EXL Manual Ups System

EXL 1000UninterruptiblePower System

Installation andUser’s Guide

86-891000-00

IMPORTANT SAFETY INSTRUCTIONSAVE THESE INSTRUCTIONS — This manual containsimportant instructions for models EXL 1050 (PNs 891050-44,891050-84), EXL 1075 (PNs 891075-44, 891075-84) andEXL 1100 (PNs 891100-44, 891100-84) that must befollowed during installation, operation and maintenance ofthe UPS and batteries.

Tightening torque for all input and output terminal blocksshall be 10.6 - 12.3 in-lbs (1.2 - 1.4 Nm).

The nominal battery voltage ratings are:EXL 1050 - 180 VdcEXL 1075 - 180 VdcEXL 1100 - 240 Vdc.

A power output disconnect switch must be provided by theuser if the EXL 1000 distribution cabinet is not installed.

Input power cables and output power cables for the 5 kVAmodel shall be rated for 10 AWG, 75°C or 10 AWG, 90°C.Input power cables and output power cables for 7.5 kVA and10 kVA models shall be rated for 6 AWG, 75°C or 6 AWG,90°C copper wire.

The EXL 1000 series UPS is intended for installation in atemperature controlled, indoor area free of conductive conta-minants.

Servicing of batteries should be performed or supervised bypersonnel knowledgeable of batteries and the requiredprecautions.

When replacing batteries, replace with the same number ofbatteries. Use Yuasa NP7-12 FR

CAUTION - Do not dispose of battery or batteries in a fire.The battery may explode.

CAUTION - Do not dispose or mutilate the battery orbatteries. Released electrolyte is harmful to the skin andeyes. It may be toxic.

CAUTION - A battery can present a risk of electrical shockand high short circuit current. The following precautionsshould be observed when working on batteries.

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.

Important Safety Instructions

86-891000-00 Important Safety Instructions

Installation and User’s Manual

Disconnect charging source prior to connecting ordisconnecting battery terminals (if applicable).

Determine if the battery is inadvertently grounded. If inadver-tently grounded, remove source of a ground. Contact withany part of a grounded battery can result in electrical shock.The likelihood of such shock will be reduced if such groundsare removed during installation and maintenance.

Interconnecting cables - Flexible cord or flexible cableassemblies used for external interconnection between partsof equipment or between components of a system are notprovided.

Internal Wiring - (AVLV2), Style Nos. 1015, 1061, 2464, 2690,2768, type SIS.

Building wire type THHN and XHHW and ribbon cable style2651. All wiring is routed away from sharp edges and movingparts. Smooth and well-rounded surfaces are provided forwiring to bear upon when passing through sheet metal walls.Where wires are bundled or run in ducts, 300 V insulatedwires are bundled and physically separated from 600 V ratedwire or occupy separate ducts. All multi-conductor style 2464wires are rated 300 V.

Size of Branch Circuit Overcurrent Protection - CAUTION -To reduce the risk of fire, connect only to a circuit providedwith 60 amperes maximum branch circuit overprotection inaccordance with the National Electrical Code, ANSI/NFPA70.

Operating temperature - 0° - 30°C at rated output. 40°C for 8hours max.

WARNINGOPENING ENCLOSURES EXPOSES HAZARDOUS VOLTAGES.ALWAYS REFER SERVICE TO QUALIFIED PERSONNEL ONLY.

WARNINGHigh voltages are present inside the EXL 1000 system. Any servicingrequiring removal of the protective covers may be undertaken only byqualified personnel certified by MGE UPS Systems.

NOTEThis equipment has been tested and found to comply with the limitsfor a Class A digital device, pursuant to Part 15 of the FCC Rules.These limits are designed to provide reasonable protection againstharmful interference when the equipment is operated in a commercialenvironment. This equipment generates, uses, and can radiate radiofrequency energy and, if not installed and used in accordance with theinstruction manual, may cause harmful interference to radio commu-nications. Operation of this equipment in a residential area is likely tocause harmful interference in which case the user will be required tocorrect the interference at his own expense.

NOTEAs standards, specifications and designs are subject to change,please ask for confirmation of the information given in this publication.This manual is a controlled document. Pages should not be removedindividually from this binder.

Important Safety Instructions

EXL 1000 Uninterruptible Power System

86-891000-00

For service call1-800-438-7373

86-891000-00 C01 06/98Copyright © 1997 MGE UPS Systems, Inc..All rights reserved. Printed in U.S.A.

MGE UPS Systems1660 Scenic AvenueCosta Mesa, CA 92626(714) 557-1636

prepared for:

EXL 1000

Uninterruptible Power System

Installation and User’s Guide

86-891000-00

86-891000-00

WarrantyThe liability of MGE UPS Systems, Inc. hereunder is limited to replacing or repairing at MGE UPS Systems, Inc.’s

factory or on the job site at MGE UPS Systems, Inc.’s option, any part or parts which are defective, including labor, for aperiod of 24 months from the date of purchase. MGE UPS Systems, Inc. shall have the sole right to determine if the partsare to be repaired at the job site or whether they are to be returned to the factory for repair or replacement. All itemsreturned to MGE UPS Systems, Inc. for repair or replacement must be sent freight prepaid to its factory. Purchaser mustobtain MGE UPS Systems, Inc.’s Return Materials Authorization prior to returning items. The above conditions must bemet if warranty is to be valid. MGE UPS Systems, Inc. will not be liable for any damage done by unauthorized repair work,unauthorized replacement parts, from any misapplication of the item, or for damage due to accident, abuse, or Act ofGod.

In no event shall MGE UPS Systems, Inc. be liable for loss, damage, or expense directly or indirectly arising from theuse of the units, or from any other cause, except as expressly stated in this warranty. MGE UPS Systems, Inc. makes nowarranties, express or implied, including any warranty as to merchantability or fitness for a particular purpose or use.MGE UPS Systems, Inc. is not liable for and Purchaser waives any right of action it has or may have against MGE UPSSystems, Inc. for any consequential or special damages arising out of any breach of warranty, and for any damagesPurchaser may claim for damage to any property or injury or death to any person arising out of its purchase of, or theuse, operation or maintenance of the product. MGE UPS Systems, Inc. will not be liable for any labor subcontracted orperformed by Purchaser for preparation of warranted item for return to MGE UPS Systems, Inc.’s factory or forpreparation work for field repair or replacement. Invoicing of MGE UPS Systems, Inc. for labor either performed orsubcontracted by Purchaser will not be considered as a liability by MGE UPS Systems, Inc.

This warranty shall be exclusive of any and all other warranties express or implied and may be modified only by awriting signed by an officer of MGE UPS Systems, Inc. This warranty shall extend to the Purchaser but to no one else.Accessories supplied by MGE Systems, Inc., but manufactured by others, carry any warranty the manufacturers havemade to MGE UPS Systems, Inc. and which can be passed on to Purchaser.

MGE UPS Systems, Inc. makes no warranty with respect to whether the products sold hereunder infringe any patent,U.S. or foreign, and Purchaser represents that any specially ordered products do not infringe any patent. Purchaseragrees to indemnify and hold MGE UPS Systems, Inc. harmless from any liability by virtue of any patent claims wherePurchaser has ordered a product conforming to Purchaser’s specifications, or conforming to Purchaser’s specific design.

Purchaser has not relied and shall not rely on any oral representation regarding the Product sold hereunder and anyoral 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 UPSSystems, Inc. be responsible for consequential damages or for any damages except as expressly stated herein.

Service and Factory Repair - Call 1 - 800 - 523 - 0142Direct questions about the operation, repair, or servicing of this equipment to MGE UPS Systems, Inc. Technical

Support Services. Include the part number and serial number of the unit in any correspondence. Should you requirefactory service for your equipment, contact MGE UPS Systems, Inc. Technical Support Services and obtain a ReturnMaterials Authorization (RMA) prior to shipping your unit. Never ship equipment to MGE UPS Systems, Inc. without firstobtaining an RMA.

Proprietary Rights StatementThe information in this manual is the property of MGE UPS Systems, Inc., and represents a proprietary article in

which MGE UPS Systems, Inc. retains any and all patent rights, including exclusive rights of use and/or manufactureand/or sale. Possession of this information does not convey any permission to reproduce, print, or manufacture the articleor articles shown herein. Such permission may be granted only by specific written authorization, signed by an officer ofMGE UPS Systems, Inc.

IBM, PC-AT, ES/9000, and AS/400 are trademarks of International Business Machines Corporation. MGE and MGEUPS Systems are trademarks of MGE UPS Systems, Inc. Other trademarks that may be used herein are owned by theirrespective companies and are referred to in an editorial fashion only.

Revision HistoryEXL 1000 Uninteruptible Power System Installation and User’s Guide86-891000-00 Copyright © 1997 MGE UPS Systems. All rights reserved. Printed in U.S.A.Revision: A00 New Release 01/97

B00 ECN 289-93 10/97C00 ECN 291-79 2/98C01 ECN 293-49 06/98

EXL 1000 Uninterruptible Power SystemInstallation and User’s Guide

Introduction1.0 . . . . . . . . . . . . . . . Scope 1 — 11.1 . . . . . . . . . . . . . . . General Description 1 — 2

1.1.1 Description of UPS Module 1 — 21.2 . . . . . . . . . . . . . . . Configuration 1 — 4

Installation2.0 . . . . . . . . . . . . . . . Scope 2 — 12.1 . . . . . . . . . . . . . . . Storage 2 — 12.2 . . . . . . . . . . . . . . . Unpacking 2 — 12.3 . . . . . . . . . . . . . . . General 2 — 42.4 . . . . . . . . . . . . . . . Final positioning 2 — 42.5 . . . . . . . . . . . . . . . Special Precautions 2 — 52.6 . . . . . . . . . . . . . . . Connections 2 — 5

2.6.1 Electrical Diagram for Power Connections 2 — 5

Operation3.1 . . . . . . . . . . . . . . . Controls and indicators 3 — 1

3.1.1 Basic controls and indicators 3 — 13.1.2 Controls and Diagnostic Display 3 — 4

3.2 . . . . . . . . . . . . . . . Checks before Start-up 3 — 53.3 . . . . . . . . . . . . . . . Powering up the EXL 1000 3 — 63.4 . . . . . . . . . . . . . . . Manual Inverter Start-up 3 — 63.5 . . . . . . . . . . . . . . . Shutting down the inverter 3 — 63.6 . . . . . . . . . . . . . . . Powering down the inverter 3 — 73.7 . . . . . . . . . . . . . . . Normal Operation 3 — 73.8 . . . . . . . . . . . . . . . Operation on battery power 3 — 83.9 . . . . . . . . . . . . . . . Battery duration 3 — 83.10 . . . . . . . . . . . . . . Return of AC input power 3 — 93.11 . . . . . . . . . . . . . . Battery Monitoring Tests 3 — 93.12 . . . . . . . . . . . . . . Overload 3 — 93.13 . . . . . . . . . . . . . . Alarms 3 — 103.14 . . . . . . . . . . . . . . Diagnostics display messages 3 — 113.15 . . . . . . . . . . . . . . Manual Bypass 3 — 14

Communications4.0 . . . . . . . . . . . . . . . Standard Functions 4 — 14.1 . . . . . . . . . . . . . . . Options 4 — 2

iii

Contents

86-891000-00

Maintenance and Service5.0 . . . . . . . . . . . . . . . Scope 5 — 15.1 . . . . . . . . . . . . . . . User Preventive Maintenance 5 — 15.2 . . . . . . . . . . . . . . . Maintenance by

Certified MGE Representatives 5 — 15.2.1 Battery Maintenance 5 — 15.2.2 Environmental Protection 5 — 25.2.3 Annual Check 5 — 25.2.4 Customer Training 5 — 25.2.5 Maintenance Contracts 5 — 2

Options6.1 . . . . . . . . . . . . . . . Extended battery cabinet 6 — 16.2 . . . . . . . . . . . . . . . Connection of an

additional battery cabinet 6 — 26.3 . . . . . . . . . . . . . . . Emergency Power Off (EPO) 6 — 46.4 . . . . . . . . . . . . . . . Battery circuit breaker

shunt trip connection 6 — 46.5 . . . . . . . . . . . . . . . Combined options 6 — 5

U-Talk7.1 . . . . . . . . . . . . . . . Introduction 7 — 1

7.1.1 Storage 7 — 17.1.2 Safety Recommendation 7 — 1

7.2 . . . . . . . . . . . . . . . Installation of the U-Talk board 7 — 27.2.1 Powering down the

EXL 1000 UPS 7 — 27.2.2 Installing the U-Talk

RS232 board 7 — 27.2.3 Returning power to the

EXL 1000 UPS 7 — 37.3 . . . . . . . . . . . . . . . Description of RS232 board 7 — 3

7.3.1 Function 7 — 37.3.2 Configuring the RS232 board 7 — 3

7.4 . . . . . . . . . . . . . . . Configuration for UPS Manager software 7 — 4

7.5 . . . . . . . . . . . . . . . U-Talk data format 7 — 5

iv Contents


86-891000-00

AppendicesA.0 . . . . . . . . . . . . . . . General Characteristics a — 1A.1 . . . . . . . . . . . . . . . Range Characteristics a — 1

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . g — 1

Illustrationsfigure description page number1-1 . . . . . . . . . . . . . . . Identification Plate 1 — 41-2 . . . . . . . . . . . . . . . EXL 1000 5kVA

front and rear view 1 — 51-3 . . . . . . . . . . . . . . . EXL 1000 7.5 & 10 kVA

front and rear view 1 — 51-4 . . . . . . . . . . . . . . . Functional diagram 1 — 62-1 . . . . . . . . . . . . . . . Unpacking the EXL 1000 UPS 2 — 22-2 . . . . . . . . . . . . . . . Removing stabilizing material

from under EXL 1000 UPS 2 — 32-3 . . . . . . . . . . . . . . . Using supplied ramp

to bring EXL 1000 off of shipping base 2 — 3

2-4 . . . . . . . . . . . . . . . Installation clearances as seen from above 2 — 4

2-5 . . . . . . . . . . . . . . . Connection diagram for a single AC input 2 — 5

2-6 . . . . . . . . . . . . . . . Removal of conduit landing cover panel (5 kVA) 2 — 7

2-7 . . . . . . . . . . . . . . . Cable connections (5 kVA) 2 — 72-8 . . . . . . . . . . . . . . . Removal of

maintenance bypass switch knob and conduit landing cover panel (7.5 & 10 kVA) 2 — 8

2-9 . . . . . . . . . . . . . . . Cable Connections (7.5 & 10 kVA) 2 — 8

3-1 . . . . . . . . . . . . . . . Location of Controls and indicators on cabinet 3 — 1

3-2 . . . . . . . . . . . . . . . Close-up of Controls and indicators 3 — 2

3-3 . . . . . . . . . . . . . . . “Load protected” LED 3 — 23-4 . . . . . . . . . . . . . . . “Battery Status” LED 3 — 23-5 . . . . . . . . . . . . . . . “Fault” LED 3 — 33-6 . . . . . . . . . . . . . . . “Load Not Protected” LED 3 — 33-7 . . . . . . . . . . . . . . . Audible Alarm 3 — 33-8 . . . . . . . . . . . . . . . “Inverter On” button 3 — 33-9 . . . . . . . . . . . . . . . “Inverter Off” button 3 — 43-10 . . . . . . . . . . . . . . Controls and

Diagnostics Display 3 — 43-11 . . . . . . . . . . . . . . Manual Maintenance Bypass

circuit breaker 3 — 53-12 . . . . . . . . . . . . . . EXL 1000 power-up 3 — 6

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figure description page number3-13 . . . . . . . . . . . . . . Indicators during

normal operation 3 — 73-14 . . . . . . . . . . . . . . Diagram of normal operation

on utility power 3 — 73-15 . . . . . . . . . . . . . . Indicators when on

battery power 3 — 83-16 . . . . . . . . . . . . . . Diagram of operation

on battery power 3 — 83-17 . . . . . . . . . . . . . . Inverter overload curve 3 — 103-18 . . . . . . . . . . . . . . Static Bypass overload curve 3 — 103-19 . . . . . . . . . . . . . . Relationship of fault codes

to EXL 1000 subsystems 3 — 133-20 . . . . . . . . . . . . . . Manual Bypass Switch 3 — 144-1 . . . . . . . . . . . . . . . Electrical connections of

15 pin D connector 4 — 14-2 . . . . . . . . . . . . . . . 15 pin D connector 4 — 16-1 . . . . . . . . . . . . . . . Connection of an additional

battery cabinet (5kVA Model) Covers Removed 6 — 3

6-2 . . . . . . . . . . . . . . . Connection of an additional battery cabinet (7.5 & 10 kVA Models) 6 — 3

6-3 . . . . . . . . . . . . . . . Connection diagram for battery circuit breaker shunt trip on terminal block XR3 6 — 5

6-4 . . . . . . . . . . . . . . . XR3 terminal block for EXL 1050, EXL 1075 and EXL 1100 6 — 5

7-1 . . . . . . . . . . . . . . . Inserting the U-Talk board into the groove 7 — 2

7-2 . . . . . . . . . . . . . . . Overview of RS232 board 7 — 37-3 . . . . . . . . . . . . . . . Close-up of

figure 7-2, section A 7 — 37-4 . . . . . . . . . . . . . . . Factory settings of

U-Talk board jumpers 7 — 47-5 . . . . . . . . . . . . . . . Configuring the

Transmission Speed 7 — 47-6 . . . . . . . . . . . . . . . Configuring the

Transmission Format 7 — 57-7 . . . . . . . . . . . . . . . Configuring the

Hx and Ix Signals Format 7 — 5

vi Contents


86-891000-00

Tablestable description page number1-1 . . . . . . . . . . . . . . . Model and Part numbers

for installation of 5 kVA, 7.5kVA and 10kVA 1 — 2

2-1 . . . . . . . . . . . . . . . Battery cabinet for an overall operating time of 30 minutes (7.5 & 10 kVA) or 24 minutes (5 kVA) at rated output power with a power factor of 0.6 6 — 1

2-2 . . . . . . . . . . . . . . . Battery cabinet for an overall operating time of 50 minutes (7.5 & 10 kVA) or 40 minutes (5 kVA) at rated output power with a power factor of 0.6 6 — 2

3-1 . . . . . . . . . . . . . . . Maximum current ratings a — 43-2 . . . . . . . . . . . . . . . Minimum cable size a — 4

viiContents


86-891000-00

This manual has been designed to provide you with all theinformation you need to install and use your EXL 1000 UPSsystem.

This manual is designed for ease of use and easy location of information.

This manual uses Noteboxes to convey importantinformation. Noteboxes come in four varieties:

If you encounter a problem while following the instructions inthis manual, we recommend that you contact our CustomerSupport Services. On request, our customer supportpersonnel can carry out the complete installation of yourequipment.

Safety

Recommendations

NOTEA NOTE noteboxindicates informationprovided as an operatingt ip or an equipmentfeature.

IMPORTANTAn IMPORTANT noteboxindicates informationprovided as an operatinginstruct ion or as anoperating tip.

CAUTIONA CAUTION noteboxindicates informationp rov i d e d t o p ro t e c tthe user and servicep e r s o n n e l a g a i n s tposs ib le equ ipmentdamage.

WARNINGA WARNING noteboxindicates informationprovided to protectthe user and servicepersonnel against safetyhazards and/or possibleequipment damage.

How to use this manual

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86-891000-00

This manual provides technical information required foroperation and maintenance of the EXL 1000 series uninter-ruptible power system (UPS). Please read this manualbefore operating the EXL 1000 equipment. Please retain thismanual for future reference.

The manual is divided into seven100 sections:

Section I — General DescriptionThis section introduces the EXL1000 family of uninter-ruptible power systems, including a general descriptionof the system and its internal components, a descriptionof available options, and system specifications.

Section II — InstallationThis section describes the installation procedures forthe EXL 1000.

Section III — OperationThis section describes operating information for EXL1000 UPS single-module systems, including anoverview of the system, its components, and theirfunctions; a description of the indicators and controlsand their functions; and operational sequences to befollowed for all conditions of normal, emergency, andmaintenance operation.

Section IV — CommunicationThis section describes communication options availabelfor the EXL 1000.

Section V — Maintenance and ServiceThis section describes user level maintenance andservice practices for the EXL 1000.

Section VI — OptionsThis section describes available add on options for theEXL1000.

Section VII — U-TalkThis section describes installation and usage of theoptional U-Talk board which allows computer systems tomonitor and controll the EXL 1000 remotely.

An appendix near the rear of this manual providesinformation on specifications of the EXL 1000.

1.0 Scope

1 — 1

Introduction

86-891000-00

A Glossary in the rear of this manual provides definitions ofterms used within the text.

The EXL1000 series are a family of Uninterruptible PowerSupplies (UPS) designed for safe reliable VAC backup powerfor the computer room, office or industrial environments.

This manual describes the function and installation of the5kVA, 7.5kVA, and 10kVA members of the EXL1000 UPSfamily. The following are the model numbers and partnumbers respectively:

Table Model and Par t numbers for instal lat ion 1-1 of 5 kVA, 7.5kVA and 10kVA

Description Model Number Part Number

UPS 4.7 kVA/3.8 kw, 208 VAC in/out EXL 1050 891050-84

UPS 5 kVA/4 kw, 240 VAC in/out EXL 1050 891050-44


UPS 7.5 kVA/6 kw, 240 VAC in/out EXL 1075 891075-44


UPS 10 kVA/8kw, 240 VAC in/out EXL 1100 891100-44

There are 7 major components within the EXL1000 UPS andthey are as follows:

1. Input EMI filter - This is an electonic filter whichprevents electrical noise (EMI) generated by the UPSfrom conducting or radiating back onto the AC inputpower lines. It also incorporates lightning strikeprotection for the UPS.

2. Input rectifier - This module takes AC input line to linevoltage and converts it to a rectified DC voltage which isfed to the input of the “chopper” module.

3 Chopper - The chopper module has two voltage inputs.A rectified AC input and a battery DC voltage. Thechopper module outputs + and - 385 Vdc which is fed tothe inverter module.

When AC input is present the chopper takes power fromthis input. When the AC input fails or is removed thechopper automatically will transfer to battery and takepower from the battery source in order to continue topower the inverter module.

4. Battery - A 180 Vdc (5 or 7.5 kVA models) or 240Vdc(10 kVA model) source is used to power the chopper

1.1.1 Description of

UPS Module

1.1 General Description

1 — 2 Introduction


86-891000-00

module which powers the inverter module which powersa user’s output load. This happens only when the ACinput fails, is out of tolorance or is removed.

5. Inverter - This power module converts the + and -385Vdc output from the chopper to 208 or 240VAC lineto line which continually outputs and powers the user’sload.

6. Static bypass switch - Solid state switch. When theinverter is overloaded, fails or is turned off, the UPSautomatically transfers it’s output load to the AC input ofthe UPS via this solid state switch called the staticbypass switch. This automatic power transfermechanism allows for no loss of output power to theuser’s load. The load’s power is never interrupted withthis type of power transfer. The inverter output,although off or disabled, is still physically connected tothe load.

7. Maintenance bypass switch - A manual hard switch.This switch is used when maintenance is required onthe UPS without interrupting power to the load. Turningthis switch to “bypass” internally connects the AC inputdirectly to the AC output of the UPS, while at the sametime physically disconnecting the inverter output fromthe load. By also turning off the input circuit breaker,the internal electronics are now physically isolated frominput and output, enabling a service technician to openthe UPS and service it without fear of electrocution. Atthe same time, the load is still being powered directly bythe AC input via the maintenance bypass switch.

1 — 3Introduction

Installation and User’s manual

86-891000-00

Figure Ident i f icat ion Plate1-1

The configuration sheet, included with the UPS, indicates allthe factory settings. Keep the sheet in a safe place as it maybe required by the after-sales support technicians if you wishto modify parameters.

1.2 Configuration

PULSAR EXL 1000

+ - CEAC

YUA

Volt :

Ah :

Article - Article - Artikel

N° Série - Serial Number - Artikel

NT

PB02

Model Number 891100-84Serial NumberSales Order No.

AC Input: L1 L2 + GND

Input Voltage: 208V Vrms L — LInput Current: 47 Arms

Frequency: 60 Hz

AC Output: L1 L2 + GND

Output Voltage: 208V Vrms L — LOutput Current: 46 Arms

Frequency: 60 Hz

Output Power: 9.5KVA/7.6KWBatt Voltage: 240VDCBatt Current: 46 Adc

LISTED55K6

016762690

UNINTERRUPTIBLE POWER SUPPLYE87247



86-891000-00

Figure EXL 1000 5kVA front and rear v iew1-2

Figure EXL 1000 7.5 & 10 kVA front and rear v iew1-3

! !

fault

Basic control andindication panel

Special command anddiagnostic display

Diagnostics and configuration connector

(reserved for after-sales support)

Standard communication port

Location of optional communications ports

Battery circuit breaker

Fans

"manual maintenancebypass" switch

Input circuit breaker

Connection cover panel

! !

fault

Basic control andindication panel

Special command anddiagnostic display

Diagnostics and configuration connector (reserved for after-sales support)Standard communication port

Location of optional communications ports

Fan

"manual maintenancebypass" switch


Utility connection cover panel

Battery connection panel

1 — 5Introduction


86-891000-00

Figure Funct ional diagram1-4

loadAC input

"static bypass" module


Rectifier module

Charger module

Battery

Battery circuit breaker

Inverter module

"manual maintenance bypass" switch



86-891000-00

This section describes installation of the EXL 1000 UPS.

The equipment must always be stored in its originalpackaging.

The equipment must be unpacked close to the installationlocation.

NOTEAfter unpacking, check the overturn indicator at the back of the device.If it is red (or otherwise indicates that the unit has been tipped overduring shipping), contact the after-sales department.

2.2 Unpacking

IMPORTANTThe battery is of the sealed type. Battery storage or prolongedshutdown of EXL 1000 should never exceed 6 months at 68°F (20°C)without recharging, for a battery initially at 100% charge. Batteryrecharge requires system start-up.The battery warranty is void if the 6month recharge interval is not respected.

2.1 Storage

2.0 Scope

2 — 1

Installation

86-891000-00

Figure Unpacking the EXL 1000 UPS2-1

unbolt from base

remove box

remove packingcorners

remove ramp

ramp for 7.5 & 10 kVA UPS

ramp for 5kVA UPS

2 — 2 Installation


86-891000-00

Figure Remove stabi l iz ing mater ia l f rom under EXL 1000 UPS2-2

Figure Use suppl ied ramp to br ing EXL 1000 off of shipping base2-3

levelling screws in the raised position

ramp (7.5/10kVA)

ramp (5kVA)

2 — 3Installation


86-891000-00

EXL 1000 cabinets are equipped with 4 wheels for movingover short distances and with jacks to immobilize the unit.The jacks must be raised prior to repositioning the unit.

Since operating temperature range is 32°F to 86°F (0°C to30°C) at rated output, a location with appropriate ventillationand cooling should be chosen for installation. Battery life isextended when it is installed in a room with an ambienttemperature of 59°F to 77°F (15°C to 25°C). Above 77°F(25°C), battery life is reduced by 50% for every additional18°F (10°C). Heat generatedfrom EXL 1000 operation mustbe taken into account when sizing the ventilation system.See the Appendices.

Power cable connections are made through the bottomsection in the back of the EXL 1000.

Ensure that service clearance to the left of EXL 1000 isgreater than 16 inches (400 mm) for side access to thebattery cells. Ensure that there is greater than 4 inches (100mm) on the left for ventilation. Ensure that front clearance isgreater than 22 inches (550 mm) for servicing. Ensure thatthere is at least 4 inches (100 mm) behind the cabinet forventilation.

Figure Instal lat ion clearances as seen from above2-4

Additional cabinets (extended battery, distribution/transformer, etc.) must be placed to the right of EXL 1000. Ifthe above installation conditions are not respected,maintenance and servicing of the unit may require systemshutdown.

4 inches minimum(for ventilation)

air exhaust

extended batterytransformer/distributioncabinet

optionother option

12 in. min.service clearance

22 in. min.service clearance

15.75 inches 15.75 inches10.5inches

P EXL1000

4 in.ventilation clearance

4 in.ventilationclearance

2.4 Final positioning

2.3 General



86-891000-00

Load cables must be run separately from all other cables(power supply or computer system interconnection cables).They should not pass near interference-emitting equipmentor sensitive loads.

Connection cables should enter at the bottom rear of the7.5/10kVA. Connection cables for the 5kVA model must be10 AWG 75°C minimum. Connection cables for the 7.5 kVAand 10 kVA must be 6 AWG 75°C minimum. Cables must beenclosed in a .75 inch flexible conduit. Cables should be suffi-ciently long to enable forward movement of EXL 1000 withoutdisconnection. Allow an extra 5 feet (1.5 meters) slack in thecables. Conduit shall be terminated to a conduit landing via a3/4 inch flexible metal conduit fitting.

Figure 2-5 shows a single-line electrical diagram for a typicalinstallation. The power cables requiring connection areshown as bold lines (see the appendices for information onselecting cable gauges).

Figure Connect ion diagram for a single AC input2-5

Make sure the unit is powered down and disconnected fromall input power before making connections to the terminalblocks at the back of the cabinet. For protection of life andproperty, ground wires should always be connected first.

Neutral system: identical upstream and downstream neutralsystems (no galvanic isolation). EXL 1000 can be used withall types of neutral systems, on the condition that standardpractices be respected.

Check that AC input power circuit breaker, installed upstreamon the low voltage switchboard, is in off (O) position;

Check that the input circuit breaker and the battery circuitbreaker are in off (O) position.

loadAC input

extended batterycabinets (optional)

XR3

XR3

XR2XR1

EXL1000

2.6.1 Electrical Diagram for

Power Connections

2.6 Connections

2.5 Special Precautions

2 — 5Installation


86-891000-00

Connection sequence:

• Remove maintenance bypass switch knob using a narrow flathead screwdriver (7.5 & 10 kVA models only).

• Remove the conduit landing cover panel that is securedwith six torx screws.

• Connect flexible conduit to conduit landing.

• Connect the AC input cables to Mains 1 terminal blockXR1. Observe phase 1 (L1), phase 2 (L2) and groundcorrespondence as indicated on the label (figure 2-7 for5 kVA and figure 2-9 for 7.5 & 10 kVA).

• Connect the AC load cables to terminal block XR2.Observe phase 1 (L1), phase 2 (L2) and ground corre-spondence as indicated on the label (figure 2-7 for 5kVA and figure 2-9 for 7.5 & 10 kVA).

• Connect the various options as indicated in the corre-sponding sections of this manual.

• Reattach the conduit landing cover panel andmaintenance bypass switch knob (7.5 & 10 kVAmodels).

NOTE5 kVA UPS conduit landings are shipped loose. Installation should bedone by authorized personnel only.

NOTEThere are two phases and one ground. There is no neutral connection.



86-891000-00

Figure Removal of conduit landing cover panel (5 kVA)2-6

Figure Cable connect ions (5 kVA)2-7

XR2load

XR1Mains 1

L1L2

L1L2

detail of connectionterminal blocks

to load (two-phase + ground)

from LV switchboard (two-phase + ground)

L+

XR3battery

L-

2 — 7Installation


86-891000-00

Figure Removal of maintenance bypass switch knob and 2-8 conduit landing cover panel (7 .5 & 10 kVA)

Figure Cable Connect ions (7.5 & 10 kVA)2-9

to load (two-phase + ground)

from LV switchboard (two-phase + ground)

XR3battery

EPOconnector(optional)

XR2load

XR1Mains 1

L+L– 1 2 3 4 L2L2L1 L1

maintenance bypass switch knob

conduit landingcover panel



86-891000-00

EXL 1000 operating controls include basic controls andindicators (figure 3-1), concerning the overall operatingstatus of the UPS and the special command and diagnosticdisplay panel (figure 3-10), which includes specific controlsand a 2-digit display for the UPS fault numbers. Thesenumbers provide UPS diagnostics.

Figure Locat ion of Controls and indicators on cabinet3-1

The basic controls and indicators are located in the upperleft-hand corner of the front panel. This panel providesinformation on the operating status of the system (see figure3-2). Interpretation of the LEDs is very easy and requires nospecial training.

The LEDs indicate normal operation (load protected), UPSfault, load not protected and operation on battery power.

3.1.1 Basic controls

and indicators

! !

fault

! !

fault

basic controlsand indicatorspanel

special command and diagnostic display

3.1 Controls and

indicators

3 — 1

Operation

86-891000-00

Figure Close-up of Controls and indicators3-2

The “Load protected” LED indicates that the EXL 1000 isoperating normally. The load is supplied by the inverteroutput. This LED also goes on during normal start-up of EXL1000.

Figure “Load protected” LED3-3

The “Battery Status” LED can be on continuously or mayflash repeatedly. If continuously lit, the “Battery Status” LEDindicates that the inverter is operating on battery powerfollowing an AC input failure or detection of an AC inputvoltage outside tolerances. When flashing, it indicates thatthe low battery shutdown warning level has been reached. Ifthe LED flashes when the battery is not in self-operatingphase, this indicates that the battery status should bechecked by an After-Sales representative.

Figure “Battery Status” LED3-4 I+ –!! O

“Battery Status” LEDContinuously on — Inverter on battery powerFlashing — low battery shutdown

or check batteries

I+ –!! O

“Load Protected” LED

I+ –!! O

audible alarm"load not protected" light"fault" light"battery status or operation on battery power" light"load protected" light"inverter on" button"inverter off" button

3 — 2 Operation


86-891000-00

The “Fault” LED indicates an operating fault or anenvironment fault. However, the load continues to besupplied by the inverter.

Figure “Fault” LED3-5

The “Load Not Protected” LED indicates that the load issupplied through the "static bypass" because of invertershutdown (voluntary or following an overload or an internalfault), or that battery power is not available because thebattery circuit breaker is in "off" position.

Figure “Load Not Protected” LED3-6

The audible alarm is activated when the load is supplieddirectly by AC input power via the “static bypass,” the inverteris operating on battery power, or when there is an operatingfault. It beeps softly and slowly for minor faults and duringinverter operation on battery power. When the low batteryshutdown warning level has been reached, the beeps getlouder and more frequent. In the event of an invertershutdown, a continuous loud alarm is emitted.

An audible alarm reset button is provided on the controls anddiagnostics display panel. Detection of a new fault willreactivate audible alarm.

Figure Audible Alarm3-7

The green “inverter on” button is used to start the inverter.

Figure “Inver ter On” button3-8 I+ –!! O

“Inverter on” button

beep...beep...

I+ –!! O

“Audible alarm” LED

I+ –!! O

“Load Not Protected” LED

I+ –!! O

“Fault” LED

3 — 3Operation


86-891000-00

The grey “inverter off” button is used to stop the inverter.

Figure “Inver ter Off ” button3-9

The controls and diagnostics display panel (figure 3-10)includes an LED display for environment and subassemblyfaults and buttons for specific controls. Faults are displayedonly when the user presses (once) one of the control buttons.

Figure Controls and Diagnost ics Display3-10

The audible alarm reset button enables the user to quiet theaudible alarm. Detection of a new alarm will set the audiblealarm off again.

The fault reset button clears the faults stored in memory.Clearing of alarms in memory is accepted only if the alarmconditions themselves have been cleared.

The security button authorizes forced operation or shutdownof the inverter. There are three tasks that can be done usingthe security button.

Forced shutdown press the security button and the "inverter off" button(figure 3-9) simultaneously for three seconds.

Forced operation press the security button and the "inverter on" button(figure 3-8) simultaneously for three seconds.

Battery manual test press the security button and the audible alarm reset buttonsimultaneously for three seconds.

fault

diagnostics displayfault resetsecurity buttonaudible alarm reset

3.1.2 Controls and

Diagnostic Display

I+ –!! O

“Inverter off” button

3 — 4 Operation


86-891000-00

Alarm, fault and status messages are displayed as numericalcodes. See section 3.14 for the meaning of the codes. Thealarm-code equivalence table is also displayed at the back ofEXL 1000.

Check the settings of the protection devices:

• Input circuit breaker is in the off (O) position.

• Battery circuit breaker is in the off (O) position,

• "Manual bypass" circuit breaker is set to "NORMAL"position (see figure 3-11)

• Check that nothing is blocking the ventilation system(air entry through the bottom and, where applicable,through the side vents)

• Check that there is a minimum of 4 inches (100mm)clearance at the back for ventilation

• Check that the EXL 1000 no longer rests on its 4wheels (leveling screws in place)

• Check that the load-circuit circuit breakers (whereapplicable) are in the off (O) position.

Figure Manual Maintenance Bypass circuit breaker3-11 BY-PASS

TE

ST

1

NO

RM

AL

TEST 2

3.2 Checks before

Start-up

IMPORTANTThe batery manual test function causes the battery to discharge com-pletely in order to update the battery monitoring parameters. Do notenable test during normal work hours because battery back-up will belessened or unavailable during this test. In the event of a networkpower cut, the uninterrupted battery power supply returns to normaloperation. The self-operating time is thus reduced.

3 — 5Operation


86-891000-00

First put the input circuit breaker in the “on” position, then putthe battery circuit breaker in the "on" position. The audiblealarm will sound and the green “load protected” LED will light.

The rectifier and the battery charger will start up. If thetransfer conditions (AC input power within tolerances) arecorrect, the inverter comes on line and supplies the loadunless the system is in "manual start-up" mode (optional,section 3.4).

The green "load protected" LED will now be on.

Figure EXL 1000 power-up3-12

In the event of a fault, the red "load not protected" light goeson. See the Alarms section (section 3.13).

To manually start the inverter,use the following steps:

Press the green "inverter on" button

The green "load protected" LED will flash

The inverter will start and if the transfer conditions arecorrect, the load will be transferred to the inverter. The red"load not protected" LED will go off and the green "loadprotected" LED will light.

Press and hold the "inverter off" button for three seconds.The green "load protected" LED will go off and the red "loadnot protected" LED will light. The audible alarm will sound. Ifthe transfer conditions are correct, the inverter will stop andthe load will be supplied directly by AC input power via the"static bypass."

In the event of fault, see the Alarms section (section 3.13).

3.5 Shutting down

the inverter

3.4 Manual Inverter

Start-up

I+ –!! O

beep...beep

"load protected" LED"inverter on" button

3.3 Powering up the

EXL 1000

3 — 6 Operation


86-891000-00

Powering down the EXL 1000 for long periods is notrecommended because the battery should remain charged.However, to carry out a power down, proceed as follows:

• Shutdown the inverter (section 3.5)

• Put the battery circuit breaker in the "off" position;

• Turn off the input circuit breaker

All the LEDs on the control panel will go off.

• Put the upstream circuit breaker(s) on the low voltageswitchboard in "off" position.

The AC input power supply is present:

the green "load protected" light (figure 3-13) is on;

the power drawn by the load is supplied by AC input powervia the rectifier and inverter modules. The battery chargerfloat charges or recharges the battery. The DC outputvoltage of the battery charger is temperature regulated toensure an optimal charge voltage.

Figure Indicators during normal operat ion3-13

Figure Diagram of normal operat ion on ut i l i ty power3-14

loadAC input

rectifier

charger battery

inverter

I+ –!! O

“Load Protected” LED

3.7 Normal Operation

WARNINGThe load is still supplied by AC input power via the "static bypass".

3.6 Powering down

the inverter

3 — 7Operation


86-891000-00

When AC input power fails or exceeds tolerances, therectifier and the battery charger shut down. The batterysupplies the power required by the inverter to supply theload.

The battery discharges.

The green "load protected" light is on.

The user is warned of operation on battery power by theaudible alarm and by the orange "battery status" light (figure3-15). This information is also available via the standardcommunication connector.

Figure Indicators when on battery power3-15

Figure Diagram of operat ion on battery power3-16

EXL 1000 has a battery monitoring function that calculatesthe remaining backup time. This function may beimplemented with a communications option.

A low battery shutdown warning signal is available via thestandard communication connector for remote indications. Itwarns the user of upcoming battery shutdown at a user-determined level of remaining power.

On the UPS itself, the audible alarm beeps louder and morerapidly, and the orange "battery status" light flashes.

3.9 Battery duration

loadAC input

static bypass

rectifier

charger battery

inverter

I+ –!! O

beep...beep...

audible alarm"battery status" LED"load protected" LED

3.8 Operation on

battery power

3 — 8 Operation


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The end of battery power occurs when the battery is fullydischarged. At this point, the inverter shuts down.

The recharge time required to restore the battery of a 5 kVAmodel to its rated backup power is 12 hours maximum. Therecharge time required to restore the battery of a 7.5 kVA or10 kVA model is 5 hours maximum.

If the end of battery backup power was not reached when theAC input power failure ends or power returns to withintolerances; EXL 1000 returns to normal operating statuswhere the inverter will receive power from the rectifier andnot the battery.

If the end of battery backup power was reached, the rectifier,the battery charger and the inverter automatically start up(the inverter must be manually started if the system is inmanual start mode).

The battery is automatically checked every month. Themessage "17" on the diagnostics display (figure 3-10) tellsthe user that the battery is in this operating mode.

It is recommended to carry out a complete discharge test onthe battery once a year in order to update the batterymonitoring parameters. This test is activated by the "batterymanual test" control. See section 3.1.2.The message "18" onthe diagnostics display tells the user that the battery is in thisoperating mode.

In these operating modes, total battery failure is indicated bythe alarm message "15" on the diagnostics display.

During a major temporary overload (greater than 150%), theload is supplied by AC input power via the static bypass.Return to the inverter is automatic, following elimination ofthe overload. The inverter can handle a minor overload for agiven duration depending on the size of the overload (seefigure 3-17).

When an overload occurs, the audible alarm sounds, theorange "fault" LED goes on, and the inverter shuts down atthe end of its corresponding overload time. When the invertershuts down, the load receives its AC input power via thestatic bypass.

To indicate that the inverter is no longer protecting the load,the green "load protected" light goes off and the red "loadnot protected" light goes on.

3.12 Overload

3.11 Battery Monitoring

Tests

3.10 Return of

AC input power

3 — 9Operation


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If the overload continues during operation via the staticbypass, the supply of power to the load is interrupted after aspecified time. See figure 3-18.

When the EXL 1000 has shut down because of an overload,the fault reset button must be pressed prior to return tonormal operation.

Figure Inver ter overload curve3-17

Figure Stat ic Bypass overload curve3-18

The status of the EXL 1000 can be determined by the status

LEDs and the audible alarm (see section 3.14). Any stateother than normal operation (green “load protected” LED on)is considered a fault by the diagnostics system.

Before undertaking any servicing or other action, note thestatus of the LEDs and the number(s) of the fault(s) indicatedon the diagnostics display. If the "Monitor Plus" option isinstalled, also note the messages in the list on the screen.

Certain faults may result in the display not functioning.

If the load still functions, it is supplied via the "static bypass;"it is not protected by the inverter.

3.13 Alarms1.05 1.1 1.3 1.5

10 mn

10 sec

1 sec

0.15 sec

rated load current In

1.7 1.9 2

1 mn

time

1.05 1.1 1.3 1.5

10 min

10 sec

1 sec

0.15 sec

rated loadcurrent In

1.7 1.9 2

1 min

time

3 — 10 Operation


86-891000-00

The diagnostics display shows numeric codes for alarms,faults and status messages. Following is a list of the numericcodes and their meanings. Figure 3-19 is a diagram of theEXL 1000’s major components and shows which subsystemsare responsible or affected by various fault codes.

11 battery circuit breaker in "off" position indicates that the battery circuit is open (battery circuitbreaker is in "off" position). The load is no longer protectedbecause battery power is no longer available in the event ofan AC input power failure. In the case of the "battery-freefrequency converter" option, it is normal for the "11"message to remain on.

12 check battery indicates that the battery should be checked (see Batterymaintenance section 5.2.1).

13 low battery shutdown warningindicates that battery power will end after a user-set timeperiod. The user must take the required measures to securethe load (load shedding, file saving and system shutdown,etc.).

14 end of battery power

15 battery faultindicates a problem with the battery (see "batterymaintenance" in the "maintenance and servicing" section.

16 ambient temperature faultthis display indicates that the ambient temperature is outsidethe tolerance range (<0°C or > 40°C).

17 battery periodic testthis message indicates that the battery is in the process ofbeing checked.

18 battery manual testthis message indicates that the battery is in the process ofbeing completely discharged in order to update the batterymonitoring parameters.

21 inverter faultindicates a fault in the inverter module; contact the after-sales support department.

3.14 Diagnostics display

messages

3 — 11Operation


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22 inverter overtemperatureindicates overheating inside the UPS; check that the EXL1000 ventilation system is working and that the ambienttemperature is within tolerances (see "appendices").

25 inverter overloadindicates an overload when the load is being supplied via theinverter. Reduce the load.

31 Mains 2 (bypass) voltage outside tolerance rangethis display indicates that the Mains 2 power supply voltageof the "static bypass" is outside the tolerance range.

32 phase shift outside tolerance rangethis display indicates that the phase between the Mains 2power supply of the "static bypass" and the "inverter module"is outside the tolerance range

34 frequency of Mains 2 (bypass) power supply to "static bypass" outside tolerancesthe output inverter voltage is no longer synchronized withMains 2. To force transfer of the load to the inverter, simul-taniously press the security button and the green "inverteron" button and hold for three seconds. Transfer results in a0.5 second break in the supply of power to the load.To force transfer of the load to the "static bypass", simultan-iously press the security button and the grey "inverter off"button. Transfer results in a 0.5 second break in the supply ofpower to the load.

35 "static bypass" overloadindicates an overload when the load is being supplied via the"static bypass". Reduce the load.

37 Mains 1 voltage outside tolerance rangethis display indicates that the voltage of the Mains 1 powersupply of the "rectifier module" is outside the tolerancerange.

39 installation faultindicates an incorrect connection at the frequency converterinput; check the connection of the Mains 1 input source toterminal block XR1.

41 load supplied via "static bypass"this display indicates that the load is powered by the Mains 2via the "static bypass"

51 battery charger faultindicates a fault in the battery charger module; contact theafter-sales support department

3 — 12 Operation


86-891000-00

61 rectifier or chopper faultindicates a fault in the rectifier module; contact the after-salessupport department

62 chopper overtemperaturesee fault "22".

63 fuse blown on Mains 1 inputindicates that the fuse has blown in the rectifier module;contact the after-sales support department.

65 chopper overloadindicates that the active power consumed is too high. Reducethe load

71 internal communication faultindicates an EXL 1000 internal fault; contact the after-salessupport department

72 internal communication self-test faultsee fault "71".

73 CPU board self-test faultsee fault "71".

Figure Relat ionship of faul t codes to EXL 1000 subsystems3-19

31 33 34 39

37 63

12 13 14 15 17 18

35 41

11

32

21 22 255116 Ambient

Temp.

61 62 65

71 72 73

3 — 13Operation


86-891000-00

If the load is no longer supplied, a manual bypass operationenabling supply is possible, while waiting for the after-salessupport personnel.

Proceed as follows:

• Switch the input circuit breaker to the "off" position.

• Switch the battery circuit breaker to "off" position.

• Check that all lights are off.

• Turn the "manual bypass" switch as indicated in figure3-20 from the "NORMAL" position to the "BYPASS" position.

Figure Manual Bypass Switch3-20

IMPORTANTThe TEST 1 and TEST 2 positions are reserved for the after-sales sup-port personnel. Leave the switch set to the "BYPASS" position until thearrival of the after-sales support personnel.Use of the switch other than as indicated above may damage EXL 1000and void the warranty.

BY-PASS

TEST 2

TE

ST

1

NO

RM

AL

3.15 Manual Bypass

3 — 14 Operation


86-891000-00

The communication connector, positioned on the back forEXL 1000 5/7.5/10kVA, supplies the following information:

• operation on the "static bypass".

• low battery shutdown warning.

• load supplied by the inverter.

• operation on battery power.

This connector enables communication with the mostcommon computer systems (AS400, NOVELL, etc.).

Figure 4-1 indicates the pin-outs for the SUB-D 15-pin femaleconnector (front view).

Figure Electr ical connect ions of 15 pin D connector4-1

Figure 15 pin D connector4-2

5 4 3 2 1

12 11 10 9

8 7 6

15 14 13

4

14

12

7

13

11

9

10

6

8

5

UPS remoteshutdown(signal between3 and 15V DC)

PIJO PC board

contact switchingcapacities:P = 2.5VAV = 30V max.I = 0.1A max.

connectorSUB-D15-pin

NO

NC

NO

NC

NO

NC

NO

NC

very low safetyvoltage signals:

operation on"static bypass"

operation on inverter

operation on battery

low batteryshutdown warning

4.0 Standard Functions

4 — 1

Communication

86-891000-00

Three options may be used simultaneously on the EXL 1000,thus enabling communication with a wide number ofcomputers and control devices.

Monitor PlusMonitor Plus is a mini terminal for control and display of ACinput power and system parameters. The Monitor Plus canbe installed locally or remotely. This option, the U-Talk optionand the JBUS option can be used with the battery monitoringfunction to provide information on available battery powerduring normal operation and remaining battery power duringoperation on battery power.

Contact 5This option offers communication of five different signals viadry relay contacts:

• operation on battery

• operation on "static bypass"

• low battery shutdown warning

• load supplied by the inverter

• general alarm

Relay-contact breaking capacities: 250V AC, 125V DC, 1A.

4.1 Options

NOTEThe remote UPS shutdown command is valid when the inverter is sup-plied by the AC input source or the battery. The inverter shuts downafter a two minute delay.

4 — 2 Communication


86-891000-00

U-TalkThis option manages an RS232 serial interface using anASCII protocol. This option is supplied with the "SolutionPac"™ CD-ROM which integrates a range of managementsoftware for MGE Uninterruptible Power Supplies underSNMP. Like the Monitor Plus and JBUS options, this optioncan be used with the battery monitoring function to provideinformation on available battery power during normaloperation and remaining battery power during operation onbattery power.

More complete information on the U-Talk option can be foundin chapter 6 of this manual.

JBUS/RS232 and JBUS/RS485These options enable remote monitoring of the EXL 1000.Like the Monitor Plus and U-Talk options, this option can beused with the battery monitoring function to provideinformation on available battery power during normaloperation and remaining battery power during operation onbattery power.

4 — 3Communication


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(this page left blank intentionally)

4 — 4 Communication


86-891000-00

Preventive maintenance for the EXL 1000 is limited to thestrict minimum. However, this chapter indicates importantprocedures to ensure continuous and correct operation.

User maintenance of the EXL 1000 is limited. The followingitems may be checked to insure safe, efficient operation.

Check the installation and operating conditions:

• Distance from wall

• Ventilation inlet and outlet vents unobstructed

• Operating temperature, particularly for the batteries

• No faults signalled by the LEDs

Consult the after-sales support department for furtherinformation concerning the services presented belowrequiring special tools, in particular the "Soft Tunor" software.

Battery status is monitored by EXL 1000 When the orange"operation on battery" light flashes and fault number. “12” isindicated on the diagnostics display, the battery should bechecked.

When the red "load not protected" light flashes and faultnumber “15” is indicated on the diagnostics display, a batteryfault is present.

To clear these alarms, press the "security" and "fault reset"buttons at the same time.

5.2.1 Battery

Maintenance

5.2 Maintenance by

Certified MGE

Representatives

5.1 User Preventive

Maintenance

WARNINGHigh voltages are present inside the EXL 1000 system. Any servicingrequiring removal of the protective covers may be undertaken only byqualified personnel certified by MGE UPS Systems.

5.0 Scope

5 — 1

Maintenance and Service

86-891000-00

The battery cells contain substances which are dangerous tothe environment. Following replacement, the after-salessupport department forwards old batteries to special organi-zations for recycling and disposal.

This complete check-up can be run only by qualifiedpersonnel certified by MGE UPS Systems.

Training courses are offered by MGE UPS Systems whichenable personnel to monitor the system and undertake basicmaintenance. Contact your MGE UPS Systems distributor forthe list of courses offered.

Your MGE UPS Systems contact can supply you with thecatalogue of maintenance contracts that indicate how youcan transfer responsibility for maintenance to qualifiedtechnicians always on call.

5.2.5 Maintenance

Contracts

5.2.4 Customer Training

5.2.3 Annual Check

5.2.2 Environmental

Protection

CAUTIONClearing the alarms by pressing "security" and "fault reset" disablesthe battery monitoring and backup time calculation functions (MonitorPlus option); contact the after-sales support department to check thecondition of the battery and replace it if necessary. The after-salessupport technician will reactivate the battery monitoring and backuptime calculation functions.

5 — 2 Maintenance and Service


86-891000-00

As standard equipment, EXL 1000 comes with an internal240 volt battery for the 10 kVA EXL 1100 and 180 volts forthe 5 kVA EXL 1050 and 7.5 kVA EXL 1075. These provide abackup time (at full rated load and a power factor of 0.6) of10 minutes for 7.5 kVA and 10 kVA models or 8 minutes for5 kVA model. The backup time can be increased to 30minutes or up to 50 minutes for the 7.5 kVA or 10 kVAmodels, 24 minutes or up to 40 minutes for the 5 kVA model,by the addition of an optional auxiliary battery cabinet.

If EXL 1000 was not factory-set for the additional cabinets,the new configuration must be entered by an MGE UPSSystems after-sales support technician.

Table Battery cabinet for an overal l operat ing t ime of 2-1 30 minutes (7.5 & 10 kVA) or 24 minutes (5 kVA)

at rated output power with a power factor of 0 .6

model number of UPS EXL1050 EXL1075 EXL1100

model number EXL 5-24 EXL 7.5-30 EXL10-30

part number 891056 891076 891101

Batteryheight (in/mm) 28.7/730 35.8/910 35.8/910

cabinet width (in/mm) 14.17/360 15.75/400 15.75/400dimensions

depth (in/mm) 16.5/420 21.65/550 21.65/550

weight (lb/kg) 147/66 262/118 331/149

6.1 Extended battery

cabinet

6 — 1

Options

86-891000-00

86-891000-006 — 2 Options


Table Battery cabinet for an overal l operat ing t ime of 2-2 50 minutes (7.5 & 10 kVA) or 40 minutes (5 kVA)

at rated output power with a power factor of 0 .6

model number of UPS EXL1050 EXL1075 EXL1100

model number EXL 5-40 EXL 7.5-50 EXL10-50

part number 891057 891077 891102

Batteryheight (in/mm) 28.7/730 35.8/910 35.8/910

cabinet width (in/mm) 14.17/360 15.75/400 15.75/400dimensions

depth (in/mm) 16.5/420 21.65/550 21.65/550

weight (lb/kg) 242/109 477/215 613/276

Prior to installation of additional battery cabinets, check thatthe protection devices are in the following positions:

• upstream circuit breaker off

• input circuit breaker off

• battery circuit breaker off

• "manual bypass" switch set to the "NORMAL" position

Position the battery cabinet on the right side of EXL 1000.Connect the terminal block in the battery cabinet to the XR3terminal block in EXL 1000 as follows:

• yellow/green cable (ground) to the yellow/green terminalon XR3

• red cable (+ pole) to the L+ terminal on XR3

• black cable (– pole) to the L– terminal on XR3

• position the two cabinets with the front panels aligned

• turn on the circuit breaker in the battery cabinet

6.2 Connection of

an additional

battery cabinet

Figure Connect ion of an addit ional battery cabinet6-1 (5kVA Model) Covers Removed

Figure Connect ion of an addit ional battery cabinet6-2 (7 .5 & 10 kVA Models)

battery cabinet terminal block

to a secondflexible conduit from EXL 1000to battery cabinet battery cabinet

(if applicable)

XR3battery

XR2load

XR1Mains

XR3battery

connection terminal blocks of EXL 1000 7.5 and 10 kVA

L L+L+L

connection terminal blocks of EXL 1000 5kVA battery cabinet terminal block

L+L L+L

to a secondarybattery cabinet(if available)

flexible conduit from EXL 1000to battery cabinet

6 — 3Options


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The end user is responsible for the installation of anemergeny power off function. Installation must be carried outin compliance with local code regulations.

To power down the entire installation via an emergencypower off function, the action should perform the following viaa single device:

• sever the AC input power to the EXL 1000

• remotely trip off the battery circuit breaker on the EXL1000

• remotely trip off the circuit breaker for the additionalbattery cabinet(s), if applicable

To accomodate the EPO function, the EXL 1000 UPS andbattery cabinets come equipped with battery circuit breakerswith shunt trip mechanisms. By applying 24 Vdc or 24 VACacross the shunt trip coil, the circuit breaker will trip off,thereby disconnecting battery input to the inverter.

• Check that the upstream circuit breaker on the lowvoltage switchboard, the input circuit breaker, and thebattery circuit breaker are all in "off" position

• Remove the connection cover panel from the EXL 1000

• Connect the 24Vdc or 24 VAC output of the EPO circuitto the shunt trip coil across terminals 1 and 4

• Once the connections are made, reposition theconnection cover panel and reset all circuit breakers

6.4 Battery circuit

breaker shunt trip

connection

CAUTIONAfter the EPO function is activated, the UPS output remains live forapproximately 3 seconds.

6.3 Emergency Power

Off (EPO)

6 — 4 Options


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Figure Connect ion diagram for battery circuit breaker6-3 shunt tr ip on terminal block XR3

Figure XR3 terminal block for EXL 1050, EXL 1075 and EXL 11006-4

Secure the shielding of the cable to the stud provided on theconnection cover panel (see appendicies.)

If several option cabinets are combined, they must be placedto the right of the UPS cabinet.

• distribution cabinet (including full galvanic isolationtransformer)

• battery cabinet(s)

6.5 Combined options

battery emergencyoff

L+1 2 3 4

L–

1 4 2 3

EXL 1000

emergencyoff button

+24 VDC/VAC

–

not used not used

6 — 5Options


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6 — 6 Options


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This chapter describes all the information you need to installand use your EXL 1000 U-TALK communications system.

If you have purchased the UPS Manager 3.0 option, thischapter will give you the information required to install yourboard (ignore the "EXL 1000 U-TALK protocol" section).

Feel free to contact us for any further information you mayrequire concerning special applications beyond the scope ofthis chapter.

If the U-Talk board must be stored prior to installation, leaveyour RS232 interface board in its original packaging in a drylocation.

If you encounter a problem while following the instructions inthis chapter, we recommend that you contact our after-salessupport service. On request, our after-sales supportpersonnel can carry out the complete installation of yourequipment.

The U-TALK option may be installed and operated by anyperson as long as the indications presented in this chapterare complied with.

NOTEAll repair or maintenance operations must be carried out by MGE after-sales support personnel.

IMPORTANTInstructions in this chapter must be followed strictly. Not adhering tothese instructions may endanger personnel, result in damage to theEXL 1000 and render the manufacturer's warranty void.

7.1.2 Safety

Recommendation

7.1.1 Storage

7.1 Introduction

7 — 1

U-Talk

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The EXL 1000 UPS includes the U-Talk communicationsboard. Installation must be done by the user.

Powering down is necessary to avoid any danger duringoperations in the boards and/or communication cables area(installation and configuration).

• press the "inverter off" button for three seconds

• the inverter shuts down if the transfer conditions arecorrect

• the "load protected" light goes off

• the "load not protected" light goes on

• the load is supplied by the mains via the "static bypass"

• switch maintenance bypass switch to “bypass”

• turn off input circuit breaker

• load is now supplied by the mains via the maintenancebypass switch

To locate the EXL 1000 UPSs communications ports forboard installation, access the rear panel. The EXL 1000communications port is located in the rear panel, along thetop edge. Two torque screws hold each board or rear coveron. Next, insert the RS232 board into grooves.

The EXL 1000 UPS can be equipped with up to threeoptional boards. It is immaterial which board is in which slot.

Figure Inserting the U-Talk board into the groove7-1

7.2.2 Installing the U-Talk

RS232 board

7.2.1 Powering down the

EXL 1000 UPS

7.2 Installation of the

U-Talk board

7 — 2 U-Talk


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The system must be powered up following installation andconnection of the RS232 board option and prior to any tests

Turn the manual bypass switch from the "By-pass" position tothe "Normal" position.

Figure Overview of RS232 board7-2

Figure Close-up of f igure 7-2, sect ion A7-3

The RS232 communications board enables data concerning

EXL 1000’s operating status to be sent to a computer.

The system provides a communications channel with anRS232 interface.

The D2 and D3 jumpers on the board must be positioned asin figure 7-3.

7.3.2 Configuring the

RS232 board

7.3.1 Function

ON

D2

D3

OFF XM5

XM3

XM4

XM1

XM2

RS

232C

A

B

7.3 Description of

RS232 board

7.2.3 Returning power to

the EXL 1000 UPS

7 — 3U-Talk


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When using UPS Manager software, and unless otherwiseindicated in the software instruction manual, check that thepositions of jumpers D1 to D8 of the RS232 board conformto figure 7-4.

Figure Factory sett ings of U-Talk board jumpers7-4

Figure Configuring the Transmission Speed ( factor y set t ings shaded)7-5 OFF

ON

XM5

XM3

XM4

D4

D5

OFF

ON

XM5

XM3

XM4

OFF

ON

XM5

XM3

XM4

OFF

ON

XM5

XM3

XM4

1200 bps

4800 bps

2400 bps

9600 bps

D4

D5

D4

D5

D4

D5

OFF

ON

XM5

XM3

XM4

D2 D3 D4 D5 D6 D7

7.4 Configuration for

UPS Manager

software

7 — 4 U-Talk


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Figure Configuring the Transmission Format ( factor y set t ings shaded)7-6

Figure Configuring the Hx and Ix Signals Format ( factor y set t ings shaded)7-7

The protocol U-TALK used enables reading or writing ofphysical measurements. The line parameters as well as theinverter’s slave number for the RS232 interface may beconfigured. For detailed information of the U-Talk protocol,refer to MGE manual "Lazarus U-Talk Protocol," part number96-153293-00.

7.5 U-Talk data format

D8

XM

7

D1

XM

6

D8

XM

7

D1

XM

6

OFF

ON

XM5

XM3

XM4

D6

D7

OFF

ON

XM5

XM3

XM4

OFF

ON

XM5

XM3

XM4

OFF

ON

XM5

XM3

XM4

8 bits, no parity and 1 stop bit

7 bits, no parity and 1 stop bit

8 bits, evenparity and 1 stop bit

7 bits, even parity and 1 stop bit

D6

D7

D6

D7

D6

D7

7 — 5U-Talk


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7 — 6 U-Talk


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EXL 1000 series are two-phase line to line input, two-phaseline to line output, Uninterruptible Power Supplies. Each UPSmay be configured in a number of ways via a specialinterface.

A modification in the configuration requires on-site servicingby the after-sales support department.

Except where indicated, the data provided are typical valuescorresponding to a rated line to line voltage of 240V at 0.8power factor load.

agency standards

design: IEC 146

safety: IEC 950 + national deviations

EN 50091 - 1

UL 1778

CSA C22.2

protection: IEC 529 (IP 215)

electromagnetic compliance: IEC 801

EN 55011

EN 55022

EN 50091-2

FCC

VCCI

environment conditions

ambient temperature (1): < 25°C recommended

0°C to 30°C permanent

35°C up to 24 hours

40°C up to 8 hours

relative humidity: 5% to 95%

maximum altitude

without derating: < 3280 ft (1000 m)

A.1 Range

Characteristics

A.0 General

Characteristics

a — 1

Appendices

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configuration

low battery shutdown

warning (minutes): 1, 2, 3, 4, 5, ...20

inverter start-up automatic or manual

battery charger: internal or external

transfer to bypass

outside tolerances: yes / no

standard color: RAL 9002

EXL 1050 EXL 1075 EXL 1100

apparent power (kVA):

220V, 230V and 240V output: 5 7.5 10

208V output: 4.7 7.1 9.5

200V output: 4.5 6.82 9.1

active power (kW):

220V, 230V and 240V output: 4 6 8

208V output: 3.8 5.67 7.56

200V output: 3.6 5.46 7.27

efficiency (%): 91 91 91

heat losses (W): 445 668 890

noise level (dBa):

on RL load: 45 46 46

on RCD load: 50 53 53

battery backup time (minutes)

at rated load (power factor 0.6): 8 10 10

maximum leakage current (mA)

directly grounded

neutral system (TT): 10 23 23

a — 2 Appendeces


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dimensions and weight EXL 1050 EXL 1075 EXL 1100

height: 28.7 in/730 mm 35.8 in/910 mm 35.8 in/910 mm

width: 14.17 in/360 mm 15.75 in/400 mm 15.75 in/400 mm

depth: 16.53 in/420 mm 21.65 in/550 mm 21.65 in/550 mm

weight: 200 lbs/90 kg 422 lbs/190 kg 466 lbs/210 kg

AC input

number of phases: 2 + ground

voltage (VAC L-L): 170 to 257

frequency (Hz): 47 to 63

power factor: > 0.99

EXL 1050 EXL 1075 EXL 1100

current distortion (%): <6 < 3.5 < 3.5

inrush current: <23 A < 36 A <46 A

AC output

number of phases: 2 + ground

voltage (VAC L-L): 208 / 240

EXL 1050 EXL 1075 EXL 1100

voltage tolerance (%): ±1.5 ±1 ± 1

frequency (Hz): 50 / 60

frequency tolerance (free-running) (%): ± 0.1

frequency tolerance (synchronized) (%): ± 1 / ± 1.5 / ± 2 / ± 3 / ± 4

synchronization rate (Hz/s): 1 / 2

a — 3Appendeces


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Table Maximum current rat ings3-1

absorbed line currents (A)

Model rated output AC input current AC output current battery optionNumber (kVA) nominal (XR1) (XR2) (XR3)

EXL 1050 5 26 23 30

EXL 1075 7.5 40 35 48

EXL 1100 10 52 46 46

Table Minimum cable size3-2

Model rated output minimum stranded minimum solidNumber (kVA) wire size (75°C) wire size (75°C)

EXL 1050 5 ≥ AWG 10 (≥ 6 mm2) ≥ AWG 10 (≥ 6 mm2)

EXL 1075 7.5 ≥ AWG 8 (≥ 12 mm2) ≥ AWG 8 (≥ 12 mm2)

EXL 1100 10 ≥ AWG 6 (≥ 16 mm2) ≥ AWG 6 (≥ 16 mm2)

a — 4 Appendeces


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backup time the period of time that the EXL 1000 can supply full rated load whilerunning on battery without AC input power. This time will increase withinstallation of an auxilliary battery cabinet.

battery circuit breaker DC-power circuit breaker that protects the battery circuit.

forced operation user-initiated connection of the load to the inverter with a 0.5 second

interruption in the supply of power.

forced user-initiated shutdown of the inverter because of incorrect shutdown AC input characteristics (Mains 1 or Mains 2) and resulting

in a 0.5 second interruption in the supply of power.

input circuit breaker AC input power circuit breaker enabling rectifier shutdown.

inverter module that transforms DC input power to AC output power.

low battery shutdown warning signal indicating the upcoming end of battery power and the resulting

inverter shutdown and interruption in the supply of power to the load.

load all devices connected to EXL 1000 output terminals.

LV switchboard low voltage (less than 600 VAC) switchboard. Power panel inside building that includes upstream circuit breakers and provides AC input power to the EXL 1000.

manual bypass a manual transfer from inverter to utility power or back via a maintenancebypass switch. This allows for safe servicing of the UPS while maintainingutility power to the load.

Mains 1 (AC input power) primary source of power for the rectifier and the inverter.

output apparent power rated AC output volts multiplied by rated AC output amps, measured in VA

output power output apparent power multiplied by power factor measured in Watts.

overload power drawn by the load in excess of the EXL 1000 rated output.

g — 1

Glossary

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powered down no power is present on input and output of EXL 1000 (battery circuitbreaker off, upstream circuit breaker off).

rated current rated output current of EXL 1000.

rectifier electronic device or circuit that converts AC input power to DC power thatsupplies the inverter module and battery charger.

"static bypass" an automatic transfer from inverter to utility power or back without an interruption to output load via an electronic solid state switch (static bypass switch).

transfer to bypass load switching from the inverter to the static or manual bypass mechanism.

transfer to inverter load switching from the static or manual bypass mechanism to the inverter.

g — 2 Glossary


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