MGE UPS Systems 40-150kVA Power Supply User Manual
Contents
1. 2 3 Storage If the equipment is to be stored prior to installation it should be stored in cool dry well ventilated location that is protected against rain splashing water chemical agents etc The equipment should be covered with tarpaulin or plastic wrapper to protect it against dust dirt paint or other foreign materials IMPORTANT Batteries should be stored no longer than three 3 months at approximately 25 77 F prior to recharging Too high or too low temperature will damage batteries Exceeding the recommended ambient storage temperature will reduce back up time and may adversely affect life 2 4 Prerequisite to Installation This section provides more information for a successful and efficient installation of the Comet 40 150kVA Installation of equipment must be handled by skilled technicians and electrician s familiar with the requirements of high energy electrical equipment The installation must comply with the requirements of the National Electrical Code NEC ANSI NFPA 70 latest issue and with local codes and requirements as applicable We strongly recommend contracting MGE Customer Support Services for startup Do not allow unqualified personnel to handle or operate the equipment 2 4 1 Environmental The Comet 40 150kVA UPS is intended for use in an environment where cont2. 4 1 4 2 Preventive Maintenance 4 1 4 3 Replacement Parts 4 2 cii Contents 86 160310 00 E00 Installation and User Manual Figures figure description page 1 1 Comet 40 80KVA 1 2 Comet 100 150kVA 1 1 1 3 Single Line Diagram for the Comet 40 80KVA 1 2 1 4 Single Line Diagram for the Comet 100 150 1 2 1 5 Front View of the Comet 40 80KVA 1 4 1 6 Rear View of the Comet 40 80kVA 1 5 1 7 Front View the Comet 100 150 1 6 1 8 Front View of Communications Components for the Comet 100 150 1 7 1 9 Pinouts on the DB15 Connector 1 10 2 1 The Comet 100 150kVA on Pallet 2 2 3 1 Power Flow For Normal Operation 3 1 3 2 Power Flow For On Battery Operation 3 1 3 3 Power Flow For Bypass Operation 3 2 3 4 Comet Front Panel GUI Controls and Indicators 3 3 3 5 Output Current Overload Curve 3 7 3
3. 1 11 1 4 1 UPSON arsen 1 11 1 4 2 Software and Communication Package 1 11 Section 2 Installation 2 0 SCOPO MC 2 1 2 1 76 NE R 2 1 2 2 xa NE EE eek eee 2 1 2 3 veo PSS ss 2 2 2 4 Prerequisite to Installation 2 2 2 4 4 Environmental 2 2 242 Mechanical db does 2 3 24 3 Electrical bee eee Saw w ge Sees 2 3 2 5 Installation Procedures 2 4 2 5 1 Placement 2 4 86 160310 00 E00 Contents ci Comet 40 150kVA section description page Section 2 Installation continued 2 6 Connections 2 4 2 6 1 Main AC Input 2 4 2 6 2 Bypass AC Input Optional 2 4 2 6 3 Remote Emergency Power Off REPO 2 4 264 AC OOutput 2 5 200 Batley APP 2 5 Section 3 Operation 3 0 2000 EE EE NE ae 3 1 3 1 Power Flow 3 1 3 1 1 Power Flow For Normal Operation 3 1 3 1 2 Power Flow For On Battery Operation 3 1 3 1 3 Power Flow For Bypass Operation
4. Commitment MGE UPS SYSTEMS ING is committed to providing easy to access factory trained experts that will provide responses to any questions that you might have Scheduling Field Service Engineer Support Scheduling of the MGE Field Service Engineers typically should be done 7 to 10 days before they are required on site If the startup of the product is critical to maintaining your schedule please call the MGE toll free telephone number at 1 800 438 7373 for assistance Return Policy for Repair of Three Phase Products RGA Should you require factory service for your equipment contact MGE Customer Care Center and obtain Return Goods Authorization RGA prior to shipping your unit Never ship equipment to MGE without first obtaining an RGA number Date RGA Number Contact Name Rev BOO 8 2005 Comet 40 150kVA This page left blank intentionally 86 160310 00 E00 Term used Q IA C 2nd AC or ac Ambient Temp Ambient noise ANSI AWG Breaker BTU or Btu BYPASS BYPASS mode Carrier C CB cm CSA dB DC Conduit 86 160310 00 E00 Glossary Definition Meaning At And or Plus or Minus Equal to or less than Number Degree Celsius Degree Fahrenheit Phase angle Ohm unit of resistance Trade Mark Second Alternating current also implies root mean square rms Temperature of surrounding air Acoustical noise of surrounding environment American Na
5. National Electrical Code National Electrical Manufacturers Association National Fire Protection Association Power factor Part number Inverter output power is the primary energy source to load Inverter output is off and the load connected at the inverter output receives power from utility line via a static transfer switch or maintenance bypass relay Occupational Safety and Health Agency Printed circuit assembly Printed circuit board Pulse Width Modulation Silicon controlled rectifier Any damage done to an article while it is in transit Single Pole Double Throw An solid state switching mechanism electronically controlled to pass AC power directly from the utility to an output load Refers to an electronic technician qualified to maintain and repair electronic equipment Not necessarily qualified to install electrical wiring DB 9 type connector on the LCD panel allowing MGE UPS SYSTEMS Customer Support Service technician to access programmable and diagnostic features of the system Underwriter s Laboratories Inc Uninterruptible Power Supply or Uninterruptible Power System Volts Volt amperes Volt amps unit for apparent power measurement equal V x l Voltage of AC type Voltage of DC type Battery voltage By way Glossary 3 Comet 40 150kVA This page left blank intentionally G 4 86 160310 00 E00 Reorder Form MGE UPS SYSTEMS 1660 Scenic Avenue Costa Mesa
6. p Apply AC input power to the unit by closing the upstream circuit breaker p Put the battery circuit breaker s in the ON position p The buzzer sounds p The status LED s go on p The rectifier starts up p The cooling fans startup p The inverter automatically starts up except if the system is in manual startup mode optional p If the transfer conditions AC input power within tolerances are correct the Inverter comes on line and supplies the load The green Load Protected LED goes on Inverter Manual Startup Typically the Inverter is configured for automatic startup mode For manual startup mode configuration contact MGE Customer Support Services For manual startup P Press the green Inverter ON pushbutton p The green Load Protected LED flashes p The Inverter starts and if the transfer conditions are correct the load is transferred to the Inverter p The red Load Not Protected LED goes off p The green Load Protected LED goes p The GUI display indicates Load Protected 86 160310 00 E00 Operation 3 5 Comet 40 150kVA 3 5 Operating Procedures 3 5 1 Normal Operation p The AC input power is present p The green Load Protected LED is on The GUI display indicates the operating status of the UPS p 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 GUI display
7. Table 1 2 UPS Manager Dry Contact Interface UPS Manager Dry Contact Interface DB15 Softunor DB9 Operation on Inverter Diagnostics for MGE Customer Care Center use only Operation on Bypass Operation on Battery Low Battery Shutdown Warning UPS Remote Inverter Shutdown Figure 1 9 Pinouts on the DB15 Connector DB15 pin connector Breaking capacity of contacts is 8 7 654 321 P 3va ee Sepi DIE V 30VDC max OOOOOOO0 15 14 13 12 11 10 9 100mA max Please note that once the UPS remote inverter shutdown signal is applied the Inverter stops and the load transfers to bypass after a predetermined time typically 2 minutes 1 10 System Description and Specifications 86 160310 00 E00 Installation and User Manual 1 4 Options and Accessories Options are available for the Comet 40 150kVA UPS s Most options must be specified at the time of the original order for factory installation Some options can be field installed contact your MGE Sales Representative for further information Auxiliary Cabinet Extended Battery Cabinets 1 4 1 UPS Options The auxiliary cabinet may provide one or both of the following options an input bypass step up down transformer and an output distribution panel An output distribution panel provides connection points for distribution of AC power to computers and other equipment Also available are external maintenance bypass cabinets Up to two Extended Battery
8. 3 2 3 2 Graphical User Interface Controls Indicators 3 2 3 3 Startup Procedures 3 5 3 3 4 Preliminary Checks 3 5 3 3 2 Powering Up the Comet 3 5 3 4 Inverter Manual Startup 3 5 3 5 Operating Procedures 3 6 3 5 1 Normal Operation 3 6 3 5 2 Operation on Battery Power 3 6 3 0 3 Battery Duration sa h n sake ew 3 6 3 5 3 1 Return to AC Power 3 6 354 Overload 3 7 3 6 Emergency Shutdown Using EPO REPO 3 8 3 7 Forced Transfer 3 8 3 8 Maintenance Bypass 3 8 3 8 1 From Normal Maintenance Bypass Mode 3 8 3 8 2 From Maintenance Bypass to Normal Mode 3 9 3 9 Shutdown Procedures 3 10 3 9 1 Inverter Shutdown 3 10 3 9 2 Powering Down 5 533 240 re ha he oe budde de ee den 3 10 3 10 u us V Sau ua w uum ee 3 10 Section 4 Maintenance 4 0 2 fet SRM E MEE dS 4 1 4 1 Battery Safety
9. 600 208 417 131 417 96 00 2438 3400 1543 50759 See notes that follow System Description and Specifications 86 160310 00 E00 Installation and User Manual NOTES 1 Total width weight and heat loss are for system line up excluding battery cabinets 2 Data does not include battery data refer to the installation drawings supplied with your equipment Consult the installation drawings provided with your equipment 1 3 1 Input Ratings Voltage 480 12 15 Frequency 60 Hz 4 Phases 3 phase sequence must be A B C clockwise Wires 3 wires plus ground 480 480 VAC only Power factor Approximately 0 98 at full load Current on UPS on BYPASS 43A 48A 50 54 60 1 3 2 AC Output Ratings Voltage inverter only Frequency Phases Wires Power factor Current 480 5OkVA 48A 60A Total harmonic distortion THD Dynamic regulation Dynamic response Overload 1 3 3 DC Ratings Battery voltage 25 C 480 VAC 65 SOKVA 100kVA 125kVA 150kVA 86A 96A 109A 120A 134A 150A 160A 180A 480 1 steady state conditions 480 5 transient conditions from 0 to 100 or 100 to 0 60 Hz 0 1 free running 3 phase sequence must be A B C clockwise 3 wires plus ground 480 480 VAC only 0 8 65kVA 80kVA 100kVA 125kVA 150kVA 96A 120A 150A 180A lt 2 linear load lt 3 for 100 non lin
10. CA 92626 Use this form to report any errors omissions or other problems you have experienced or to order additional hardcopies of this document free copy of this document may be downloaded from the proprietary MGE Rep Web site Please contact your MGE UPS SYSTEMS Representative for assistance NAME COMPANY STREET ADDRESS CITY I would like to order STATE ZIP quantity 75 00 each additional copies of the Comet 40 150kVA Installation and User Manual 86 160310 00 E00 would like to report the following problems with this document 1660 Scenic Avenue Costa Mesa California 92626 714 557 1636 www mgeups com Contact MGE United States MGE UPS SYSTEMS 1660 Scenic Ave Costa Mesa CA 92626 Tel 714 557 1636 800 438 7373 Fax 714 557 9788 email info mgeups com www mgeups com Canada MGE UPS SYSTEMS 19 2789 Thamesgate Drive Mississauga ON LAT 4E8 Tel 905 672 0990 877 672 0990 Fax 905 672 7667 email info mgeups com www mgeups com Latin America and Other International MGE UPS SYSTEMS 1660 Scenic Ave Costa Mesa CA 92626 Tel 714 513 7831 Fax 714 434 0199 email info mgeups com www mgeups com MGE UPS SYSTEMS
11. Cabinets are available to provide extra back up time during power outage These options are internal to the Comet Isolated Redundant System This option is used to connect the static switch and maintenance bypass to UPS without Standard Battery Subsystem External Batteries Communication Options Monitor Plus Contact 5 U Talk JBUS RS485 reserve UPS source for redundancy This option allows for the connection of a customer supplied battery system to the UPS Communication options may be used simultaneously on the Comet thus enabling communication with a wide number of computers and control devices Mini terminal for control and display of system parameters This option can be in stalled locally or remotely This option offers communication of five different signals via dry relay contacts Load on UPS Load on Bypass Operation on Battery Low Battery Shutdown Warning Summary Alarm major or minor faults This option manages an RS232 serial interface using an ASCII protocol This option enables remote monitoring of the Comet 1 4 2 Software and Communication Package Solution Pac 86 160310 00 E00 p Automatic file shutdown during power outage or severe brownout for stand alone systems p Automatic file shutdown for network servers plus additional monitoring and network communication functions p Automatic file shutdown with user friendly control panel and advanced decision making functions for Win
12. about replacement parts and customer service A Glossary provides definitions of abbreviations and terms used in this manual NOTE This manual provides technical information required for operation and maintenance of the Comet 40 150kVA Uninterruptible Power System UPS Please read this manual before operating the Comet 40 150kVA equipment Please retain this manual for future reference Symbol Usage and Section Descriptions 86 160310 00 E00 System Description and Specifications 1 0 Scope Provides general description of the Comet 40 150kVA Uninterruptible Power Systems major components available options and system specifications 1 1 General Description The Comet family consists of compact high efficiency Uninterruptible Power Systems which are available in power ratings from 40 150kVA and are optimized for compatibility with nonlinear computer type loads Computer aided UPS diagnostics and modular construction assure that any required service can be identified and completed rapidly Remote system monitoring remote annunciation of UPS performance signals and communication capabilities allow total control of the UPS by its user See Figures 1 1 and 1 2 The Comet UPS and its auxiliary equipment are designed for installation in a room where humidity and temperature can be controlled The recommended and maximum environmental parameters are listed in the Specifications section of this document Figure 1 1 Comet 40 80kVA Figur
13. indicates Load Protected 3 5 2 Operation on Battery Power When AC input power fails or is out of tolerance the Rectifier shuts down and the battery supplies the power required by the Inverter to supply the load The battery discharges p The green Load Protected LED is on The GUI display indicates the operating status of the UPS The user is warned of operation on battery power by the buzzer and by the yellow Battery Status LED This information is also available via the standard UPS MANAGER DB15 connector 3 5 3 Battery Duration During an AC input power failure the duration of Inverter operation on battery power depends on p The rated capacity of the battery P The power drawn by the load p The battery temperature p The charge level of the battery p The age of the battery The real backup time which depends on the actual load may be greater if the Inverter operates at less than full rated load It is possible during operation on battery power to increase the battery backup time by reducing the power drawn by the load shedding of non priority load A low battery shutdown warning signal is available via the standard UPS MANAGER DB15 connector for remote indications It warns the user of upcoming battery shutdown at a user determined level of remaining power On the UPS itself the buzzer beeps louder and more rapidly and the yellow Battery Status LED flashes rapidly The end of battery power occurs when th
14. local codes and regulations Not necessarily qualified to maintain or repair electrical or electronic equipment Federal Communications Commission Field effect transistor Frequency The change in frequency per unit of time Given in term of Hz per second Hz sec Ground safety Hertz frequency measurement unit 1Hz is one cycle per second See on line mode Current International Electrotechnical Commission Institute of Electrical and Electronic Engineers The input circuit from the building power panel to the equipment An electrical circuit that generates an AC voltage source from DC voltage source Insulated gate bipolar transistors Input Output Information Technology KiloVolt Ampere is equal to 1000 Volt Ampere Line Liquid Crystal Display unit Light Emitting Diode Main AC input source Bypass AC input source Milliampere Maximum Thousand circular mil standard wire sizes for multiple stranded conductors over 4 0 AWG in diameter is Roman numerical system indicating 1000 Glossary 86 160310 00 E00 Module NC NO NEC NEMA NFPA PF PN On line mode Off line mode OSHA PCA PCB PWM SCR Shipping damage SPDT Static Transfer Technician Test connector UL UPS V VA VA VAC or Vac VDC or Vdc ve Via 86 160310 00 E00 Installation and User Manual Refers to individual power inverter module Neutral Normally closed Normally open
15. terminated at the Bypass Input Terminal Block TB3 for 40 80kVA and the bypass busbars for 100 150kVA This option provides a separate AC input source for bypass operation 2 6 3 Remote Emergency Power Off REPO The control connections are available for Remote Emergency Power Off REPO through a customer supplied normally closed pushbutton With REPO connected the jumper on the REPO terminal blocks must be removed Installation 86 160310 00 E00 Installation and User Manual 2 6 4 AC Output The connections to be made are the three phases and ground cables from the load source to the UPS The output cables are terminated at the Output Terminal Block TB2 for 40 80kVA and the output busbars for 100 150KVA 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 5 Battery The connections to be made are the positive negative and ground cables from the battery cabinet to the UPS These are terminated at the appropriate connections in the UPS cabinet see Figures 2 3 and 2 4 Additionally control wires and temperature sensors in the battery cabinet must be terminated Refer to the battery cabinet installation drawings for more details Figure 2 3 Connections for Comet 40 80kVA UPS Separate Bypass Main Input Output Fan Control Fan and Input Terminal Battery Terminal Block Terminal Blo
16. 00 16873 480 208 139 54 139 32 75 832 1360 617 15169 480 480 60 54 60 32 75 832 880 400 10276 600 208 139 44 139 60 00 1524 2820 1279 16873 65kVA 52 kW 208 208 180 162 180 32 75 032 2115 960 17552 220 220 170 153 170 32 75 832 2115 960 17552 480 208 180 70 180 32 75 832 1590 721 15433 480 480 78 70 78 32 75 832 970 440 11328 600 208 180 57 180 60 00 1524 2910 1320 17552 80kVA 64 kW 208 208 222 200 222 32 75 832 2115 960 21603 220 220 210 190 210 32 75 832 2115 960 21603 480 208 222 86 222 32 75 832 1590 721 21603 480 480 96 86 96 32 75 832 970 440 13992 600 208 222 70 222 60 00 1524 2910 1320 21603 100kVA 80 kW 208 208 278 256 278 69 50 1765 3400 1543 28300 220 220 263 242 263 69 50 1765 3400 1543 28300 480 208 278 109 278 42 75 1086 2450 1112 22278 480 480 120 109 120 42 75 1086 1460 662 15420 600 600 96 89 96 96 00 2438 3700 1678 28300 600 208 218 91 278 69 50 1765 3400 1543 28300 125 100 208 208 347 316 347 69 50 1765 3400 1543 38247 220 220 328 298 328 69 50 1765 3400 1543 38247 480 208 347 134 347 42 75 1086 2450 1112 30662 480 480 150 134 150 42 75 1086 1460 662 20804 600 600 120 109 120 96 00 2438 3700 1678 38247 600 208 347 109 347 69 50 1765 3400 1543 38247 150kVA 120 kW 208 208 417 378 417 69 50 1765 3400 1543 50759 220 220 394 375 394 69 50 1765 3400 1543 50759 480 208 417 160 417 42 75 1086 2450 1112 41560 480 480 180 160 180 42 75 1086 1460 662 26351 600 600 145 131 145 69 50 1765 3700 1678 50759
17. 6 Output Power Overload Curve 3 7 Tables table description 2 acca ddaa a ee wk a Wa s page 1 1 Comet 40 150kVA Specifications 1 8 1 2 UPS Manager Dry Contact Interface 1 10 2 1 Recommended upstream protective device sizing 2 3 MGE Warranty amp Proprietary Rights for Three Phase Products MGE Standard Three Phase Warranty Proprietary Rights Statement Warranty and Product Registration User Information Product Information Warranty Extension Warranty Customer Care Center Three Phase Products Technical Support and Product Services Who to Contact Scheduling Field Service Engineer Support Return Policy for Repair of Three Phase Products RGA Glossary Reorder Form 86 160310 00 E00 Contents C iii Comet 40 150kVA CAUTION Record All Serial Numbers RECORD ALL SERIAL NUMBERS FOR THE COMET UPS AND ACCESSORIES THESE SERIAL NUMBERS WILL BE REQUIRED IF YOUR SYSTEM NEEDS SERVICE KEEP THIS MANUAL IN PLACE WHERE YOU CAN REFERENCE THE SERIAL NUMBERS IF SERVICE IS REQUIRED UPS SERIAL NUMBER BATTERY SERIAL NUMBER ADDITIONAL MODULES SERIAL NUMBERS NOTES CAUTION Record All Serial Numbers 86 160310 00 E00 86 160310 00 E00 This page left blank intentionally Installation and User Manual CV Comet 40 150kVA Symbol Usage Thi
18. 6 160310 00 E00 Maintenance Comet 40 150kVA 4 3 Replacement Parts There are no user serviceable parts inside the Comet UPS Three levels of replacement parts are available for the Comet The three levels are designated A B and C The level that you should keep on hand for your installation will vary depending on the type of maintenance planned on site and the configuration of your UPS system Having the replacement parts on hand will prevent any unacceptable delays because of time involved obtaining spares during critical periods such as system startup Any items used during start up will be replaced by MGE at no charge Contact MGE Customer Care Center at 1 800 438 7373 for specific recommendations A description of each level is provided below Level Description A This level of replacement parts consists of consumable items specifically power and control fuses It is recommended to have these items on hand during installation of the UPS systems including initial startup B This level of replacement parts is recommended when the user can tolerate short duration UPS down time to obtain replacement parts in the event of major UPS failure This level of replacement parts consists of consumable items specifically power and control fuses fans and the most critical circuit board assemblies C This level of replacement parts is recommended when the user can tolerate only minimum of down time the event of major UPS failur
19. C SWITCH BYPASS INPUT OPTIONAL RECTIFIER INVERTER MAIN INPUT BATTERY TO LOAD A 86 160310 00 E00 Operation 3 1 Comet 40 150kVA 3 2 3 1 3 Power Flow For Bypass Operation Should there be an internal fault in the UPS the load will automatically be transferred to the Static Switch If bypass AC input is within tolerance The load is supplied without interruption while the UPS is bypassed see Figure 3 3 Figure 3 3 Power Flow For Bypass Operation STATIC SWITCH BYPASS INPUT 777777 OPTIONAL RECTIFIER INVERTER MAIN INPUT TO LOAD BATTERY _ Graphical User Interface Controls and Indicators The Graphical User Interface GUI display controls and indicators are located on the front panel in the upper left hand corner of the Comet UPS and consist of the following See Figure 3 4 for arrangement p Graphical User Interface GUI display p An alert buzzer p Four 4 LED s which indicate the overall operating status of the UPS p An Inverter ON an Inverter OFF and an EPO pushbutton p Three 3 control keys The basic Comet indications consist of the following p Normal operation load protected p Battery power is not available load not protected p Downgraded operation fault p Danger of a break in the supply of power to the load load not protected p Operation on battery power When the buzzer is activated it will provide an audible warni
20. Optional F1 F2 F3 Input Fuses F4 F5 F6 Output Fuses SR1 Rotary Switch Rectifier Static Switch Assembly Inverter Assembly Feedback PCA DC Power Supply PCA Interconnect PCA High Frequency Power Supply PCA FU1 FU6 Power Supply Fuses Teleservice Receptacles J1 J2 amp Fuse FU13 Heatsink Cooling Fans TB3 Separate Bypass Input Terminal Block Battery Connections TB1 Main Input Terminal Block TB2 Output Terminal Block SR2 Fan Control Switch FU7 FU12 Fan and Teleservice Fuses Ground Busbar Neutral Busbar Bottom of Top Entry Channel Battery Charger 86 160310 00 E00 Installation and User Manual Figure 1 6 Rear View of the Comet 40 80kVA TOP ENTRY CONDUIT LANDING N TOP ENTRY CHANNEL T1 INPUT TRANSFORMER OPTIONAL T2 OUTPUT TRANSFORMER OPTIONAL 86 160310 00 E00 K y EN System Description and Specifications Comet 40 150kVA Figure 1 7 Front View of the Comet 100 150kVA 1 Input Contactor 2 K3N Output Contactor 3 2 Bypass Input 4 F1 F2 F3 Input Fuses 5 F4 F5 F6 Output Fuses 6 SR1 Rotary Switch 7 Rectifier Static Switch 9 Inverter Assembly Chopper Assembly Hr arnie H N reg 0 11 Interconnect PCA 7 l IK 7 12 Gro
21. ad protected LED Inverter on Inverter off Fault Reset Security Key Buzzer Reset This display provides specific information concerning normal UPS operation as well as faults This red Emergency Power Off EPO pushbutton is used to stop the unit during an emergency situation only All power is removed from the load This red LED turns on when any of these conditions occur P Direct supply of power to the load by AC input power via the Static Switch because of Inverter shutdown voluntary or following an overload or an internal fault p Battery power is not available Battery circuit breaker is the OFF position or battery not connected This yellow LED indicates an operating fault or an environmental fault However the load continues to be supplied by the Inverter This yellow LED indicates p Inverter operation on battery power following an AC input failure or detection of an AC input voltage outside of tolerances p It flashes to indicate that the low battery shutdown warning level has been reached p If the LED flashes when the system is not on battery power battery conditions should be checked This green LED indicates that the Comet is operating normally The load is protected and supplied via the Inverter output Bypass Switch SR1 must be in the NORMAL position This green pushbutton is used to start the inverter This gray pushbutton is used to stop the inverter This key clears the fault
22. ck Switch Teleservice Fuses Block TB3 Connections TB1 TB2 SR2 FU7 FU12 Optional elle lle Ground Busbar Neutral Busbar ru MF Figure 2 4 Connections for Comet 100 150kVA UPS OUTPUT BYPASS INPUT 86 160310 00 E00 Installation 2 5 COMET 40 150kVA Chaptername 86 160310 00 E00 Comet 40 150kVA This page left blank intentionally 86 160310 00 E00 3 0 3 1 Operation Scope Important information on the Comet 40 150kVA systems operation procedure sequences for normal on battery and bypass operation with descriptions of the control and display indicators Power Flow 3 1 1 Power Flow For Normal Operation During normal operation the AC input source supplies the Rectifier which converts the incoming AC power to DC The rectifier in turn supplies the Inverter which converts DC power to AC to supply the attached load see Figure 3 1 Figure 3 1 Power Flow For Normal Operation STATIC SWITCH BYPASS INPUT OPTIONAL RECTIFIER hid TO LOAD BATTERY 3 1 2 Power Flow For On Battery Operation When AC input power fails the UPS goes to on battery operation DC power is supplied from the UPS battery system to the inverter which converts battery power DC to AC power to supply the attached load see Figure 3 2 Figure 3 2 Power Flow For On Battery Operation STATI
23. cle in which MGE UPS SYSTEMS INC retains any and all intellectual property rights including exclusive rights of use and or manufacture and or sale Possession of this information does not convey any permission to reproduce print manufacture or have made the article or articles shown herein Such permission may be granted only by specific written authorization signed by an authorized officer of MGE UPS SYSTEMS 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 For Three Phase Warranty outside of the United States Canada and Mexico refer to Three Phase International Warranty January 2005 Rev C00 Warranty and Product Registration Thank you for choosing MGE UPS SYSTEMS ING for your power protection distribution and quality requirements We are pleased to have you join our increasing family of users In order to maximize the value you receive from this product and to ensure that you are kept informed of product or software updates we recommend that you take a few minutes to register your new purchase You may register online at the URL noted below Should you not have Internet access you may mail or fax this form back attn Warranty Registration as indicated at the bottom of the page Regi
24. dows This package includes an easy to use load System Description and Specifications 1 11 COMET 40 150kVA 1 12 Chaptername 86 160310 00 E00 Comet 40 150kVA This page left blank intentionally 1 13 86 160310 00 E00 2 0 2 1 2 2 Installation Scope Installation of the Comet 40 150 UPS which include receiving handling and storage procedures prerequisites to installation installation procedures and startup procedures CAUTION Scheduling of the MGE Field Service Engineers typically should be done 7 to 10 days before they are required on site If the startup of the product is critical to maintaining your schedule please call the MGE toll free telephone number at 1 800 438 7373 for assistance Receiving Before accepting the shipment from the freight carrier inspect the exterior surfaces of shipping container s packaging and equipment for damage that may have occurred during transit If the shipping containers or equipment show evidence of damage note the damage on the receiving document bill of lading prior to signing for receipt of equipment Verify that the equipment nameplate corresponds with the equipment ordered Damage claims should be filed directly with the carrier Replacements for damaged components can be ordered by calling 1 800 438 7373 Handling Any equipment shipped on a shipping pallet is intended for handling by a pallet jack or a fork lift truck Move the equipmen
25. e This level of replacement parts consists of consumable items specifically power and control fuses fans significant set of circuit board assemblies Maintenance 86 160310 00 E00 Warranty amp Proprietary Rights Statement for Three Phase Products Applicable within the United States Canada and Mexico MGE Standard Three Phase Warranty MGE UPS SYSTEMS INC MGE warrants three phase products it manufactures to be free from defects in materials and workmanship for a period of three hundred sixty five 365 days counting from the date of purchase by or for the first end user Purchaser if applicable the date of MGE s completion of initial startup of the subject product provided however said warranty shall not exceed eighteen 18 months from the date of delivery of the subject product to Purchaser the Warranty Period MGE s liability hereunder is limited to replacing or repairing at MGE s factory or on the job site at MGE s option any part or parts that are defective and reported to MGE during the Warranty Period MGE 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 for repair or replacement must be sent freight prepaid to its factory Purchaser must obtain MGE s Return Goods Authorization prior to returning items The conditions stated herein must be
26. e please ask for confirma tion of the information given in this publication ATTENTION Comme les normes sp cifications et produits peuvent changer veuillez demander confirmation des informations contenues dans cette publication WARNUNG Normen Spezifizierungen und Pl ne unterliegen Anderungen Bitte verlangen Sie eine Best tigung ber alle Informationen die in dieser Ausgabe gemacht wurden 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 interfer ence 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 To reduce the risk of fire or electric shock install controlled indoor environment free of conductive contaminants This equipment is intended only for installations in RESTRICTED ACCESS LOCATION ATTE NTION Pour r duire le riske d inccendie ou d lectrocution installer dans une enciente int rieure contr l e en temp rature et humidit et sans contaminants c
27. e 1 2 Comet 100 150kVA 86 160310 00 E00 System Description and Specifications 1 1 Comet 40 150kVA Figure 1 3 and 1 4 show single line diagrams of a typical UPS system installation During normal operation utility power Main Input is supplied to the UPS where it is converted to DC voltage The Inverter converts the DC voltage from the Rectifier to three phase regulated AC voltage which supplies the critical load During power failure conditions the Inverter is supplied by the stored energy in the batteries and the load is powered continuously with no disruption Figure 1 3 Single Line Diagram for the Comet 40 80kVA UPS CABINET STATIC SWITCH BYPASS AC INPUT P OPTIONAL TO AC CRITICAL INPUT OUTPUT LOAD FUSES RECTIFIER INVERTER FUSES Ne BATTERY Figure 1 4 Single Line Diagram for the Comet 100 150kVA UPS CABINET STATIC SWITCH Cat EXE T Dm 1 OUTPUT INPUT FUSES RECTIFIER INVERTER FUSES 77777377 Jari BYPASS AC INPUT TO CRITICAL LOAD MAIN AC INPUT BATTERY 1 2 System Description and Specifications 86 160310 00 E00 1 2 Major Components Installation and User Manual The following is description of the cabinets and major components Refer to Figures 1 5 to 1 8 UPS Cabinet Auxiliary Cabinet Battery Cabinet Rectifier Inverter Static Switch Battery Syst
28. e Bypass line and moving SR1 to NORMAL will result in interruption of power to the load 1 Move the fan control switch SR2 to the ON position if the cooling fans were de energized during maintenance 2 Turn the manual bypass switch SR1 to the TRANSFER position 3 Wait for the GUI display to go on at least 5 seconds 4 Turn the Inverter off by pressing the gray Inverter OFF pushbutton on the front panel for approximately 3 seconds if your Comet has been programmed to automatically restart CAUTION ALWAYS turn the Inverter off before rotating the Manual Bypass Switch SR1 5 Close the battery disconnect circuit breaker s 6 Turn the manual bypass switch SR1 to the NORMAL position 7 Turn the Inverter on by pressing the green Inverter ON pushbutton on the front panel If the transfer conditions are not satisfied bypass out of tolerance or other reason a forced transfer will be required Refer to the Forced Transfers section for more information Now the UPS is in normal operating mode The green Load Protected LED is illuminated on the front panel and the operating status of the UPS is provided by the GUI display 86 160310 00 E00 Operation 3 9 Comet 40 150kVA 3 9 3 10 3 10 Shutdown Procedures 3 9 1 Inverter Shutdown Press and hold the gray Inverter OFF pushbutton for 3 seconds The green Load Protected LED goes off The red Load Not Protected LED goes on T
29. e battery reaches shutdown level At this point the Inverter shuts down and the UPS goes into Stand By mode Load is no longer supported If the input AC power does not return to within tolerance within approximately 2 hours the unit will shutdown Once input AC power returns the batteries begin their charging cycle It takes approximately 10 hours of online operation to restore 10 minutes of backup time 3 5 3 1 Return to AC Power When the AC input power failure ends or power returns to within tolerances If the end of battery backup power was not reached the Comet returns to normal operating mode P If the end of battery backup power was reached and unit is in Standby mode the Rectifier and the Inverter automatically start up the inverter must be manually started if the system is in manual startup mode D If the end of Stand By mode was reached follow the Startup procedure Operation 86 160310 00 E00 Installation and User Manual 3 5 4 Overload When an Inverter temporary overload occurs the load is transferred to the Static Switch Return to normal mode of operation is automatic following elimination of the overload The Inverter can handle continuous overload for given duration depending on the size of the output current overload see Figure 3 5 or the output power overload see Figure 3 6 When an overload occurs The buzzer sounds The yellow Fault LED goes on The Inverter shuts down at the
30. e temperature less than 25 C This charges the battery thus avoiding possible irreversible damage 86 160310 00 E00 Certification Standards and Safety of Persons iii Comet 40 150kVA This page left blank intentionally iv 86 160310 00 E00 Contents section 0 se 6110 kiska EEE NE page Revision AS ON J ul usss seen eq d de IMPORTANT SAFETY INSTRUCTIONS Certification Standards Three Phase UPS iii Safety of Pel SOS iii Product Safety m iii Special Precautions iii CAUTION Record All Serial Numbers C iv Symbol Usage u CR dudes dard C Vi Section Descriptions C vi Section 1 System Description and Specifications 1 0 TAS 1 1 1 1 General Description 1 1 1 2 Major Components 1 3 1 3 wells Ae 1 8 1 3 1 AC Input Ratings 1 9 1 3 2 AC Output Ratings 1 9 1 00 DO ISSUES Lae ee aaa 1 9 1 3 4 Mechanical Specifications UPS Cabinet Only 1 10 1 3 5 Environmental Specifications 1 10 1 3 6 DB15 Connector Pinouts and Designations 1 10 1 4 Options and Accessories
31. ear load with a crest factor of less than 3 0 1 for balanced load 2 5 for 100 unbalanced load 5 for 100 step load change 105 110 of rated current for 10 minutes gt 110 130 of rated current for 1 minute gt 130 150 of rated current for 10 seconds gt 150 of rated current for 0 15 seconds float 490 nominal 432 Vdc minimum 360 Vdc Maximum Current at cut off voltage 96 SOKVA 120 ADC 86 160310 00 E00 65 154 ADC 80kVA 189 ADC 100kVA 235 ADC 125kVA 294 ADC 150kVA 353 ADC System Description and Specifications Comet 40 150kVA 1 3 4 Mechanical Specifications UPS Cabinet Only Height 66 70 in 1694 mm Width 32 75 in 832 mm Depth 33 42 in 823 mm Weight at 480 and 480 out 40 50kVA 65 80kVA 100 150kVA 880 Ibs 400 kg 970 Ibs 440 kg 1460 Ibs 662 kg 1 3 5 Environmental Specifications Temperature Operating 0 C to 30 32 F to 86 F continuous 15 C 60 F to lt 25 C lt 77 F recommended 40 C 104 F up to 8 hrs at 75 load Non operating and storage 30 C to 70 C 22 F to 158 F Humidity 0 to 95 non condensing Altitude lt 3000 ft 1000m up to 6000 ft lt 2000 m 28 C 82 F maximum 1 3 6 0815 Connector Pinouts and Designations The UPS Manager connector enables communication with the most common computer systems AS 400 NOVELL etc or with the optional UPS Manager UM1 software
32. ed source like the Comet 208 208V UPS CAUTION The customer supplied upstream protective device shall open in one cycle when 10 times the output rated current is applied or in the event of an output short circuit when the unit is working on Static Switch Refer to the upstream circuit breaker manufacturer s characteristic curves for proper trip settings Table 2 1 Recommended upstream protective device sizing INPUT VOLTAGE 40kVA 50 65 80kVA 100kVA 125kVA 150kVA 208 150A 175A 225A 300A 350A 450A 500A 220 150A 175A 225A 300A 350A 450A 500A 480 80A 100A 125A 150A 200A 225A 600 60A 70A 80A 100A 125A 150A 200A Size determined using nominal input currents 86 160310 00 E00 Installation 2 3 Comet 40 150kVA 2 5 2 6 Installation Procedures The steps to be followed are p Placement of the UPS and associated equipment p Connection of input power output power and control cables Installation of UPS equipment must be handled by skilled technicians and electrician s familiar with the special requirements of high energy electrical equipment We strongly recommend contracting MGE Customer Support Services for start up of the installed Comet UPS system Do not allow unqualified personnel to handle or operate the Comet UPS Refer to the installation drawings for proper placement and connections of auxiliary cabinets 2 5 1 Placement Move the Comet UPS battery cabinets if any and auxiliary cabin
33. em 86 160310 00 E00 Converts the input AC power to direct current and charges the battery DC power is converted back to clean AC power by the inverter for the critical load Section 3 describes the operation in detail Performs the voltage conversion for the input AC and or bypass AC using step up and or step down transformers The battery cabinet 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 tolerances The internal Battery Charger maintains the charge of the battery system The DC output voltage of the charger is tempera ture regulated to ensure an optimal charge voltage If customer supplied battery system is to be used an external battery charger may be necessary The standard battery system is housed separate enclosure For systems where additional back up time is required up to two 2 additional battery cabinets are available standard battery cabinet is available an adjacent configuration or stand alone configuration Adjacent battery cabinets are attached to the right side of the UPS using c brackets provided with the cabinet Stand alone battery cabinets are remote from the UPS Refer to the battery cabinet installation drawing for more details An external battery system can also be supplied by the customer Converts the AC input voltage from the utility source into a DC voltage sup
34. end of its corresponding overload time The load is supplied by AC input power via the Static Switch The green Load Protected LED goes off The red Load Not Protected LED goes on The operating status of the UPS is provided by the GUI display If the overload continues during operation via the Static Switch the supply of power to the load is interrupted after a specified time When the Comet shuts down because of continuous overload the Fault Reset key must be pressed prior to return to normal operation and after elimination of the overload Figure 3 5 Output Current Overload Curve 15 rated load current 0 15 5 1 05 1 1 1 3 1 5 1 7 1 9 3 Figure 3 6 Output Power Curve time 1 mn 10 5 15 rated load power 0 35 1 7 1 9 2 P kw 86 160310 00 E00 Operation 3 7 Comet 40 150kVA 3 6 3 7 3 8 Emergency Shutdown Using EPO REPO A CAUTION Pressing the Emergency Power Off EPO or Remote Emergency Power Off REPO pushbutton disconnects the attached load The EPO is to be used during emergency situations only where a hazard to personnel or equipment exists such as during a fire DO NOT USE THE EPO TO TURN THE UPS ON OR OFF Follow the procedures listed in this section for turning the Inverter on and off During an emergency situation such as a fire in the computer or electrical room the UPS and all downstream devices can be instantly shut down by pressing the EPO p
35. ets if any to their final location see Figure 2 2 For cabinets installed adjacent to each other alignment is critical to properly install the mechanical and cable interconnections Allow at least 36 inches clearance above all cabinets for maintenance and cooling Figure 2 2 Placement of UPS and other Cabinets For side and rear clearances BATTERY refer to each cabinet s CABINET 5 installation drawing 36 recommended Connections Electrical connections and cabinet interconnection will vary depending upon the configuration of your Comet UPS system Refer to Figures 2 3 amp 2 4 and to the installation drawings supplied with your equipment CAUTION Before making any electrical connections verify that all battery disconnect circuit breaker QF1 are in the off position Customer supplied upstream protective devices and distribution circuits should be OFF 2 6 1 Main AC Input The connections to be made are the three phases and ground cables from the utility AC power source to the UPS The main AC input cables are terminated at the Main Input Terminal Block TB1 for 40 80kVA and the input busbars for 100 150kVA Complete wiring instructions for your installation are provided on the installation drawings supplied with the equipment 2 6 2 Bypass AC Input Optional The connections to be made are the three phases and ground cables from the bypass AC input power source to the UPS The bypass AC input cables are
36. he buzzer sounds The Inverter stops if the transfer conditions are correct The load is transferred and supplied via the Static Switch 3 9 2 Powering Down It is recommended not to power down the Comet for long periods because the battery should remained charged However to carry out a power down proceed as follows p Shut down the Inverter p Put the battery circuit breaker in the OFF position p Put the upstream main circuit breaker the OFF position p All the indicating LED s the control panel go off Alarms 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 different LED s and the GUI messages displayed on the panel If an alarm is present and the load still functions it is supplied via the Static Switch i e it is not protected Table 3 1 Alarm Indications status or action producing the indication mi inverter start up phase prior to load transfer The inverter on button has been pressed m normal operation m load supplied by Comet UPS SR1 in normal position inverter shutdown following pressing of the inverter off button or a major fault mi load supplied via the static switch m operation on battery power load supplied by Comet UPS m end of battery power or battery should be checked B mino
37. ible to pay any invoice therefore This warranty shall be exclusive of any and all other warranties express or implied and may be modified only by writing signed by an authorized officer of MGE UPS SYSTEMS This warranty shall extend to the Purchaser but to no one else Accessories supplied by MGE but manufactured by others carry any warranty the manufactur ers have made to MGE 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 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 any products 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 ING be responsible for consequential damages or for any other damages except as expressly stated herein Proprietary Rights Statement The information in this manual is the property of MGE UPS SYSTEMS INC and represents a proprietary arti
38. met for MGE s warranty to be valid MGE will not be liable for any damage done by unauthorized repair work unauthorized replacement parts from any misappli cation of the subject product for damage due to accident abuse or act of God such as earthquake flood inclement weather rain or fire or relating to Purchaser s failure to follow proper environmental conditions for the product In no event shall MGE be liable for loss damage or expense directly or indirectly arising from the use of or any defects in the subject product from any other cause except as expressly stated in this warranty 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 PARTICULAR PURPOSE OR USE OR NON INFRINGEMENT MGE is not liable for and Purchaser waives any right of action it has or may have against MGE 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 or the use operation or maintenance of the subject product The warranty stated herein includes parts and labor however MGE will not be liable for any labor subcontracted or performed by Purchaser for preparation of the warranted item for return to MGE s factory or for preparation work for field repair or replacement and MGE will not be respons
39. ng to the operator by sounding a pulsed beep when any of the following conditions occur p The load is supplied directly by AC input power via the Static Switch p The Inverter is operating on battery power p Any operating faults or change in operating status 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 sound volume and the frequency of the beeps increase In the event of an Inverter shutdown a continuous alarm is emitted A buzzer reset key is provided on the front panel Detection of a new fault will reactivate the buzzer Operation 86 160310 00 E00 Installation and User Manual Figure 3 4 Comet Front Panel GUI Controls and Indicators Load Protected MGE Ups SS TEMS Eas 2 EMERGENCY POWER OFF 1 Graphical User Interface GUI Display 7 Inverter ON green pushbutton 2 Emergency Power Off Switch Inverter OFF gray pushbutton 3 Load Not Protected red LED 9 Fault Reset Key 4 Fault yellow LED Security Key 5 Battery Status yellow LED 11 Buzzer Reset Key 6 Load Protected green LED NOTE For details on the Graphical User Interface GUI display please refer to manual 86 160316 00 86 160310 00 E00 Operation 3 3 Comet 40 150kVA Graphical User Interface Display Emergency Power Off Load not protected LED Fault LED Battery Status LED Lo
40. onducteurs Ce mat riel est destin seulement pour des installations dans un EMPLACEMENT RESTREINT D ACCES WARNUNG Um die Gefahr von Feuer und elektrischem Schock zu reduzieren muss das Ger t in einem temperatur und feuchtigkeitskontrollierten Raum frei von leitungsf higen Verunreinigungen installiert werden Dieses Ger t ist nur f r die Installation an einem Ort mit qeingeschrankter Zugangserlaubnis vorgesehen Diese Ausr stung ist nur f r Anlagen in einem EINGESCHRaNKTEN ZUGRIFF STANDORT bestimmti i Important Safety Instructions 86 160310 00 E00 Installation and User Manual 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 Certification Standards Three Phase UPS p IEC 1004 ANSI C62 41 Standards for Surge Withstand Ability FCC Part 15 Subpart J Class A UL cUL 1778 Standard for Uninterruptible Power Supply Equipment NEMA PE 1 Uninterruptible Power Systems NFPA 70 National Electrical Code ISO 9001 Safety of Persons p The UPS has its own internal power source the battery Consequently the power outlets may be energized even if the UPS is disconnected from the AC power source p The UPS must be properly grounded p The battery supplied with the UPS contains small amount
41. plying the Inverter Converts the DC voltage supplied from either the Rectifier or the battery system into three phase AC voltage An AC output filter is used to achieve computer grade sinewave output voltage waveform with total harmonic distortion of less than 2 under linear load conditions Transfers the load between the Inverter output and the bypass AC source without interrupting the supply of power to the load allowing the load to continue operation in the event of a UPS fault The Static Switch circuit assures that voltage from the UPS output cannot be fed back to the utility input lines 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 tolerances The internal Battery Charger maintains the charge of the battery system The DC output voltage of the charger is temperature regulated to ensure an optimal charge voltage If customer supplied battery system is to be used an external battery charger may be necessary System Description and Specifications Comet 40 150kVA Figure 1 5 Front View of the Comet 40 80 PET Lol am ________ j Von SER System Description and Specifications 2 2 99 C 9 G9 2 9 2 2 0 0 CO KA1 Input Contactor K3N Output Contactor KA2 Bypass Input Contactor
42. r fault load continues to be supplied via inverter m UPS shutdown E load supplied via maintenance bypass Legend of alarm indications table UU buzzer off light off buzzer on 00 ra light on light flashing ZIN Operation 86 160310 00 E00 4 0 4 1 4 2 Maintenance Scope Preventive maintenance and battery safety instructions for Comet 40 150kVA UPS and information about replacement parts and customer service Battery Safety IMPORTANT SAFETY INSTRUCTIONS FOR SERVICING BATTERIES A Servicing of batteries should be performed or supervised by personnel knowledgeable with batteries and the required precautions Keep unauthorized personnel away from batteries When replacing batteries use the same model and manufacturer of batteries CAUTION Do not dispose of battery or batteries in a fire The battery may explode CAUTION Do not open or mutilate the battery or batteries Released electrolyte is harmful to the skin and eyes It may be toxic E CAUTION battery can present a risk of electrical shock and high short circuit current The following precautions should be observed when working with batteries 1 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 Disconnect charging source prior to connecting or disconnecting battery terminals po XT ws eS D Determine if ground fa
43. rol of temperature and humidity is provided The maximum operating and recommended environmental parameters are provided in the Specifications section of this document The Comet UPS generates heat and exhausts air through the top portion of its enclosure Heat loss data is provided in Table 1 1 Consult the installation drawings provided with your equipment 2 2 Installation 86 160310 00 E00 Installation and User Manual 2 4 2 Mechanical The Comet UPS can be mounted raised computer room floor or flush mounted on concrete floor All floors must be level On a raised floor conduits can be run below the floor with cut outs made in the floor tiles as shown on the installation drawings Allow at least three feet of clearance in front of the UPS for normal operation access to the UPS controls The Comet requires at least 36 inches top clearance for ventilation 2 4 3 Electrical Electrical service for the Comet UPS should be supplied on its own dedicated branch circuit Main input cables and upstream protective devices must be provided and sized per the National Electrical Code NEC ANSI NFPA 70 latest issue and as appropriate for your load and distribution requirements Cable sizing data is provided on the installation drawings supplied with the equipment The Comet 480 480V UPS is separately derived source The Comet 208 208V UPS is separately derived source The neutral must be grounded on separately deriv
44. s manual uses five icon symbols with text to convey important information and tips WARNING Information provided to protect the user and service personnel against safety hazards and or possible equipment damage CAUTION Information provided to protect the user and service personnel against possible equipment damage A ELECTRICAL Information provided to protect the user and service personnel against possible electrical hazard and equipment damage IMPORTANT Information provided as an operating instruction or as an operating tip NOTE Information provided as an operating tip or an equipment feature Section Descriptions C VI 1 System Description and Specifications Provides a general description of the Comet 40 150kVA Uninterruptible Power Systems major components available options and system specifications 2 Installation Installation of the Comet 40 150kVA UPS which include receiving handling and storage procedures prerequisites to installation installation procedures and startup procedures 3 Operation Important information on the Comet 40 150kVA systems operation procedure sequences for normal on battery and bypass operation with descriptions of the control and display indicators NOTE For details on the Graphical User Interface GUI display please refer to manual 86 160316 00 4 Maintenance Preventive maintenance and battery safety instructions for Comet 40 150kVA UPS and information
45. s of toxic materials To avoid accidents the directives listed below must be observed 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 Batteries constitute a danger electrical shock burns The short circuit current may be very high Precautions must be taken for all handling remove watches rings bracelets and any other metal objects use tools with insulated handles Do not lay tools or metal parts on top of batteries Product Safety A protection circuit breaker must be installed upstream and be easily accessible The UPS can be disconnected from the AC power source by opening the input circuit breaker UPS must be connected to a nearby power source that is easily accessible Never block the ventilation grates of the UPS The UPS must be installed in a controlled environment Special Precautions p The UPS connection instructions and operation described in the manual must be followed in the indicated order p Check that the indications on the rating plate correspond to your AC powered system and to the actual electrical consumption of all the equipment to be connected to the UPS p Before and after the installation if the UPS remains de energized for a long period the UPS must be energized for a period of 24 hours at least once every 3 months for a normal storag
46. s stored in memory Clearing of alarms in memory is accepted only after the alarm conditions themselves have been corrected This key enables forced operation The security key must be held down while the desired function is executed Refer to the Forced Transfer section This key allows the user to silence the buzzer after particular alarm However the buzzer will sound if another alarm occurs Operation 86 160310 00 E00 3 3 3 4 Installation and User Manual Startup Procedures 3 3 1 Preliminary Checks p Check the settings of the protection devices P Verify that the battery circuit breaker s are in the OFF position p Verify that the Manual Bypass Switch SR1 is set to the NORMAL position p Verify that the fan switch SR2 is set to the ON position p Check that the ventilation system is not blocked air entry through the bottom front and exhaust through the top p Check that there is a minimum of 36 inches clearance at the front and top for ventilation p Check that the Comet no longer rests on its 4 wheels lifting levelers in place p Check that the load circuit breaker s where applicable are in the OFF position 3 3 2 Powering Up the Comet A CAUTION As soon as AC input power is supplied to the Comet customer supplied up stream circuit breaker is in the ON position the load is initially supplied via the Static Switch The Graphical User Interface GUI display will begin to startup
47. sound silence the alarm by pressing the Buzzer Reset pushbutton If the transfer conditions are not satisfied bypass out of tolerance or other reason a forced transfer will be required Refer to the Forced Transfers section for more information 2 Switch the battery circuit breaker QF1 to the OFF position NOTE The battery circuit breaker QF1 will automatically trip open if left in the ON position when the UPS is placed in the Maintenance Bypass mode 3 Turn the manual bypass switch to the TRANSFER position then to the BYPASS position 4 All indicating LED s go off Operation 86 160310 00 E00 Installation and User Manual NOTE The cooling fans will remain operational when the UPS is placed on Maintenance Bypass mode to prevent the optional input output transformers inside the UPS from overheating If it is necessary to de energize the fans move the fan control switch SR2 to the OFF position CAUTION In this mode of operation the UPS is ready for maintenance but voltage is still present on terminal blocks and various internal components Now the UPS is ready for maintenance 3 8 2 From Maintenance Bypass to Normal Mode WARNING Failure to follow the proper Startup sequence will result in load loss After SR1 is set to TRANSFER it takes the UPS five 5 to six 6 seconds to test the input power before turning on the Static Switch During this time the load is still supplied by the Maintenanc
48. ster your product at http www mgeups com email warranty menu htm Please be prepared with the following information to register and validate your product s warranty keep informed on software and product updates and register your extension Warranty if purchased with the product User Information Last name First name Company name Address Zip code City State Province Country Tel Fax Email Product Information Model Serial Number Date of purchase Warranty Extension Warranty have purchased warranty extension Warranty Reference Contract Number Thank you from all of us at MGE MGE UPS SYSTEMS INC 1660 Scenic Avenue Costa Mesa CA 92626 USA Tel 714 557 1636 Fax 714 557 9788 41 000154 53 Rev B02 8 2005 MGE Customer Care Center Three Phase Products Technical Support and Product Services Technical questions If you encounter problem while following the instructions in this manual or have questions about the operation repair or servicing of your equipment please direct calls to MGE UPS SYSTEMS ING Customer Care Center or visit our web site www mgeups com for complete service information To insure that your questions are correctly answered please obtain the serial number of the unit and include them in any discussions or correspondence Serial number Who To Contact Customer Care Center 1 800 438 7373 Hours 24 7 Customer FAQ or International calls 1 714 557 1636
49. t to its intended location while still mounted on its pallet and remove the equipment from the pallet when it is near its final location See Figure 2 1 The Comet UPS and optional auxiliary cabinets have heavy duty casters to allow the equipment to be moved into position easily once they have been unloaded from the shipping truck Once the UPS is in its final position the leveling jacks on all four bottom corners should be lowered to secure the cabinet in place Refer to the installation drawings that were shipped with the cabinets Battery cabinet weighing less than 3000 Ibs are equipped with casters for ease of handling on site For shipment these cabinets are mounted on pallets to prevent movement on ramps and other inclined surfaces A forklift 4000 Ibs capacity or greater is required to remove the battery cabinet from its pallet The 42 battery cabinets should be lifted from the side only For battery cabinets weighing more than 3000 Ibs no casters are provided and therefore must be moved by forklift only 86 160310 00 E00 Installation Comet 40 150kVA If the equipment is to be stored for more than three months before installation it should be unpacked and connected to an AC input source to allow the batteries to be recharged Refer to the installation instructions that follow and the installation drawings Figure 2 1 The Comet 100 150kVA on Pallet MGE
50. tional Standard Institute American Wire Gauge Electrical circuit interrupter British thermal unit Defined as the amount of heat required to raise the tempera ture of one pound of water by 1 F See Static Transfer switch See off line mode The company or individual responsible for delivering goods from one location to another Common Circuit breaker Centimeter Canadian Standards Association Decibels Direct current A flexible or rigid tube enclosing electrical conductors Glossary 1 Comet 40 150kVA C S S Current rating dBA dBrnC DC or dc Digital Meter Earth ground ECO Mode Electrician FCC FET Frea Frequency slew rate GND Hz Inverter mode IEEE Input branch circuit Inverter IGBT I O or IT KVA L LCD LED Mains or Mains 1 Mains 2 MCM Customer Support Service The maximum current that conductor or equipment can carry reliably without damage Decibel Adjusted Decibel above reference noise Direct current or voltage The LCD display on the front panel of inverter system ground circuit that has contact with the earth Operating mode by which the load is supplied directly by the AC source if it is within the tolerances defined by the user This mode reduces the consumption of electrical power Refers to an installation electrician qualified to install heavy duty electrical components in accordance with
51. ults exists If so remove the source of 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 Preventive Maintenance The following preventive maintenance routines should be considered the minimum requirements your installation and site may require additional preventive maintenance to assure optimal performance from your installed Comet UPS and associated equipment These routines should be performed twice a year more often if required We strongly recommend contracting MGE Customer Support Services for preventive and remedial maintenance at 1 800 438 7373 The technician or electrician performing preventive maintenance on the UPS must be familiar with the indicators controls and operation of the UPS a Isolate and de energize all Comet UPS equipment for all maintenance operations Lock and tag all upstream circuit breaker s during maintenance b Ensure that all equipment is clean and free of dust dirt and debris The exterior of the UPS enclosure may be cleaned with a mild solution of soap and water lightly applied with a lint free cloth c Clean replace the air intake filters exhaust plates and the enclosure interior with a vacuum cleaner d Initiate the startup procedure as described in Section 3 e Test the main operating sequences as applicable to your installation see Section 3 8
52. und Busbar PER 13 Neutral Busbar option Ml Charger PCA 15 Heatsink Cooling Fans DC Cap Modules 17 TB5 Control Terminal Block FU1 FU21 Control Fuses Power Supplies Assembly TH TEN 5 n 1 6 System Description and Specifications 86 160310 00 E00 Installation and User Manual Figure 1 8 Front View of Communications Components for the Comet 100 150 TOP CONDUIT LANDING FOR CABLE ACCESS TO PCA S COMMUNICATION PCAs 7 NS SAM Ft NTN y ET v REST NNN BOTTOM CONDUIT LANDING 86 160310 00 E00 System Description and Specifications Comet 40 150kVA 1 3 Specifications The Comet 40 150kVA UPS systems are rated for various input and output voltages see Table 1 1 When different input and or output voltages are specified optional transformers provide step up down functions as required Table 1 1 Comet 40 150kVA Specifications INPUT OUTPUT OUTPUT CURRENT TOTAL NET HEAT VOLTAGE VOLTAGE CURRENT on UPS WIDTH WEIGHT LOSS VAC Amperes on bypass in mm Ib kg Btu hr Amperes 40kVA 32 kW 208 208 111 102 111 32 75 832 1760 800 13500 220 220 105 96 105 32 75 832 1760 800 13500 480 208 111 43 111 32 75 832 1360 617 12135 480 480 48 43 48 32 75 832 880 400 8220 600 208 111 35 111 60 00 1524 2820 1279 13500 50kVA 40 kW 208 208 139 127 139 32 75 832 1760 800 16873 220 220 131 120 131 32 751632 1760 8
53. ushbutton on the front panel of the UPS cabinet or by pressing the Remote Emergency Power Off REPO optional pushbutton The EPO or REPO pushbuttons should not be used for normal shutdown of the equipment If the EPO pushbutton has been pressed it must be reset by pressing it again and by pressing the Fault Reset key on the front panel to allow the UPS to restart Forced Transfer CAUTION Using the forced transfer functions will cause the load to experience a power interruption for a minimum of 500 milliseconds Be certain that the load can tolerate this interruption Forced transfer is required if bypass input is out of tolerance The load can be transferred from the Inverter output to the bypass input source or back with a power interruption of 500 milliseconds Transferring the Load to Bypass Input From Inverter On the front panel press the Security key and hold it while pressing the gray Inverter OFF pushbutton for 3 seconds Transferring the Load to Inverter From Bypass Input On the front panel press the Security key and hold it while pressing the green Inverter ON pushbutton for 3 seconds Maintenance Bypass This procedure assumes that the UPS is operating normally with the attached load supplied via the Inverter 3 8 1 From Normal Maintenance Bypass Mode 1 Stop the Inverter by pressing the gray Inverter OFF pushbutton on the UPS front panel for approximately three 3 seconds The audible alarm will
54. www mgeups com x gt s lA S pum gt S Gi w s yg E S Q 3 5 2 S S gt lt UPS SYSTEMS Revision History Installation and User Manual Comet 40 150kVA Installation and User Manual Comet 40 150kVA UPS Installation and User Manual 86 160310 00 Revision A00 B00 C00 D00 E00 Initial Release ECN 289 91 ECN 290 30 ECN 002456 ECN 004466 Copyright 2005 MGE UPS SYSTEMS INC All rights reserved Printed in U S A MGE UPS SYSTEMS INC 1660 Scenic Avenue Costa Mesa CA 92626 714 557 1636 Customer Care Center 1 800 438 7373 Hours 24 7 86 160310 00 E00 03 1997 01 1998 07 1998 02 2002 08 2005 MGE UPS SYSTEMS Comet 40 150kVA IMPORTANT SAFETY INSTRUCTIONS SAVE TH ESE INSTRU CTIONS This manual contains important instructions for the Comet 40 150 that must be followed during operation and maintenance of the equipment 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 ffnen der Geh use legen gef hrliche Spannungen bloss Service sollte immer nur von qualifizierten Personal durchgef hrt werden WARNING As standards specifications and designs are subject to chang
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