m p e rs
OFF
XM5
XM3
ON
XM4
D2 D3 D4 D5 D6 D7
Figure
7-5
C o n f i g u r i n g t h e Tr a n s m i s s i o n S p e e d ( fa c t o r y s e t t i n g s s h a d e d )
OFF
XM5
OFF
XM5
XM3
XM4
ON
XM4
D4
D5
D4
D5
ON
XM3
1200 bps
2400 bps
OFF
XM5
OFF
XM5
XM3
XM4
ON
4800 bps
7—4
XM4
D4
D5
D4
D5
ON
XM3
9600 bps
U-Talk
86-891000-00
Installation and User’s Manual
Figure
7-6
C o n f i g u r i n g t h e Tr a n s m i s s i o n F o r m a t ( fa c t o r y s e t t i n g s s h a d e d )
OFF
XM5
OFF
XM5
XM3
ON
8 bits, no parity and 1 stop bit
OFF
XM4
D6
D7
D7
XM4
D6
ON
XM3
8 bits, evenparity and 1 stop bit
XM5
OFF
XM5
XM3
XM4
ON
7 bits, no parity and 1 stop bit
7.5
86-891000-00
7 bits, even parity and 1 stop bit
XM6
XM7
XM6
C o n f i g u r i n g t h e H x a n d I x S i g n a l s F o r m a t ( fa c t o r y s e t t i n g s s h a d e d )
XM7
Figure
7-7
XM4
D6
D7
D6
D7
ON
XM3
D8
D1
D8
D1
U-Talk data format
The protocol U-TALK used enables reading or writing of
physical measurements. The line parameters as well as the
inverter’s slave number for the RS232 interface may be
configured. For detailed information of the U-Talk protocol,
refer to MGE manual "Lazarus U-Talk Protocol," part number
96-153293-00.
U-Talk
7—5
EXL 1000 Uninterruptible Power System
(this page left blank intentionally)
7—6
U-Talk
86-891000-00
Appendices
A.0
General
Characteristics
EXL 1000 series are two-phase line to line input, two-phase
line to line output, Uninterruptible Power Supplies. Each UPS
may be configured in a number of ways via a special
interface.
A modification in the configuration requires on-site servicing
by the after-sales support department.
Except where indicated, the data provided are typical values
corresponding to a rated line to line voltage of 240V at 0.8
power factor load.
A.1
Range
Characteristics
agency standards
design:
IEC 146
safety:
IEC 950 + national deviations
EN 50091 - 1
UL 1778
CSA C22.2
protection:
IEC 529 (IP 215)
electromagnetic compliance:
IEC 801
EN 55011
EN 55022
EN 50091-2
FCC
VCCI
environment conditions
86-891000-00
ambient temperature (1):
< 25°C recommended
0°C to 30°C permanent
35°C up to 24 hours
40°C up to 8 hours
relative humidity:
5% to 95%
maximum altitude
without derating:
< 3280 ft (1000 m)
a—1
EXL 1000 Uninterruptible Power System
configuration
low battery shutdown
warning (minutes):
1, 2, 3, 4, 5, ...20
inverter start-up
automatic or manual
battery charger:
internal or external
transfer to bypass
outside tolerances:
yes / no
standard color:
RAL 9002
EXL 1050
EXL 1075
EXL 1100
220V, 230V and 240V output:
5
7.5
10
208V output:
4.7
7.1
9.5
200V output:
4.5
6.82
9.1
220V, 230V and 240V output:
4
6
8
208V output:
3.8
5.67
7.56
200V output:
3.6
5.46
7.27
efficiency (%):
91
91
91
heat losses (W):
445
668
890
on RL load:
45
46
46
on RCD load:
50
53
53
battery backup time (minutes)
at rated load (power factor 0.6):
8
10
10
maximum leakage current (mA)
directly grounded
neutral system (TT):
10
23
23
apparent power (kVA):
active power (kW):
noise level (dBa):
a—2
Appendeces
86-891000-00
Installation and User’s manual
dimensions and weight
EXL 1050
EXL 1075
EXL 1100
height:
28.7 in/730 mm
35.8 in/910 mm
35.8 in/910 mm
width:
14.17 in/360 mm
15.75 in/400 mm
15.75 in/400 mm
depth:
16.53 in/420 mm
21.65 in/550 mm
21.65 in/550 mm
weight:
200 lbs/90 kg
422 lbs/190 kg
466 lbs/210 kg
EXL 1050
EXL 1075
EXL 1100
current distortion (%):
<6
< 3.5
< 3.5
inrush current:
<23 A
< 36 A
<46 A
EXL 1050
EXL 1075
EXL 1100
voltage tolerance (%):
±1.5
±1
±1
frequency (Hz):
50 / 60
frequency tolerance (free-running) (%):
± 0.1
frequency tolerance (synchronized) (%):
± 1 / ± 1.5 / ± 2 / ± 3 / ± 4
synchronization rate (Hz/s):
1/2
AC input
number of phases:
2 + ground
voltage (VAC L-L):
170 to 257
frequency (Hz):
47 to 63
power factor:
> 0.99
AC output
86-891000-00
number of phases:
2 + ground
voltage (VAC L-L):
208 / 240
Appendeces
a—3
EXL 1000 Uninterruptible Power System
Table
3-1
M a x i mu m c u r r e n t r a t i n g s
absorbed line currents (A)
Table
3-2
a—4
Model
Number
rated output
(kVA)
AC input current
nominal (XR1)
AC output current
(XR2)
battery option
(XR3)
EXL 1050
5
26
23
30
EXL 1075
7.5
40
35
48
EXL 1100
10
52
46
46
M i n i mu m c a b l e s i z e
Model
Number
rated output
(kVA)
minimum stranded
wire size (75°C)
minimum solid
wire size (75°C)
EXL 1050
5
≥ AWG 10 (≥ 6 mm2)
≥ AWG 10 (≥ 6 mm2)
EXL 1075
7.5
≥ AWG 8 (≥ 12 mm2)
≥ AWG 8 (≥ 12 mm2)
EXL 1100
10
≥ AWG 6 (≥ 16 mm2)
≥ AWG 6 (≥ 16 mm2)
Appendeces
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Glossary
backup time
battery circuit
breaker
forced
operation
forced
shutdown
the period of time that the EXL 1000 can supply full rated load while
running on battery without AC input power. This time will increase with
installation of an auxilliary battery cabinet.
DC-power circuit breaker that protects the battery circuit.
user-initiated connection of the load to the inverter with a 0.5 second
interruption in the supply of power.
user-initiated shutdown of the inverter because of incorrect
AC input characteristics (Mains 1 or Mains 2) and resulting
in a 0.5 second interruption in the supply of power.
input circuit
breaker
AC input power circuit breaker enabling rectifier shutdown.
inverter
module that transforms DC input power to AC output power.
low battery
shutdown
warning
signal indicating the upcoming end of battery power and the resulting
inverter shutdown and interruption in the supply of power to the load.
load
all devices connected to EXL 1000 output terminals.
LV switchboard
low voltage (less than 600 VAC) switchboard. Power panel
inside building that includes upstream circuit breakers and
provides AC input power to the EXL 1000.
manual bypass
a manual transfer from inverter to utility power or back via a maintenance
bypass switch. This allows for safe servicing of the UPS while maintaining
utility power to the load.
Mains 1
(AC input power) primary source of power for the rectifier and the inverter.
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output apparent
power
rated AC output volts multiplied by rated AC output amps, measured in VA
output
power
output apparent power multiplied by power factor measured in Watts.
overload
power drawn by the load in excess of the EXL 1000 rated output.
g—1
EXL 1000 Uninterruptible Power System
powered down
rated
current
g—2
no power is present on input and output of EXL 1000 (battery circuit
breaker off, upstream circuit breaker off).
rated output current of EXL 1000.
rectifier
electronic device or circuit that converts AC input power to DC power that
supplies the inverter module and battery charger.
"static bypass"
an automatic transfer from inverter to utility power or back without an
interruption to output load via an electronic solid state switch (static
bypass switch).
transfer to
bypass
load switching from the inverter to the static or manual bypass mechanism.
transfer to
inverter
load switching from the static or manual bypass mechanism to the inverter.
Glossary
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