MGE UPS Systems EPS 6000 User manual

I
EPS6000
150to750kVA
Uninterruptible
PowerSystem
User’sGuide
MGE
UPS SYSTEMS

-
e
EPS6000 150to 750 kVA
Uninterruptible Power System
User's Guide
For service call
1-000-430-7373
66-130033-00 BOO 1 l/96
Copyright (B 1996 MGE UPS Systems, Inc.. All rights
reserved. Printed in U.S.A.
MGE UPS Systems
1660 Scenic Avenue
Costa Mesa, CA 92626 MGE
UPS SYSTEMS
[phone]

IMPORTANT SAFETY INSTRUCTION
SAVETHESE INSTRUCTIONS -This manual contains important instructions for EPS 6000
inverters that must be followed during installation. operation and maintenance of the
equipment.
I
0
WARNING
OPENING ENCLOSURES EXPOSES HAZARDOUS
VOLTAGES. ALWAYS REFER SERVICE TO
QUALIFIED PERSONEL ONLY
WARNING
As standards, specifications, and designs are
subject to change, please ask for confirmation of
the information given in tihs publicaion.
This manual is a controlled document, pages should
not individually be removed from this binder.
NOTE
This equipment generates, uses, and can radiate
radio frequency energy and, if not installed and
used in accordance with instruction manual, may I
I
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. I

EPS 6000 150 to 750 kVA
Uninterruptible Power System
User’s Guide

Contents
Section IIntroduction
section description
1.0 ScoDe
page number
1 -1
1.1
1.2
1.3
1.4
Section II
2.0
2.1
2.2
2.3
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
.
iii
1.4.2
1.4.3
Yi'.i
2.1.2
. .
2i.i' . . .
2.2.2
2.2.3
2.2.4
2.3.1
2.3.2
2.3.3
2.3.3.1
2.3.3.2
2.3.3.3
2.3.3.4
General Description
Description of UPS Module
Major Internal Components
Rectifier/Battery Charger
lnvarter
hefter Transformer
Static Switch
Battery System
.Options
Specifications. UPS Modules
Electrical
Mechanical
Environmental
Operation
Scope
System Operation Overview
Normal Operation
On-Battery Operation
Indicators and Controls
Front Panel
Alphanumeric Display
and Controls
Hidden Panel
Circuit Breakers
and Contactors
Using the
Alphanumeric Display
Settings
Alarms
Measurements
Voltage Measurements
Current Measurements
Power and
Frequency Measurements
Battery Measurements
l-l
I
-6
l-6
1 -6
1
-6
1
-6
1 -6
1 - 14
1
- 16
1 - 16
1 - 17
1 - $7
2-l
2-l
2-l
2-l
2-2
2-3
2-5
2-0
2-11
2- 19
2 - 20
2 - 21
2-22
2-23
2 - 24
2 - 25
2 - 26
0
iii
0

-
0
EPS 6000 150 to 750 kVA Uninterruptible Power System
section
2.4
2.4.1
2.4.2
2.4.3
2.4.4
2.4.4.1
2.4.4.2
2.4.5
2.4.5.1
2.4.5.2
2.4.6
2.4.6.1
2.4.6.2
2.4.6.3
description page number
Normal Operating Procedures 2-26
Checks Before Start-up 2 - 26
start-up 2 - 27
Checks After Start-up 2 - 28
Shut-down 2-26
Emergency Shut-down
Using EPO 2 - 26
Normal Shut-down 2-29
Isolation for Maintenance 2-29
Without Maintenance Bypass 2-29
With Maintenance Bypass 2-30
Forced Transfers 2 - 31
Uninterrupted Transfer
Conditions 2
- 31
Forced Transfer From
Bypass AC Input Source
to lnverter
2-31
Forced Transfer From
lnverter to Bypass AC Input 2 - 31
2.5 . LCD Messages 2-32
Section Iii Maintenance and Service
3.0 .............. Scope 3-l
3.1 .............. Safety Instructions 3-l
3.2 .............. Preventive Maintenance 3-l
3.3 .............. Replacement Parts 3-2
3.4 .............. Troubleshooting and
MGE Servicing 3-2
Glossary..........................................g--1
l
iv Contents

User’s guide
0
Illustrations
figure
l-l .
l-2 . . . . .
1-3
l-4
l-5
l-6
.
1-7 . .
l-8
l-9
l-10
l-11
1-12
1-13
2-3
2-4
.
.
description page number
EPS 6000 UPS
150 - 375 kVA Pictorial l-3
Typical Single-line Diagram:
EPS 6000 460 VAC Input/Output
Single-Module 225 kVA UPS
With Battery Cabinet l-3
EPS 6000 UPS
500 kVA Pictorial l-4
Typical Single-Line Diagram:
EPS 6000 460 VAC Input/Output
Single Module 500 kVA UPS
With Battery Cabinet l-4
EPS 6000 UPS
750 kVA Pictorial l-5
Typical Single-Line Diagram:
EPS 6000 460 VAC Input/Output
Single Module 750 kVA UPS
With Battery Cabinet l-5
EPS 6000
Major Internal Components,
Single-Module UPS
150 - 225 kVA
l-7
EPS 6000
Major Internal Components,
Sinale-Module UPS 300/375 kVA 1 - 6
EPS 6000
Major Internal Components
500kVA UPS Cabinet
EPS 6000
Major Internal Components
500 kVA Input/Output Cabinet
EPS 6000
Major Internal Components
750 kVA UPS Cabinet 1
EPS 6000
Major Internal Components
750 kVA UPS Cabinet 2
EPS 6000
Major Internal Components
750 kVA UPS Cabinet 3
Power Flow, Normal Operation
Power Flow.
On-battery Operation
Power Flow, Bypass Operation
EPS 6000
Controls and Indicators
l-9
l-10
l-11
l-12
1- 13
2-l
2-2
2-2
2-3

EPS 6000 150 to 750 kVA Uninterruptible Power System
figure
description page number
2-5 EPS 6000 Front Panel 2-3
2-6
2-7
2-6
2-9
Z-10
2-l 1
2-12
Z-13
2-14
Z-15
Z-16
Z-17
Z-18
2-19
Z-20
Z-21
2-22
2-23
Alphanumeric
Display and Controls
Hidden Panel
EPS 6000
Major Internal Components,
Single-Module UPS
150 - 225 kVA
EPS 6000
Major Internal Components,
Single-Module UPS
300/375 kVA
Single EPS 6000 500 kVA
Major Internal Components
UPS Cabinet
Single EPS 6000 500 kVA
Major internal Components
Input/Output Cabinet
Single EPS 6000 500 kVA
Major Internal Components
UPS Cabinet 1
Single EPS 6000 500 kVA
Major Internal Components
UPS Cabinet 2
Single EPS 6000 500 kVA
Major Internal Components
UPS Cabinet 3
2-6
2-8
2 - 12
Z-13
2- 14
2- 15
2- 16
2- 17
Z-18
Location of Circuit Breakers and
Switches Within the Electrical Path
of the UPS Cabinet
2- 19
Alphanumeric Display 2- 19
General Display Configuration 2
- 20
Display Settings Display 2
- 21
Displaying Alarm Messages 2
- 22
Location of Sensors
Within the EPS 6000 UPS 2-22
Voltage Measurements 2-23
Current Measurements 2 - 24
Power and Frequency
Measurements 2 - 25
Tables 2-24 Battery Measurements 2
- 26
table description page number
l-l EPS 6000 Model Numbers.
Single-Module UPS Modules l-2
Vi
Contents

User’s guide
0
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.
This manual uses Noteboxes to convey important information. Noteboxes come in four
varieties:
I
personnel against safety
hazards and/or possible
equipment damage
L
IMPORTANT
An IMPORTANT notebox
indicates information
provided as an operating
instruction. or as an
I
operating tip.
a
CAUTION
A CAUTtON notebox
indicates information
provided to protect the
I
user and service
PerSOnnel against
possible equipment
damage.
r
NOTE
A NOTE notebox
indicates information
provided as an
operating tip or an
equipment feature.

0
EPS 6000 150 to 750 kVA Uninterruptible Power System

Introduction
1.0 Scope This manual provides technical information required for
operation and maintenance of the single EPS 6000 winter.
ruptible power system (UPS). Please read this manual before operating the EPS 6000
equipment. Please retain this manual far future reference.
The manual is divided into three sections:
Section I -General Description
This section introduces the EPS 6000 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 - operation
This section describes operating information for EPS 6000 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 Ill- Maintenance and Service
This section describes maintenance of the EPS 6000 UPS, including safety instruction
preventive maintenance. information about replacement parts, and customer service.
A Glossary in the rear of this manual provides definitions of terms used within the text. A
separate manual. the EPS 6000 UPS Installation Manual. (MGE part number 66-130035-00)
provides detailed installation instructions.
1.1 General Description EPS 6000 is a family of compact. high-efftciency uninter-
ruptible power systems, available in power ratings for
single-module systems from 150 to 500 WA. EPS 6000 UPS are optimized for compatibility
with non-linear computer-type loads. Computer-aided UPS diagnostics and modular construc-
tion assures that any required Service on the UPS can be identified and completed rapidly.
Remote system monitoring, remote annunciation of UPS performance signals, and telecom-
munication capabilities allow total control of the UPS by the user.
The EPS 6000 UPS. baltery, and all auxiliary equipment is listed for safety by Underwriter’s
Laboratories. Inc. (UL) under UL Standard 1776 and under Canadian Standards Association
(CSA) standard C22.107.
Major components of the EPS 6000 UPS family include:
.EPS 6000 UPS module
- EPS 6000 auxiliary cabinet
.EPS 6000 battery cabinet
l-l
*

EPS 6000 150 to 750 kVA Uninterruptible Power System
Each of these cabinets is described below. Figure 1-l. l-3 and l-5 show an EPS 6000 single-
module UPS. Figure l-2. I-4 and 1-6 show single-line diagrams of typical single-module
installations (one UPS module. and one battery). Table 1-l identifies single-module EPS 6000
UPS model numbers.
Table EPS 6000 Model Numbers, Single-Module UPS Modules
l-l
MODEL
NUMBER
INPLn OuTFur OLnPbT 1NPu-r ToTAl TOTAL “EAT AIR
“OLTACZ VOLTAGE RAT040 CB wlmH WEIGHT Loss FLOW
WAC) WC) WAhw) m?=4 mm (kSm)
w.w 1-m)
EPS 6150
FPS-615Or22.66
z
206 206 150/120 400 3.325/l%
3.013/6.644 40.494 25Wi70
EPS-
-. 6X0/42.66-
460 206 150/120 400 2.460/97 2.664/4.676 30.618 2500170
EPS-6150144.66 460 460 150/120 400 1.610163.5 2.044/4.506
25.603 25OW70
EPS 6225
EPS-6225n2.66 206 206 225/160 400 3.325/131 3.01316644
49,797 2500,70
EPS-6225/42.66
460 206 225/160 400 2.460/97 2.665/5.676 46.227 2500/70
EPS-6225144.66 460
460 225,160 400 1.610/6X5 2.044/4.506 39,202 25XVi’O
EPS 6300
EPS-6300122.66 : 206 206 300/240 600 4.1151162
4.45119.615 66.396 25OOf70
EPS-6300/42.66
460 206 300/240 600 2.6701113 3.6W/9.379 61.636 2500/70
EPS-6300/44.66
460 460 300/240 600 1.610163.5 2.514/5.543 52.269 2500,70
EPS 6375
EPS-6375R2.66 206 206 375/300 700 4.115,162 4.736/10.440 82.995 2500,i’O
j375142.66
460 206 375/3oc
EPS-t i 700 2.670/113 4,007/6.636
77.045 25OOt70
EPS.6?75,dd fifi
,_ _. __ All” _ _ 480 _ _ 1751X~-, 700 1.610163.5 2.54515.612 65.336 25OOnO
EPS 6500
EPS-6500/44.66
460 460 500,400 ,000 2.565/113 4.244n.211 79,453 3400195
EPS 6750
EPS-6750144.66 460 460
750/600 1600 4.950/195 6.200/13.6Ol 13,lCDl 59001165
NOTES:
1. Total width, weight. and heat loss are for system line-up including auxiliary cabinets but excluding pallets
2. Data does not include battery data; refer to the installation drawings supplied with your equipment.
3. Information provided is for standard configurations: data may change with optional equipment. Consult the
installation drawings provided with your equipment.
l-2 introduction

User’s guide
0
Figure
l-l
EPS 6000 UPS 150 - 375 kVA Pictorial
Figure
l-2
Typical Single-line Diagram: EPS 6000 480 VAC Input/Output
Single-Module 225 kVA UPS With Battery Cabinet
;..,.......................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
: EPS 6000 UPS CABINET
FUSES RECTIFIER,
INVERTER FUSES (OPTIONAL):
CHARGER :
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . ..~
: EPS6000
: SAlTERY
: CABINET(S)
Introduction l-3
e

EPS 6000 150 to 750 kVA Uninterruptible Power System
Figure EPS 6000 UPS 500 kVA Pictorial
l-3
Figure Typical Single-Line Diagram: EPS 6000 460 VAC Input/Output
l-4
l/O CABINET
Single Module 500 kVA UPS With Battery Cabinet
f i,b’iibiiii.. . . . . . . . . . . . . . . . . . . . *. . . . . . . . . ;; . . . . . . . . . . . . . ..:
.
BYPASS
AC INPUT,
MAINS 2
MAIN
AC INPUT/
MAiNS I
BACKFEED
PROTECTION STATIC SWITCH (OPTIONAL)
n
: i
(14s
: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
: i:
UPS CABINET
_.T
:
Ql
FUSES: RECTIFIER, ,N”ERTER FUSES
:(OPTIONAL):
-.............,...........
. . . . . . . . . . . . . . . . . . . . . ..s..........
: BATTERY
i......................:
TO
ATTACHED
LOAD
l-4 Introduction

User’s guide
0
Figure
EPS 6000 UPS 750 kVA Pictorial
1-5
‘S CABINET 2
Figure Typical Single-Line Diagram: EPS 6000 480 VAC Input/Output
0
1-6 Single Module 750 kVA UPS With Battery Cabinet
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..*...............
: 110 CABINET
1 .
~......“............................
. “PS CABINETS
‘ATIC SWITCH
CGBP
(OPTIONAL)
MAIN
AC lNP”T,
MAINS 1
: BATTERY
: CABINET(S) D+ :
TO
ATTACHED
LOAD
Introduction
l-5
0

a
EPS 6000 150 to 750 kVA Uninterruptible Power System
1.2
Description of UPS Following is a description of the EPS 6000 UPS major
Module Major internal components. Refer to the single-line diagram provided in Figures l-2. 1-4 and 1-6, and the component
Internal locators provided in Figure t-7 through Figure 1-13.
Components
1.2.1
Rectifier/Battery
Charger
1.2.2 lnverter
phase AC voltage. An AC output filter is used to achieve a computer-grade sinewave output
voltage waveform, with a total harmonic distortion of less than 2% under linear-load conditions.
1.2.3
lnverter
Transformer
1.2.4 Static Switch
supply of power to the load. allowing the load to continue operation while the UPS is being
maintained, or in the event of a UPS fault. The static switch circuit assures that voltage from
the UPS output cannot feed back to the utility input lines.
1.2.5
Battery System
The rectifier/battery charger converts the AC input voltage
from the utility source into a DC voltage. supplying the
invertar and regulating the charge of the battery system. A
capacitor bank filters the DC voltage.
The inverter chops the DC voltage supplied from either the
rectifierlbanery charger or the battery system into s three-
During normal operation. the inverter transformer provides
complete electrical isolation between the UPS output to the
attached load and the utility power source input as well as
the UPS battery source.
The static switch transfers the load between the inverter
output and the bypass AC source without interrupting the
The battery system stores energy for use by the inverter.
The stored energy is utilized in the event that the AC input
power from the utility source fails. or falls outside of acceptable tolerance.
The battery system may be an MGE battery cabinet designed for operation with the EPS 6000
UPS. or a customer-supplied battery installation. MGE-supplied EPS 6000 battery cabinets
may be a provided as stand-alone enclosures, or as enclosures designed to be mounted
adjacent to the EPS 6000 UPS module.
The EPS 6000 comes with a Special battery ambient temperature sensor which allows the
optimization of the DC voltage level as a function of the temperature, ensuring that the battery
is properly charged and preserving its longevity.
0
l-6 Introduction
I

User’s guide,
Figure
EPS 6000 Major Internal Components,
l-7 Single-Module UPS 150
- 225 kVA
Introduction

EPS 6000 150 to 750 kVA Uninterruptible Power System
Figure EPS 6000 Major Internal Components,
Single-Module UPS 300/375 kVA
AC CWAcnOR
ASSEMBLY
i
0
l-8
Introduction
i

User’s guide
Figure EPS 6000 Major Internal Components
l-9 5OOkVA UPS Cabinet
AC CAPACITOR
ASSEMBLY
FBl TO FB6
EPOZ
CHARGER 6 TREZ
(BEHIND PLATE,
OBEZ
RAUZ
DC CAPACITERS
(BEHIND EACH INYERTER)
INVERTERS (x6)
4PACITORS ’ u,,,,u ,
CARDCAGE: -
Ct CRIZ PCA I ::::I
4-CROZ/D06ZPCA
6 ALEZ PCA K3NZ
K3N
STATIC SWITCH
OUTPUT FUSES
F7. F6. F9
ACPZ
ALBZ
FlO.Fll.Fl6.Fl9
FlZ.Fl3
BAITERY
CONNECTION
(OPTIONAL)
AC CAP ASSY.
Introduction l-9
0

EPS 6000 150 to 750 kVA Uninterruptible Power System
Figure
EPS 6000 Major Internal Components
l-10 500
kVA Input/Output Cabinet
NEUTRAL CONNECTION GROUND CONNECTION
\ /
I ‘I
II I
‘I I
III +-
III Ii II
I
,NPUT FUSE
F1.FZ.I
FUSES F14.F
FUSES F16.F
’ AC CAPACITORS
\
BONDING
JUMPER
, SHUNT
/
CURRENT WMRS
FZO.FZt.F22
\
STATIC SWITH
0
1- 10
/r/troduction