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MGE UPS Systems POWER-SURE 700 Installation And User Manual Download Page 41

Maintenance

3 —19

Installation and User Manual

3.11

Replacement Parts

Individual components are available upon request. Please contact MGE for specific part numbers and prices. 

See Section 3.7 in this manual for component location and description. When contacting MGE Service at 

1-800-523-0142, please have the unit’s full model number and serial number for identification. 

3.12

Part Numbers

Table 3-1:  Power-Sure™ 700 Power Conditioners Part Numbers.

Part Number

kVA

Input Voltage 

Output Voltage

Hz

TBN-010K-6

10

TBN-015K-6

15

TBN-025K-6

25

TBN-030K-6

30

208

480/277

60

TBN-045K-6

45

TBN-050K-6

50

TBN-075K-6

75

TBL-010K-6

10

TBL-015K-6

15

TBL-025K-6

25

TBL-030K-6

30

TBL-045K-6

45

TBL-050K-6

50

208

208/120

60

TBL-075K-6

75

TBL-100K-6

100

TBL-125K-6

125

TBL-150K-6

150

TBL-225K-6

225

TBL-300K-6

300

TCN-010K-6

10

TCN-015K-6

15

TCN-025K-6

25

240

480/277

60

TCN-030K-6

30

TCN-045K-6

45

TCN-050K-6

50

TCL-010K-6

10

TCL-015K-6

15

TCL-025K-6

25

TCL-030K-6

30

240

208/120

60

TCL-045K-6

45

TCL-050K-6

50

TCL-075K-6

75

TCL-100K-6

100

86-108814-00 B01

Summary of Contents for POWER-SURE 700

Page 1: ...Three Phase Power Conditioners Installation and User Manual w w w m g e u p s c o m Power Sure ...

Page 2: ...e 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...

Page 3: ...ENT 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 How to use this manual and Symbol Usage This manual is designed for ease of use and easy location of information Locate specific topics in the Table of Contents T...

Page 4: ..._____ ADDITIONAL SERIAL NUMBERS ____________________________ ______________________________ ____________________________ ______________________________ ____________________________ ______________________________ ____________________________ ______________________________ ____________________________ ______________________________ ____________________________ ______________________________ ________...

Page 5: ... Three Phase Power Conditioners Installation and User Manual 86 108814 00 Revision A00 Initial Release 09 2003 A01 ECN 003787 02 2004 B00 ECN 004681 08 2006 B01 ECN 005088 12 2006 For service call 1 800 523 0142 Copyright 2006 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 ...

Page 6: ... This page left blank intentionally Power Sure 700 Three Phase Power Conditioners vi 86 108814 00 B01 ...

Page 7: ...n and Storage 1 2 1 4 General Description 1 2 1 4 1 Electrical and Performance Specifications 1 3 1 4 2 Main Transformer Specification 1 3 1 4 3 Input Breaker 1 4 1 5 Monitoring the Power Sure 700 1 4 1 6 Protection for the Power Sure 700 1 4 Section 2 Installation and Operation section description page 2 0 Scope 2 1 2 1 Installation Notes 2 1 2 2 MGE UPS Systems Power Sure 700 2 1 2 3 Power Sure ...

Page 8: ...ard 49120 407415 3 15 3 9 2 Control Card Adjustment Procedure 3 16 3 9 3 Over Under Voltage Detection Board 35867 3 17 3 9 3 1 Undervoltage Adjustment 3 17 3 9 3 2 Overvoltage Adjustment 3 17 3 9 3 3 Delay Adjustment 3 18 3 10 Manual Bypass Switch Option 3 18 3 10 1 Normal Mode 3 18 3 10 2 Bypass Mode 3 18 3 10 3 Remote Emergency Power OFF REPO Optional 3 18 3 11 Replacement Parts 3 19 3 12 Parts ...

Page 9: ... Major Components Rear View 3 9 3 5 Power Sure 700 45 150kVA Major Components Rear View 3 10 3 6 Power Sure 700 225 300kVA Cable Connections Input Output Locations 3 11 3 7 Power Sure 700 10 30kVA SCR Heatsink Assembly 3 12 3 8 Power Sure 700 45 50kVA SCR Heatsink Assembly 3 13 3 9 Power Sure 700 75 150kVA SCR Heatsink Assembly 3 14 3 10 Power Sure 700 225 300kVA SCR Heatsink Assembly 3 15 3 11 Po...

Page 10: ... This page left blank intentionally Power Sure 700 Three Phase Power Conditioners c iv 86 108814 00 B01 ...

Page 11: ...location and storage electrical and mechanical specifications monitoring and internal protection for components Section 2 Installation and Operation This section describes installation requirements system dimensions cable connections and start up procedures for the Power Sure 700 Three Phase Power Conditioners Section 3 Maintenance This section contains preventive maintenance for the Power Sure 70...

Page 12: ...d location that is protected from rain splashing water chemical agents etc The equipment should be covered with a tarpaulin or plastic wrapper to protect it against dust dirt paint or other foreign materials 1 4 General Description The Power Sure 700 is a continuous duty power conditioner designed to supply reliable clean regulated power to critical loads An efficient design with state of the art ...

Page 13: ...ng on kVA rating Turn On Characteristics When energized voltage overshoot will be less than 5 of nominal for 1 cycle or less Overload Rating 1000 for 1 cycle and 200 for 10 seconds Ambient Rating 10 to 40 degrees Celsius Optional extended input regulation range provided on some units If provided reference description next to the units specification tag 50 Hz models available Listed to UL1012 Stand...

Page 14: ...t is interfaced with a REMOTE EMERGENCY POWER OFF PUSH BUTTON By pressing this button the input breaker will trip and disable the Power Sure 700 completely The input breaker must be physically reset before unit will turn on again 2 The electronic regulating devices are protected with fast acting semi conductor fuses These fuses are designed to clear before damage occurs to the more expensive SCR r...

Page 15: ...preparation Installation of the equipment must be handled by skilled technicians and electricians familiar with the special requirements of high voltage electrical equipment The installation must comply with the requirements of the National Electrical Code ANSI NFPA 70 latest issue and local codes as applicable and safety standard UL1012 listed UL1449 compliant meets FCC Cat A We strongly recommen...

Page 16: ...LY ENVIRONMENTAL CLEARNESS TO REMOVE TOP REMOVE RETAINING SCREW IN REAR OF TOP LIFT REAR AND SLIDE FORWARD TO REMOVE SIDE REMOVE RETAINING SCREW IN TOP OF PANEL LIFT PANEL STRAIGHT UP A OUTPUT B C CONDITIONED POWER ALERT G N L3 L2 L1 H3 H2 H1 INPUT TERMINALS ALLEN BRADLEY 1492 CE2 12 I O WIRE REAR VIEW COOLING FANS OPTIONAL BYPASS OUTPUT TERMINALS CONSISTS OF PK9 GROUNDING BAR WIRE 14 ga 4 ga ta 2...

Page 17: ...IBUTION OPTIONAL HOLE PROVIDED 1 OUTPUT CONDUIT OUTPUT TERMINALS ILSCOTA2 0 WIRE RANGE 14 AWG 2 0 PK9 WIRE RANGE 14GA 4AWG FRONT VIEW RIGHT SIDE VIEW REAR VIEW 29 736 6m TOP VIEW 12 304 8m FOR INSTALLATION PURPOSES ONLY COOLING FANS 12 304 8m FOR INSTALLATION PURPOSES ONLY ENVIRONMENTAL CLEARNESS TO REMOVE TOP REMOVE RETAINING SCREW IN REAR OF TOP LIFT REAR AND SLIDE FORWARD TO REMOVE SIDE REMOVE ...

Page 18: ...HT RECOMMENDED OUTPUT CONDUIT LOCATION SEE NOTE RECOMMENDED INPUT CONDUIT LOCATION SEE NOTE INPUT CIRCUIT BREAKER REAR VIEW H1 H2 L2 L3 N G L1 H3 25 COPPER BAR ÿ 0 312 1 000 1 000 500 25 COPPER BAR OUTPUT TERMINATION ÿ 0 312 1 000 1 500 750 G BY PASS SWITCH OPTIONAL FIELD WIRING TERMINALS ACCESS COVER INPUT TERMINATION NOTE RIGHT SIDE PANEL MAY USED FOR OPTIONAL INPUT OUTPUT CONDUIT LOCATIONS TOP ...

Page 19: ... is microprocessor controlled to achieve optimum correction time of input voltage sags and surges The response time is typically one 1 2 cycle for 100 correction therefore a very smooth switch takes place undetected by computer equipment 41 5 1054 1m 77 207 159 9m 35 889m 2 75 69 85m 56 1422 4m 50 5 1282 7m 2 75 69 85m 32 1812 8m POWER ON ALERT INPUT CIRCUIT BREAKER TERMINATE INPUT CABLES AT CIRCU...

Page 20: ...lagging power loads to be connected to the conditioner 2 5 Power Sure 700 Cable Connections 2 5 1 Input Wire Size Grounding and Output Wiring Conduit should be used for both input and output wiring Minimum ground wire size is based on 1990 Nation Electric Code Table 250 95 Input wire size is based on 1990 NEC Table 310 16 specifying not more than 3 conductors in a raceway based on ambient of 30 de...

Page 21: ... VAC input and 208 VAC output Table 2 2 208 VAC Input and 208 VAC Output Wire Size Chart Unit Size Input Input Minimum Maximum in kVA Breaker Wire Ground Wire Output Size Size Size Current 10 40 Amp 8 10 28 15 60 Amp 8 8 42 25 110 Amp 4 4 70 30 110 Amp 4 4 83 45 175 Amp 1 2 125 50 175 Amp 1 2 139 75 300 Amp 2 0 2 0 208 100 350 Amp 4 0 4 0 278 125 450 Amp 2 pcs 1 0 2 pcs 1 0 347 150 600 Amp 2 pcs 3...

Page 22: ...ITH NO LOAD ON THE SYSTEM 1 Re install all panels that may have been removed during installation 2 Make sure the input circuit breaker is in the off position 3 Energize the primary building power 4 Turn on the main AC input breaker 5 Verify that the output voltage is within the specified range 6 Verify output phase rotation is correct 7 Turn the system off 8 Connect the loads one at a time and rep...

Page 23: ...e sure all cooling fans are running A At each service inspection remove top and side panels and carefully remove any accumulated dust dirt or foreign particles Special care should be exercised in cleaning the thyristors heat sinks and the control assembly B Inverse Parallel Silicon Rectifiers SCRs or Thyristors The silicon controlled rectifiers SCRs usually fail in the shorted mode When this happe...

Page 24: ... ______________________________________________________________________________________________ 6 Check Tightness of Electrical Connections Input Connections__________ Output Connections__________ Heatsink Connections SCRs __________ Circuit Board Connections__________ By Pass Switch__________ Fuse Connections__________________ Fan Connections__________ Transformer Connections__________ 7 Exercise...

Page 25: ...lance as needed Input Output A____________Amps A____________Amps B____________Amps B____________Amps C____________Amps C____________Amps N____________Amps G____________Amps 12 Fans Operational _________________________________________________________________________________________ 13 Testing Shutdown Circuitry ie REPO Over Under Voltage ____________________________________________________________...

Page 26: ...utput Detection PCB WARNING THERE ARE DANGEROUSLY HIGH VOLTAGES PRESENT WITHIN THE ENCLOSURE OF THE POWER SUPPLY SYSTEM UNDER NO CIRCUMSTANCES SHOULD ANY PERSON REACH WITHIN THE ENCLOSURE OF THIS EQUIPMENT ALL SERVICE TO THIS PIECE OF EQUIPMENT SHOULD BE PERFORMED BY QUALIFIED PERSONNEL ONLY 3 3 Troubleshooting Power Line and Electrical Connections NOTE Circuit diagrams in this manual are for refe...

Page 27: ...y physically burned or broken components 4 Check all fuses in system see NOTE Also check time delay fuses semi conductor fuses fan fuses circuit board fuses and SCR fusible link wire NOTE Remove fuses from circuit when checking to avoid false readings 3 4 Checking the Power Modules SCR Refer to Section 3 8 Figures for specific 10 30kVA SCR 45 50kVA SCR 75 150kVA SCR and 225 300kVA for SCR assembli...

Page 28: ...bad Test procedure Completely isolate SCR under test by removing all connections to the device Hook up the following test circuit to each individual SCR Plug in SCR tester With Switch 1 open light bulb should be off If not replace SCR Close Switch 1 Light bulb should illuminate to about 3 4 brilliance If not replace SCR Figure 3 2 Test Wire Diagram 6 Reassemble the power module assembly making sur...

Page 29: ...ing voltages on wires feeding the TB1 Molex connector to the control card on all 3 phases Pins 1 3 4 6 VAC Pins 7 8 120 VAC NOTE When the connector is plugged in this voltage is around 3 VAC If this voltage is incorrect or not present then check the fuses associated with the filter card or replace filter card and re check voltages 5 Turn main AC circuit breaker off Plug in connectors TB1 and TB3 O...

Page 30: ...n over under detect 35867 NOTE P1 pot turned clockwise decrease in output voltage and counter clockwise increase in output voltage By changing this adjustment on phase1 you may see the output voltage change from line to neutral on two phases It is best to use procedures in Steps 1 9 of Section 3 6 3 6 Final Testing and Adjustments 1 Connect AC voltmeter to output of system with proper meter scale ...

Page 31: ...ation Diagrams Figure 3 3 Power Sure 700 10 15kVA Major Components Figure 3 4 Power Sure 700 25 30kVA Major Components Rear View SENSE CARD CONTROL CARD INPUT CIRCUIT BREAKER MULTI SHIELDED ISOLATION TRANSFORMER OUTPUT FILTERING OUTPUT TERMINAL PADS INPUT TERMINAL BLOCK SNUBBER CARD HEATSINK SCR POWER MODULE SEMI CONDUCTOR FUSES SENSE CARD CONTROL CARD SEMI CONDUCTOR FUSES SCR POWER MODULE HEATSIN...

Page 32: ...ONTROL CARD HEATSINK REGULATOR ASSEMBLY COOLING FAN OUTPUT TERMINAL PADS MULTI SHIELDED ISOLATION TRANSFORMER OUTPUT FILTERING INPUT TERMINAL PADS SEMI CONDUCTOR FUSES SCR POWER MODULE SNUBBER CARD Maintenance Power Sure 700 Three Phase Power Conditioners 3 10 86 108814 00 B01 ...

Page 33: ...25 4m 1 25 4m 2 50 8m 32 1812 8m OUTPUT TERMINALS CUSTOMER SIDE TOP VIEW LIFT OFF ACCESS PANEL 9 228 6m 45 1143m Clearance CABINET COOLING FAN LIFT OFF ACCESS PANEL OUTPUT CONDUIT LOCATION INPUT CONDUIT LOCATION 8 203 2m 8 203 2m 5 CLEARANCE REQUIRED THIS SIDE OUTPUT ACCESS PLATE OUTPUT TERMINALS LIFT OFF ACCESS PANEL 6 CLEARANCE REQUIRED THIS SIDE 36 CLEARANCE REQUIRED THIS SIDE EDGE FRAMING FOR ...

Page 34: ...GATE CONNECTIONS G1 1 THROUGH G1 7 G2 1 THROUGH G2 7 TYPICAL FUSIBLE LINK THERMAL SENSOR TAP WIRES FROM POWER TRANSFORMER K2 1 THROUGH K2 7 CONNECTIONS TYPICAL CABLE TO TRANSFORMER SEMI CONDUCTOR FUSE POWER MODULE Maintenance Power Sure 700 Three Phase Power Conditioners 3 12 86 108814 00 B01 ...

Page 35: ...00 45 50kVA SCR Heatsink Assembly SHUNT GATE CONNECTIONS G1 1 THROUGH G1 7 G2 1 THROUGH G2 7 TYPICAL FUSIBLE LINK THERMAL SENSOR TAP WIRES FROM POWER TRANSFORMER K2 1 THROUGH K2 7 CONNECTIONS TYPICAL CABLE TO TRANSFORMER SEMI CONDUCTOR FUSE POWER MODULE 86 108814 00 B01 ...

Page 36: ...H G1 7 G2 1 THROUGH G2 7 TYPICAL FUSIBLE LINK CONTINUOUS THROUGH EACH POWER MODULE THERMAL SENSOR TAP WIRES FROM POWER TRANSFORMER K2 1 THROUGH K2 7 CONNECTIONS TYPICAL INPUT CABLE POWER MODULE HEATSINK DIODE Maintenance Power Sure 700 Three Phase Power Conditioners 3 14 86 108814 00 B01 ...

Page 37: ...nts of Circuit Cards 3 9 1 Power Sure 700 Control Card 49120 407415 WARNING ALL SERVICE TO THIS PIECE OF EQUIPMENT MUST BY PERFORMED BY QUALIFIED PERSONNEL GATE LEADS TYPICAL FUSIBLE LINK CONTINUOUS THROUGH EACH POWER MODULE THERMAL SENSOR CABLE TO TRANSFORMER TYPICAL POWER MODULE HEATSINK INPUT CABLE DIODE 86 108814 00 B01 ...

Page 38: ...output of unit under adjustment 4 Remove both TB2 connectors on all control boards 49120 407415 Turn power on 5 With DC voltmeter on the millivolt scale check between TP1 and TP GND and adjust P2 so meter reads 0 millivolts or as close as possible Figure 3 11 Power Sure 700 Controller Card Top View 6 Use Formula X below to calculate the next adjustments You must calculate each input phase for each...

Page 39: ...utral If output is not correct make sure input power is stable and repeat adjustment procedure NOTE P1 Pot turned clockwise decrease in output voltage and counter clockwise increase in output voltage By changing this adjustment on 1 phase you may see the output voltage change from line to neutral on 2 phases It is best to use procedures in Steps 1 9 when adjusting 3 9 3 Over Under Voltage Detectio...

Page 40: ...power to the critical loads The Power Sure 700 should have the switch in the normal position unless a failure has occurred 3 10 2 Bypass Mode With the switch in the bypass position the Power Sure 700 will provide clean power to the critical loads In the bypass position the unit will not regulate the incoming voltage The Power Sure 700 should be placed in the bypass position when a failure of the s...

Page 41: ...Conditioners Part Numbers Part Number kVA Input Voltage Output Voltage Hz TBN 010K 6 10 TBN 015K 6 15 TBN 025K 6 25 TBN 030K 6 30 208 480 277 60 TBN 045K 6 45 TBN 050K 6 50 TBN 075K 6 75 TBL 010K 6 10 TBL 015K 6 15 TBL 025K 6 25 TBL 030K 6 30 TBL 045K 6 45 TBL 050K 6 50 208 208 120 60 TBL 075K 6 75 TBL 100K 6 100 TBL 125K 6 125 TBL 150K 6 150 TBL 225K 6 225 TBL 300K 6 300 TCN 010K 6 10 TCN 015K 6 ...

Page 42: ... TDN 050K 6 50 480 480 277 60 TDN 075K 6 75 TDN 100K 6 100 TDN 125K 6 125 TDN 150K 6 150 TDN 225K 6 225 TDN 300K 6 300 TEL 010K 6 10 TEL 015K 6 15 TEL 025K 6 25 TEL 030K 6 30 TEL 045K 6 45 TEL 050K 6 50 600 208 120 60 TEL 075K 6 75 TEL 100K 6 100 TEL 125K 6 125 TEL 150K 6 150 TEL 225K 6 225 TEL 300K 6 300 TEN 010K 6 10 TEN 015K 6 15 TEN 025K 6 25 TEN 030K 6 30 TEN 045K 6 45 TEN 050K 6 50 600 480 2...

Page 43: ... 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 26 28 27 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 55 54 53 52 51 K1 7 G1 7 G2 7 K2 7 K1 6 G1 6 G2 6 K2 6 K1 5 G1 5 G2 5 K2 5 G1 4 K1 4 G2 4 K2 4 K1 3 G1 3 G2 3 K2 3 K1 2 G1 2 K2 2 G2 2 K1 1 G1 1 G2 1 K2 1 K2 1 G2 1 G1 1 K1 1 K2 2 G2 ...

Page 44: ... 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 K2 1 G2 1 G1 1 K1 1 K2 2 G2 2 G1 2 K1 2 K2 3 G2 3 G1 3 K1 3 K2 4 G2 4 G1 4 K1 4 K2 5 G2 5 G1 5 K1 5 K2 6 G2 6 G1 6 K1 6 K2 7 G2 7 G1 7 K1 7 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 K2 1 G2 1 G1 1 K1 1 K2 2 G2 2 G1 2 K1 2 K2 3 G2 3 G1 3 K1 3 K2 4 G2 4 G1 4 K1 4 K2 5 G2 5 G1 5 K1 5 K2 6 G2 6 G1 6 K1 6 K2 7 G2 7 G1 7 K1 7 TB...

Page 45: ...G2 1 G1 1 K1 1 K2 2 G2 2 G1 2 K1 2 K2 3 G2 3 G1 3 K1 3 K2 4 G2 4 G1 4 K1 4 K2 5 G2 5 G1 5 K1 5 K2 6 G2 6 G1 6 K1 6 K2 7 G2 7 G1 7 K1 7 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 K2 1 G2 1 G1 1 K1 1 K2 2 G2 2 G1 2 K1 2 K2 3 G2 3 G1 3 K1 3 K2 4 G2 4 G1 4 K1 4 K2 5 G2 5 G1 5 K1 5 K2 6 G2 6 G1 6 K1 6 K2 7 G2 7 G1 7 K1 7 TB 2 TB 1 TB 3 1 2 3 4 5 6 4 2 8 3 1 7 63 62 58 57...

Page 46: ... This page left blank intentionally Power Sure 700 Three Phase Power Conditioners A 4 86 108814 00 B01 ...

Page 47: ... 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 responsible to pay any invoice therefore This warranty shall be ...

Page 48: ...GE UPS SYSTEMS INC 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 t...

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Page 52: ...C 800 438 7373 Fax 714 557 9788 email info mgeups com www mgeups com Canada MGE UPS SYSTEMS 9 2789 Thamesgate Drive Mississauga ON L4T 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 ...

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