MGE UPS Systems 3.5 to 21 kVA N+1 User manual

3.5 to 21 kVA N+1
Inverter
Owner's Manual

IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS This manual contains important instructions for all static
inverters, that must be followed during installation, operation, and maintenance of the equipment.
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 user's own expense.
WARNING
As standards, specifications, and designs are subject to change, please ask for
confirmation of the information given in this publication.
ATTENTION
Comme les normes, spécifications et produits peuvent changer, veuillez demander
confirmation des informations contenues dans cette publication.
WARNUNG!
Normen, Spezifizierungen und Pläne unterliegen Anderungen. Bitte verlangen Sie eine
Bestätigung über alle Informationen, die in dieser Ausgabe gemacht wurden.
WARNING
Opening enclosures expose hazardous voltages. Always refer service to qualified
personnel only.
ATTENTION
L'ouverture des cabinets expose des tensions dangereuses. Assurez-vous toujours que
le service ne soit fait que par des personnes qualifiees.
WARNUNG!
Das öffnen der Gehäuse legen gefährliche Spannungen bloss. Service sollte immer nur
von qualifizierten Personal durchgeführt werden.

WARNING
HIGH LEAKAGE CURRENT. Earth connection essential before connecting supply.
ATTENTION
COURANT DE FUITE ELEVE. Raccordement a la terre indispensable avant le
raccordement au reseau.
WARNUNG!
Hoher Ableitstrom Vor Inbetriebnahme Schutzleiterverbindung herstellen.
WARNING
To reduce the risk of fire or electric shock, install in a temperature and humidity
controlled indoor area free of conductive contaminants.
This equipment is intended only for installations in a RESTRICTED ACCESS LOCATION.
ATTENTION
Pour réduire le riske d'inccendie ou d'électrocution, installer dans une enciente
intérieure contrôlée en température et humidité et sans contaminants conducteurs.
Ce matériel est destiné seulement pour des installations dans un EMPLACEMENT
RESTREINT d'cAccès.
WARNUNG!
Um die Gefahr von Feuer und elektrischem Schock zu reduzieren, muss das Gerät in
einem temperatur - und feuchtigkeitskontrollierten Raum, frei von leitungsfähigen
Verunreinigungen, installiert werden. Dieses Gerät ist nur für die Installation an einem
Ort mit eingeschränkter Zugangserlaubnis vorgesehen.
Diese Ausrüstung ist nur für Anlagen in einem EINGESCHRäNKTEN ZUGRIFF
STANDORT bestimmti.

3.5 to 21 kVA N+1 Inverter
page ii

This manual covers these models:
Product: List number: Comcode reference: Rating:
64034 407-607-853 3.5 kVA
64074 7.0 kVA
64104 10.5 kVA
64144 14.0 kVA
64174 17.5 kVA
64214 21.0 kVA
3.5 kVA to 21.5 kVA Inverter
Owner's Manual
For service call
1-800-523-0142
86-153460-01 X1 03/02
Copyright © 2002 MGE UPS Systems, Inc.
All rights reserved. Printed in U.S.A.
MGE UPS Systems, Inc.
1660 Scenic Avenue
Costa Mesa, CA 92626
[phone]
Owner’s Manual
page iii

3.5 to 21 kVA N+1 Inverter
Owner’s Manual
3.5 to 21 kVA N+1 Inverter
page iv
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 12
months from the date of purchase. The 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 the 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 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 the 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 the MGE UPS Systems, Inc. This warranty shall extend to the Purchaser but to no one else.
Accessories supplied by MGE UPS 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
3.5 to 21 kVA N+1 Inverter Owner’s Manual
86-153460-01
Copyright © 2002 MGE UPS Systems, Inc. All rights reserved Printed in U.S.A.
Revision: X0 12/2001
Revision: X1 RND-000999 03/2002

Owner’s Manual
Contents page v
Contents
section description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page
Important Safety Instructions . . . . . . . . . . . . . .Inside Front Cover
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
Service & Factory Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
Property Rights Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix
Chapter I - Introduction
1.0 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Standard Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.3 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.3.1 DC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.3.2 AC Output (per module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.3.3 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.3.4 Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.3.5 Total Harmonic Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.3.6 Line Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.3.7 Load Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.3.8 Output Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.3.9 Short Circuit Current (SCC) . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.3.10 Overload Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.3.11 Transient Deviation and Recovery . . . . . . . . . . . . . . . . . . . . . .1-4
1.3.12 EMI Emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.4 Indicators and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.5 Remote Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.6 Mechanical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.7 Environmental Specification . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.7.1 Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.7.2 Shipping Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.7.3 Storage Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.7.4 Operating Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.7.5 Operating Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.7.6 Audible Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.7.7 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1.7.8 Thermal Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1.7.9 Safety Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1.7.10 Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

3.5 to 21 kVA N+1 Inverter
Contentspage vi
section description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page
Chapter II - Installation & Operation
2.0 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.1 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.1.1 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.1.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 Prerequisites to Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2.0 Mechanical Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.2.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.3 Common Installation Procedure . . . . . . . . . . . . . . . . . . . . . . .2-5
2.3.0 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.3.1 Input and Output Cable Connections . . . . . . . . . . . . . . . . . . . .2-5
2.3.1.1 AC Input Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.3.1.2 DC Input Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.3.1.3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2.3.2 AC Input/Output Voltage Selection . . . . . . . . . . . . . . . . . . . . .2-7
2.3.3 Software Configuration Set-Up . . . . . . . . . . . . . . . . . . . . . . . .2-7
2.3.3.1 Dual Processor Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2.3.3.2 System Personalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2.3.3.3 Redundant Controller Set-Up . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2.3.4 Power Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2.3.5 Start-Up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2.3.5.1 Power-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2.3.5.2 Powering Up the Inverters . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2.3.6 De-Energizing the System . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Chapter III - Maintenance
3.0 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.1 Safety Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2.1 Preventative Maintenance Procedures . . . . . . . . . . . . . . . . . .3-1
3.2.2 Dust Removal and Exterior Cleaning . . . . . . . . . . . . . . . . . . . .3-1
3.2.3 Air Intake Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.2.4 AC Fan Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . .3-2
3.2.5 DC Fan Replacement Procedure . . . . . . . . . . . . . . . . . . . . . .3-2
3.3 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.4 Troubleshooting and Servicing . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.4.1 Installation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.4.2 Inverter System Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.4.2.1 DC Input Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.4.2.2 AC Output Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.4.2.3 Cable Connection and Static Switch Module . . . . . . . . . . . . . .3-4
3.4.2.4 ON-LINE Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.4.2.5 OFF-LINE Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.4.2.6 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.4.2.7 Inverter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.4.2.8 Battery Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.4.2.9 Dual Half-Bridge Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3.4.2.10 Average Current Mode Control . . . . . . . . . . . . . . . . . . . . . . . .3-5

Owner’s Manual
Contents page vii
section description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page
Chapter IV - Theory of Operation
4.0 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.1 “Receiver” Cabinet “Controller” . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 LCD “Display” Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.3 Alarm Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.4 Installation “Set-Up” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.5 DC Input Power Connections . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.6 Inverter AC Output Distribution . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.7 Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.7.1 Power Module Configuration . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4.7.1.1 Battery Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4.7.1.1.1 Battery Booster Operstion . . . . . . . . . . . . . . . . . . . .4-7
4.7.1.2 Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4.7.1.2.1 Dual Inverters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4.7.1.2.2 Inverter Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4.7.1.2.3 Inverter Control . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4.7.1.2.4 Average Current Mode . . . . . . . . . . . . . . . . . . . . . . .4-9
4.7.1.2.5 Inverter Sweep Generator . . . . . . . . . . . . . . . . . . . .4-9
4.7.1.2.6 Fault Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
4.7.1.2.7 Internal Power Supply . . . . . . . . . . . . . . . . . . . . . .4-10
4.8 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
4.8.1 “Controller” Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
4.8.1.1 “Controller” Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
4.8.1.2 DC Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
4.8.1.3 Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
4.8.1.4 Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4.8.1.5 Alarm Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4.8.1.6 “Watch Dog” Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4.8.1.7 High Voltage Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
4.8.1.8 Under Voltage Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
4.8.1.9 Sine Wave Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
4.8.1.10 “Display” Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
4.8.1.11 “Controller” Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
4.8.2 Static Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
4.8.2.1 Static Switch Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
4.8.3 Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
4.8.3.1 Output Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
4.8.3.2 Back-Feed Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .g-1
Figure Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page
1-1 System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
2-1 Installation Drawing, 7 kVA Inverter System . . . . . . . . . . . . . .2-3
2-2 Front View, 7 kVA, System Component Description . . . . . . . . .2-4
2-3 Static Switch Jumper Positions . . . . . . . . . . . . . . . . . . . . . . . .2-6

Figure Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page
3-2 Dual Inverter and Waveform Diagram . . . . . . . . . . . . . . . . . . .3-5
4-1 Block Diagram of the 21 kVA Inverter System . . . . . . . . . . . . .4-2
4-2 Block Diagram of the S4 Inverter Power System . . . . . . . . . . .4-3
4-3 Block Diagram of Power Module . . . . . . . . . . . . . . . . . . . . . . .4-5
4-4 Voltage and Current Waveforms of DC/DC Battery Booster . . .4-6
Table Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page
1-1 Inverter System Characteristics . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-2 Inverter Module Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-3 S4 AC Output Current Ratings . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-4 Alarm Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-5 S4 Receiver Cabinet Mechanical Dimensions and Weights . . .1-6
3-1 Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.5 to 21 kVA N+1 Inverter
Contentspage viii

Owner’s Manual
page ix
How To Use This Manual: This manual is designed for ease of use and easy location of information.
To quickly find the meaning of terms used within the text, look in the Glossary.
To quickly find a specific topic, look in the Index.
This manual uses Noteboxes to convey important information. Noteboxes come in four varieties:
A WARNING notebox
indicates information
provided to protect the
user and service
personnel against safety
hazards and/or possible
equipment damage
WARNING
A CAUTION notebox
indicates information
provided to protect the
user and service
personnel against
possible equipment
damage.
CAUTION
An IMPORTANT notebox
indicates information
provided as an operating
instruction, or as an
operating tip.
IMPORTANT
A NOTE notebox
indicates information
provided as an
operating tip or an
equipment feature.
NOTE

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3.5 to 21 kVA N+1 Inverter
page x

Introduction
1.0 Scope
This manual provides technical information for installation, operation, and maintenance of MGE UPS Systems’
modular inverter systems series ranging from 3.5 kVA to 21 kVA. Please read this manual thoroughly before
installing and operating the system. Please retain this manual for future reference.
The manual is divided into four sections:
Section I — Introduction
This section introduces the S4 3.5 to 21 kVA static inverters, including a general description of the
inverter and its components, and inverter specifications.
Section II — Installation & Operation
This chapter describes installation of the inverters, including receiving, handling, and storage proce-
dures; prerequisites to the installation; installation procedures; and start-up procedures.
Section III — Maintenance
This section describes maintenance of the inverters, including preventive maintenance routines, and
recommended spare parts.
Section IV — Theory of Operation
An appendix provides a glossary of technical terms at the end of this manual provides definitions of
terms used within the text. An index makes it easy to quickly locate topics of interest.
1.1 General Description
This static, modular inverter system series provide stable, distortion-free AC power from a DC input source at a
selectable output voltage and frequency prior to shipment, for sensitive equipment which must be operated in
WARNING
An AC output will be present at the output terminals
immediately when AC input is energized.
ATTENTION
La tension alternative de sortie appara ît dès la mise sous
tension de l'entrée.
WARNUNG
Eine Ausgangsspannung liegt an den Ausgangsklemmen,
sobald der Netzeingang angeschlossen wird.
Owner’s Manual
Introduction page 1 — 1

3.5 to 21 kVA N+1 Inverter
Introductionpage 1 — 2
locations where commercial AC power is not available. With a built-in static transfer switch, the inverter also forms
a reliable and economical part of uninterruptible power supply systems in either on-line or off-line mode. See
chapter 8, Theory of Operation, for detailed information on inverter characteristics. This series employed modular
design to provide N+1 redundancy, and twin controller cards to double reliability. There are three distinctive parts
in these tower inverter systems. The top part is a built-in module that houses the twin controller, alarm cards, LCD
unit, and LED indicators. The center part is a built-in module that houses a static transfer switch, and where input
and output connectors are located. It is easily recognized by twin fan front panel. Above and below this static switch
module are individual inverter modules rated 3.5 kVA/3kW each (those with single fan front panel).
Topaz S4 systems are available in six receiver cabinet configurations housing 1 to 6 inverters, a static transfer
switch console and redundant microcontroller modules.
Figure 1-1: System Configurations
3.5 kVA 7 kVA/3.5 kVA 10.5 kVA/7 kVA 14 kVA/10.5 kVA 17.5 kVA/14 kVA 21 kVA/17.5 kVA
N+1 N+1 N+1 N+1 N+1
1.2 Standard Products
Consult table 1 below for the system(s) you are working on.
Table 1-1: Inverter System Characteristics
Part Power Nominal Input Maximum Nominal Output Selectable
Number rating Input Voltage Input Current Amperes at selectable Output
(kVA) Voltage Range @ -40VDC output voltage of: Frequency
(VDC) (VDC) (Amperes) 120 220 230 240 Hz
64034 3.5 (-48) (-40 to -60) 88 29 16 15 14.5 50 or 60
64074 7 (-48) (-40 to -60) 176 58 32 30 29 51 or 60
64104 10.5 (-48) (-40 to -60) 265 87 48 45 43.5 52 or 60
64144 14 (-48) (-40 to -60) 353 116 64 60 58 53 or 60
64174 17.5 (-48) (-40 to -60) 441 145 80 75 72.5 54 or 60
64214 21 (-48) (-40 to -60) 529 174 96 90 87 55 or 60

Table 1-2: Inverter Module Dimensions
Inverter Module HEIGHT (in/cm) DEPTH (in/cm) WIDTH (in/cm) WEIGHT (lb/kg)
64004-9MSK1 5.18 / 13.3 15.12 / 38.85 15.76 / 40.5 46 / 20.44
Note: Weight: 1 six-mod receiver = 135 lbs. 1 UPS Module = 46 lbs.
Total System Weight, 21 kVA system = 411 lbs.
1.3 Electrical Specifications
Electrical Specifications are subject to revision without notice.
1.3.1 DC Input
Nominal: -48Vdc; Operating Range: -39.5Vdc to -60 Vdc
1.3.2 AC Output (per module)
Voltage: 120Vrms or 240Vrms
Current: 25Arms or 12.5Arms
Frequency: 50Hz or 60Hz
Table 1-3: S4 AC Output Current Ratings
UNIT 3.5 kVA 7 kVA 10.5 kVA 4 kVA 17.5 kVA 21 kVA
AC AMPERES) (AC AMPERES) (AC AMPERES) (AC AMPERES) (AC AMPERES) (AC AMPERES)
VAC
100* 27.3 54.5 81.8 109.1 136.4 163.6
110 27.3 54.5 81.8 109.1 136.4 163.6
115 26.1 52.2 78.3 104.3 130.4 156.5
120 25.0 50.0 75.0 100.0 125.0 150.0
200 15.0 30.0 45.0 60.0 75.0 90.0
220 13.6 27.3 40.9 54.5 68.2 81.8
230 13.0 26.1 39.1 52.2 65.2 78.3
240 12.5 25.0 37.5 50.0 62.5 75.0
* 100VAC version needs to be derated.
1.3.3 Efficiency
85% minimum, 88% typical (on-line mode); 97% typical (off-line mode) at full kVA/Watt load.
NOTE
An external DC circuit breaker or fuse should be used at the DC source.
Owner’s Manual
Introduction page 1 — 3

1.3.4 Power Factor
Rated kVAis available over a power factor range of 0.6 lagging to 0.6 leading at nominal voltage. Watt rating should
not be exceeded.
1.3.5 Total Harmonic Distortion
Less than 1% for linear load conditions, 3% maximum for crest factor loads up to 3:1.
1.3.6 Line Regulation
System output voltage variation, less than 1% over the DC voltage range.
1.3.7 Load Regulation
System output voltage variation, less than 1% from zero to full load at nominal DC input.
1.3.8 Output Frequency
User-selectable, 50Hz or 60Hz. Free run frequency stability shall be within +/-0.02% of the selected frequency.
1.3.9 Short Circuit Current (SCC)
300% minimum of rated load current for four cycles. A SCC is defined as a current that exceeds 150% of rated
current.
1.3.10 Overload Capability
Continuous overload up to 108% of rated VA/watts at 40°C maximum.
1.3.11 Transient Deviation and Recovery
Within 20% of average value for any change in output current or step change in input voltage within specified limits.
Recovery within 1millisecond from zero to full load
1.3.12 EMI Emission
Less than 30dBrnc.
1.4 Indicators and Controls
See Figure 2-2 on page 2—4 for the location of indicators and control switches.
There are six LED indicators divided into three groups – DS1 and DS2, DS3 and DS4, DS5 and DS6 - on the
“Display” front panel. DS1 and DS2 are indicators of controller A; DS3 and DS4 are indicators for controller B; DS5
and DS6 are for output capacitors’fuse indicators. Failure of output capacitors will trip output fuses, and will activate
DS5 and/or DS6 indicators
At power-up, one of the two controller units will be up quicker than the other and will take control the system.
Consequently either DS1 (if controller A is in charge) or DS3 (if controller B is in charge) will be on blinking green,
signaling that the system output is ready to be turned on.
The inverter output voltage is turned ON and/or to Stand-by via switch SW1 located on the left side of the LCD
“Display” Panel. Pushing it up is to turn the inverter ON, and pushing it down is to turn the inverter OFF. WARNING:
In the “Stand-by” position, if AC power is applied to the AC input terminal block, AC power will be on the output of
the unit. When the output voltage is on, DS2 (or DS3) indicator will be on green steadily, signaling that every thing
is normal.
3.5 to 21 kVA N+1 Inverter
Introductionpage 1 — 4

The system measurement information is displayed on the LCD “Display” panel. Switch SW3 is pushed down (or up)
to scroll the LCD’s screens for more information. Individual inverter module has only one control, an ON/OFF circuit
breaker, located at the upper left corner of the front panel. This breaker is used to energize (or de-energize) the
inverter module.
Note: The module circuit breakers must be turned on prior to turning the system output voltage on.
LCD Readout
The LCD unit displays two lines (out of a total of seven lines) of information at a time. Each line can be scrolled
up (or down) independently by toggling switch SW3. Typical seven lines of information are shown below:
Line 1 INV: off normal Inverter off/on
Line 2 BYP: static normal Static bypass on/normal operation
Line 3 LOAD: 120V 100% Load % on nominal
Line 4 AC IN: 120V 60 Hz AC input voltage/frequency
Line 5 DC IN: 48.0V 073.5A DC voltage/DC current
Line 6 LOAD: 03000 W 025.0A Load Power (W)/Current (A)
Line 7 INV: 1 of 6 60 Hz Inverter(s) in operation/frequency
1.5 Remote Alarm
The system provides three alarm signals, namely, Utility alarm, Minor alarm, and Major alarm.
5.1 Utility alarm – Utility alarm is ON when utility input voltage is lost/out of tolerance.
5.2 Minor alarm – The system sends out this signal to indicate something is not functioning properly, but inverter
can still maintain the load.
5.3 Major alarm – Whenever load is lost power and the system is energized.
For alarm connection, see Table 1-4.
Alarm Relays
There are three alarm relays. All relays are “form C” type, that is, the relay has a normally open and a normally
closed contact set.
The “Major Alarm” relay will be energized when the system is operating properly, that is, power is being supplied to
the load either from the Inverter or from the Utility. There are two sets of “form C” contact sets on the “Major Alarm”
relay.
The “Minor Alarm” relay will be de-energized, and will be energized for the “alarm” condition. A “Minor” alarm will
be issued if the system is not operating properly. Such an alarm will be issued during over load, battery voltage not
within specified limits, power modules over temperature and module fault.
The “UtilityAlarm” relay will be de-energized during normal operation and will be energized for the “alarm” condition.
This alarm will be issued if the utility voltage is not within specified limits or the input frequency is not within proper
limits.
The table below shows the “alarm” and the “non-alarm” terminal block connections. This terminal block is located
in the top, left side of the receiver cabinet. The small front panel must be removed to gain access to the terminal
block.
Owner’s Manual
Introduction page 1 — 5

Table 1-4: Alarm Connections
J21 terminal block screw position --- 1 2 3 4 5 6 7 8 9 10 11 12
MAJOR ALARM --- X X
MAJOR ALARM --- X X
No Major Alarm --- X X
No Major Alarm --- X X
Minor Alarm --- X X
No Minor Alarm --- X X
Utility Alarm --- X X
No Utility Alarm --- X X
“X” indicates a short circuit between J21 terminal block points.
1.6 Mechanical Specification
Table 1-5: S4 Receiver Cabinet Mechanical Dimensions and Weights
MODEL
3.5 kVA 7 kVA 10.5 kVA 14 kVA 17.5 kVA 21 kVA
HEIGHT (in/cm) 15.75 / 40.5 21 / 54 26.25 / 67.5 31.5 / 81 36.75 / 94.5 42 / 107.9
DEPTH (in/cm) 18.5 / 47.5 18.5 / 47.5 18.5 / 47.5 18.5 / 47.5 18.5 / 47.5 18.5 / 47.5
WIDTH (in/cm) 17 / 43.7 17 / 43.7 17 / 43.7 17 / 43.7 17 / 43.7 17 / 43.7
RECEIVER WEIGHT (lb/kg) 67 / 30.4 88 / 39.9 100 / 45.4 111 / 50.3 122 / 55.3 136 / 61.7
RECEIVER + MODULES 114 / 51.7 182 / 82.6 241 / 109.3 299 / 135.6 357 / 161.9 418 / 189.6
WEIGHT (lb/kg)
RECEIVER SHIPPING 78 / 35.8 100 / 45.4 112 / 51.6 123 / 55.8 134 / 60.8 148 / 67.1
WEIGHT (lb/kg)
1.7 Environmental Specifications
1.7.1 Operating Temperature
All models operate to specifications from 0 to +50° C (+32° F. to +122° F).
1.7.2 Shipping Temperature
-40° C to +75° C (-40° F. to +192° F.) for shipping;
Not recommended for storage.
1.7.3 Storage Temperature
-40°C to +60°C (-40°F to +166°F)
1.7.4 Operating Humidity
0 to 90% relative, without condensation.
1.7.5 Operating Altitude
200 feet below to 10,000 feet above sea level
3.5 to 21 kVA N+1 Inverter
Introductionpage 1 — 6

1.7.6 Audible Noise
Less than 65 dBA per Type 2, IEC and ANSI SI.4, when measured in a 40 dBA environment at a distance of 4 feet
from any surface. At nominal ambient (+23C) and 75% load, typical audible noise is 50 dBA in the ON-LINE mode,
56 dBA in the OFF-LINE mode.
1.7.7 Cooling
Forced air. Air intake is through the front of the unit, exhaust out the sides.
1.7.8 Thermal Dissipation
Heat rejection: 602.28 BTU/Hr for each rated KW of the inverter system. This is based on an inverter efficiency of
85% at full load and does not include load dissipation.
kVA rating 3.5 7 10.5 14 17.5 21
Watts 529 1059 1582 2118 2647 3177
BTU/Hr 1807 3614 5421 7227 9034 10841
Est. A/C, TONS 0.151 0.301 0.452 0.602 0.753 0.903
1.7.9 Safety Approvals
Meets UL/CSA 60950 (listed) and European Standard EN60950.
1.7.10 Reliability
Calculated MTBF at 25° C ambient temperature
Owner’s Manual
Introduction page 1 — 7

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3.5 to 21 kVA N+1 Inverter
Introductionpage 1 — 8