MGE UPS Systems 5103304XXX User manual

86-153719-00 B00 - Page 1
Comet EXtreme
4.5/6/9/12 kVA
Installation and
User Manual
www.mgeups.com

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Introduction
Thank you for selecting an MGE UPS SYSTEMS product to protect your electrical equipment.
The Comet EXtreme range has been designed with the utmost care. We recommend that you take
the time to read this manual to take full advantage of the many features of your UPS.
MGE UPS SYSTEMS pays great attention to the environmental impact of its products.
Measures that have made Comet EXtreme a reference in environmental protection include:
◗production in an ISO 14001 certified factory;
◗recycling of Comet EXtreme at the end of its service life.
To discover the entire range of MGE UPS SYSTEMS products and the options available
for the Comet EXtreme range, we invite you to visit our web site at www.mgeups.com
or contact your MGE UPS SYSTEMS representative.
For service call
1-800-438-7373
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.
Note

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Safety Instructions
Important: Save these instructions.
This manual contains important instructions for Comet EXtreme UPS Models that must be followed during
installation, operation and maintenance of the UPS and batteries.
The Comet EXtreme UPS Models that are covered in this manual are listed below.
5103304XXX
5103306XXX
5103309XXX
5103312XXX
5103354XXX
5103356XXX
5103359XXX
5103362XXX
Tightening torque for all input and output terminal blocks shall be 10.6 - 12.3 in - lbs. (1.2 - 1.4 Nm) for 4.5
and 6 kVA models and 21.8 - 26.1 in - lbs (2.5 - 3 Nm) for 9 and 12 kVA models.
The normal battery voltage for all models is 240 VDC.
The Comet EXtreme server UPS is intended for installation in a temperature controlled indoor area, free of
conductive contaminants.

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Safety of persons
A UPS has its own internal power source (the battery). Consequently, the output terminals may be energized
even if the UPS is disconnected from the AC-power source.
Dangerous voltage levels are present within the UPS. It should be opened exclusively by qualified
service personnel.
The UPS must be properly earthed.
The battery supplied with the UPS contains small amounts of toxic materials. To avoid accidents,
the directives listed below must be observed.
◗ Never operate the UPS if the ambient temperature and relative humidity are higher than the levels
specified in the documentation.
◗ Never burn the battery (risk of explosion).
◗ Do not attempt to open the battery (the electrolyte is dangerous for the eyes and skin).
◗ Comply with all applicable regulations for the disposal of the battery.
Product safety
The UPSs connection to the AC-power source must be protected by a circuit breaker
that is easily accessible.
The UPS can be disconnected from the AC-power source by opening the circuit breaker.
◗ Never install the UPS near liquids or in an excessively damp environment.
◗ Never let a liquid or foreign body penetrate inside the UPS.
◗ Never block the ventilation grates on the front or back of the UPS.
◗ Never expose the UPS to direct sunlight or a source of heat.
Special precautions
The UPS connection instructions contained in this manual must be followed in the indicated order.
Check that the indications on the rating plate correspond to your AC-power system and to the actual
electrical consumption of all the equipment to be connected to the UPS.
If the UPS is positioned flat, check that not more than five modules are stacked on top of each other.
If the UPS must be stored prior to installation, storage must be in a dry place.
The admissible storage temperature range is -40°C to +50°C.
If the UPS remains de-energized for a long period, we recommend that you energize the UPS
for a period of 24 hours, at least once every month.
This charges the battery, thus avoiding possible irreversible damage.

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Warning
Batteries can present a risk of electrical shock and/or burn from high short circuit current. Observe proper
precautions. Do not open battery packs. There are NO user-servicable parts within. Do not allow anything
to touch the battery terminals. Do not pierce battery pack wiring insulation. Do not allow conductive tools or
jewelry to touch battery packs or battery terminals.

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Foreword
Using this document
Information may be found primarily by consulting:
◗the contents;
◗the index.
Pictograms
Important instructions that must always be followed.
Information, advice, help.
Visual indication.
Action.
Audio indication.
In the illustrations on the following pages, the symbols below are used:
LED off.
LED on.
LED flashing.

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Contents
1. Presentation
1.1 Comet EXtreme range ................................................................................................................ 9
1.2 Back ........................................................................................................................................... 11
1.3 Control panel ............................................................................................................................... 12
2. Installation
2.1 Unpacking and checks ............................................................................................................... 13
"Tower" and "rack" model: 4,5 and 6 kVA ..................................................................................... 13
"Tower" and "rack" model: 9 and 12 kVA ...................................................................................... 13
2.2 Installation (rack version) .......................................................................................................... 14
2.3 Battery-module connections ..................................................................................................... 15
2.4 Connection to the RS 232 communications port (optional) ................................................... 16
2.5 Installation of the communications-card option ...................................................................... 16
2.6 Connection to the connection modules ................................................................................... 17
2.7 Emergency Power Off................................................................................................................. 18
3. Operation
3.1 Operating mode .......................................................................................................................... 19
ON-LINE mode ............................................................................................................................. 19
3.2 Start-up ........................................................................................................................................ 20
3.3 Bargraph indications .................................................................................................................. 20
3.4 Failure of AC input power and operation on battery power .................................................... 21
Transfer to battery power .............................................................................................................. 21
Threshold for the low-battery shutdown warning .......................................................................... 21
End of backup time ....................................................................................................................... 21
Sleep mode ................................................................................................................................... 21
Return of AC input power .............................................................................................................. 21

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Contents
3.5 Personalization ............................................................................................................................ 22
Function .................................................................................................................................................. 22
"ON / OFF conditions" tab ....................................................................................................................... 22
"Battery" tab ............................................................................................................................................ 23
"Output" tab ............................................................................................................................................. 23
"By-pass" tab .......................................................................................................................................... 23
3.6 Shutdown ...................................................................................................................................... 24
4. Maintenance
4.1 Troubleshooting ........................................................................................................................... 25
4.2 Replacement of the electronic module ...................................................................................... 26
5. Environment ............................................................................................................................ 27
6. Appendices
6.1 Glossary ........................................................................................................................................ 28
6.2 Index .............................................................................................................................................. 30

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1. Presentation
1.1 Comet EXtreme range
4,5 and 6 kVA tower models:
4,5 and 6 kVA rack models:
Electronic module
Battery module
Dimensions in inches
(H x W x D)
17.45 x 6.81 x 18.3
17.45 x 6.81 x 18.3
Electronic module
Battery module
Weight in lbs.
31
106
Electronic module
Battery module
Dimensions in inches
(H x W x D)
6.97(4u) x 19.01 x 18.19
6.97(4u) x 19.01 x 18.19
Electronic module
Battery module
Weight in lbs.
40
112

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1. Presentation
9 and 12 kVA tower models:
9 and 12 kVA rack models:
Electronic module
Battery module
Dimensions in inches
(H x W x D)
17.45 x 8.50 x 18.3
17.45 x 6.81 x 18.3
Electronic module
Battery module
Weight in lbs.
48
106
Electronic module
Battery module
Dimensions in inches
(H x W x D)
8.7 (5u) x 19 x 18.18
6.96 (4u) x 19 x 18.18
Electronic module
Battery module
Weight in lbs.
60
112

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1. Presentation
1.2 Back
3
2
1RS232 communications port.
battery circuit breaker.
communications-card option.
EXB battery module connector.
rating plate.
manual by-pass switch.
connection module.
output terminal block.
input terminal block.
Comet EXtreme 4,5 and 6 kVA:
Comet EXtreme 9 and 12 kVA:
5a
6
7
8
9
4
4
10
5b
emergency power off.
EXB battery module connector.
5b
connector for
battery extension modules.
emergency power off.

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1. Presentation
1.3 Control panel
Alarms
UPS overload
electronics fault
battery fault
ambient temp.
> 40°C
12
13
14
hold down to display
percent load.
15
lamp test or buzzer OFF.
16
operation on manual bypass.
17
operation in Automatic Bypass mode.
18
operation in ON-LINE mode.
19
operation on battery power.
20
ON/OFF.
21
11
% battery
remaining
100%
80%
50%
20%
% load
100%
80%
50%
20%

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2. Installation
2.1 Unpacking and checks
Electronic module
Comet EXtreme 4,5 and 6 kVA:
RS 232 communications cable.
"Solution Pac" CD ROM.
"UPS Driver" diskette.
24
22
23
documentation.
telescopic rails for mounting in 19" bay with mounting hardware.
cable for connection to battery module.
25
26
27
23
24
25
22
Battery module
25
27
23 24
25
22
25
26
26
27
23
24
25
22
25
27
23 24
22
25
27
25
27
27
26
26
Comet EXtreme 9 and 12 kVA:
Electronic module
Battery module

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2. Installation
2.2 Installation (rack version)
Rack mounting diagram with rails.
The rails and the necessary mounting hardware are supplied with the UPS in the package.
1
2
3
33
3
4

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2. Installation
2.3 Battery-module connections
Check that the battery circuit breaker is OFF.
Check that the battery circuit breaker is OFF.
Comet EXtreme 4,5 and 6 kVA:
Comet EXtreme 9 and 12 kVA :
2
2
27
27
2
2
4
4
Connect cable to the connectors of the electronic and
battery modules.
Connect cable to the connectors of the electronic and
battery modules.
4
27
427
* Transformer connections (120 volt models)
Refer to Transformer Installation Guide.

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2. Installation
2.4 Connection to the RS 232 communications port (optional)
2.5 Installation of the communications-card option
Slots for communications card.
It is not necessary to shut down the UPS to install
the communications card:
1. Remove the slot cover .
2. Insert the card in the slot.
3. Secure the card with the two screws.
1. Connect the RS 232 communications cable to the serial
port on the computer.
2. Connect the RS 232 communications cable to the RS 232
communications port on the UPS.
The UPS can now communicate with all MGE UPS SYSTEMS
supervision, set-up or safety software.
Pin-out diagram for the RS 232 communications port
on the UPS.
1
22
22
RD TD
RTS
OV
5 4 3 2 1
9 8 7 6
1
22
1
3
3

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2. Installation
This type of connection must be carried out by qualified electrical personnel.
Before carrying out any connections, check that the battery circuit breaker is OFF
and that the upstream protection devices ( AC-power source) are open (OFF).
The overall cable diameter and the cross-sectional area
of the three wires depends on the UPS rating.
1. Remove the terminal-block cover .
2. Remove the cable entry knockouts from the cover.
3. Loosen the cable clamp .
4. Insert the cable supplying the equipment and the power cable
through the terminal-block cover .
Always connect the earthing wire first.
5. Connect the three wires of the equipment cable to the output
terminal block .
6. Connect the three wires of the power cable to the input
terminal block .
7. Tighten the cable clamp .
8. Refit and secure the terminal-block cover .
Earthing wires
cable size
gauge
2.6 Connection to the connection modules
EXtreme 4,5 to 6 kVA
EXtreme 9 to 12 kVA
20 to 6 AWG
20 to 6 AWG
29
28
9
10
29
29
9
10
28
28
28
29
9
10
2
28

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2. Installation
2.7 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 Comet EXtreme
◗remotely trip off the battery circuit breaker on the Comet EXtreme
◗remotely trip off the circuit breaker for the additional battery cabinet(s), if applicable
To accomodate the EPO function, the Comet EXtreme 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 battery module
◗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
1234
Emergency Power Off
emergency
off button
+24 VDC/VAC–
Battery circuuit breaker shunt trip connection
Connection diagram for battery circuit breaker shunt trip on terminal block
5b

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19
20
3. Operation
3.1 Operating mode
ON-LINE mode
This is the standard operating mode, set by default in the factory.
It makes use of electronic double conversion of the input power.
Two possible cases:
LED is ON: AC input power is available. Power is drawn
from the AC-power source and supplied to the protected
equipment via the UPS.
LED is ON: AC input power is not available. Power is drawn
from the battery and supplied to the protected equipment.
19
20

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3. Operation
11 14
11
12
13
14
15
2
21
The protected equipment connected to the UPS can be energized, whether AC input power is available
or not.
Prior to initial start-up, check the UPS voltage settings. If the protected equipment voltage is other
than 208 V / 60 Hz, the UPS settings must be modified using the "UPS Driver" software
(see section 3.5).
1. Set the battery circuit breaker(s) to ON.
2. Press the ON / OFF button .
All connected equipment is energized. The buzzer sounds.
LEDs , and go ON.
If LEDs , and do not go ON or if LEDs , , or flash, there is a fault (see section 4.1).
3.3 Bargraph indications
LEDs to provide three different indications.
1. Remaining backup time in percent (in ON-LINE mode).
2. Percent load drawn by the protected equipment,
when button is pressed.
3. Operating faults (flashing LED and beeps):
Overload.
UPS fault.
Battery fault.
Excessive ambient temperature.
3.2 Start-up
18 19 20
21
15
18 19 20
11
12
13
14
24
2
11 12 13 14