Mge Ups Systems Ex 5Rt Users Manual 86 86000 00 A01 UM

EX 11RT 742fa8aa-19e7-4c4d-bccf-aefafc33a882

EX 5RT to the manual 742fa8aa-19e7-4c4d-bccf-aefafc33a882

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EX 5RT / EX 7RT/ EX 11RT System
Installation and User Manual

86-86000-00 A01

EX 5/7/11 RT System

IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS – This manual contains important instructions for MGE UPS SYSTEMS, INC. products that must
be followed during operation and maintenance of the equipment.

WARNING

Opening enclosures expose hazardous voltages. Always refer service to
qualified personnel only.

ATTENTION

L'ouverture des cabinets expose des tensions dangereuses. Assurez-vous toujours
que le service ne soit fait que par des personnes qualifiees.

WARNUNG!

Das öffnen der Gehäuse legen gefährliche Spannungen bloss. Service sollte immer
nur von qualifizierten Personal durchgeführt werden.

WARNING

As standards, specifications, and designs are subject to change, please ask for confirmation of the information given in this publication.

ATTENTION

Comme les normes, spécifications et produits peuvent changer, veuillez demander
confirmation des informations contenues dans cette publication.

WARNUNG!

Normen, Spezifizierungen und Pläne unterliegen Anderungen. Bitte verlangen Sie
eine Bestätigung über alle Informationen, die in dieser Ausgabe gemacht wurden.

NOTE

This equipment has been tested and found to comply with the limits for a Class A
digital device, pursuant to part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is
operated in a commercial environment.
This equipment generates, uses, and can radiate radio frequency energy and, if not
installed and used in accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this equipment in a residential
area is likely to cause harmful interference in which case the user will be required to
correct the interference at user's own expense.

Certification Standards
◗

IEEE 587-1980/ANSI C62.41 1980 Standards for Surge Withstand Ability

◗

FCC rules and regulations of Part 15, Subpart J, Class A

◗

UL listed under 1778, Standards for Uninterruptible Power Supply Equipment

◗

IEC 61000-4-2 (ESD) : level4.

◗

IEC 61000-4-3 (Radiated field) : level 3.
IEC 61000-4-4 (EFT) : level4.

ii

◗

IEC 61000-4-5 (Fast transients) : level4.

◗

IEEE-C6241 Category B (ring wave).

◗

IEC 61000-4-6 (electromagnetic field).

◗

IEC 61000-4-8 (conducted magnetic field).

Important Safety Information and Standards

86-86000-00 A01

Installation and User Manual

Safety of Persons
◗

The UPS has its own internal power source (the battery). Consequently, the power outlets may be energized even if the UPS is disconnected from
the AC power source.

◗

The UPS must be properly grounded.

◗

The battery supplied with the UPS contains small amounts of toxic materials. To avoid accidents, the directives listed below must be observed:
-

Never burn the battery (risk of explosion).

-

Do not attempt to open the battery (the electrolyte is dangerous for the eyes and skin).

-

Comply with all applicable regulations for the disposal of the battery.

-

Batteries constitute a danger (electrical shock, burns). The short-circuit current may be very high. Precautions must be taken for all handling:
remove watches, rings, bracelets and any other metal objects, use tools with insulated handles.

-

Do not lay tools or metal parts on top of batteries.

Product Safety
◗

A protection circuit breaker must be installed upstream and be easily accessible..

◗

The UPS can be disconnected from the AC power source by opening the input circuit breaker.

◗

UPS must be connected to a nearby power source that is easily accessible.

◗

Never block the ventilation grates of the UPS.

◗

The UPS must be installed in a controlled environment.

Special Precautions
◗

The UPS connection instructions and operation described in the manual must be followed in the indicated order.

◗

Check that the indications on the rating plate correspond to your AC powered system and to the actual electrical consumption of all the equipment
to be connected to the UPS.

◗

Before and after the installation, if the UPS remains de-energized for a long period, the UPS must be energized for a period of 24 hours, at least
once every 6 months (for a normal storage temperature less than 25°C). This charges the battery, thus avoiding possible irreversible damage.

How to use this manual and Symbol Usage
This manual is designed for ease of use and easy location of information.
Typographical conventions use “< >” angle brackets in procedures to denote a prompt for User action:

For example: 1. After the selections are complete, click on the  button.
This manual uses four icon symbols with text to convey important information and tips.

86-86000-00 A01

WARNING

Indicates information provided to protect the user and service personnel against safety
hazards and/or possible equipment damage.

CAUTION

Indicates information provided to protect the user and service personnel against possible
equipment damage.

IMPORTANT

Indicates information provided as an operating instruction, or as an operating tip.

NOTE

Indicates information provided as an operating tip or an equipment feature.

Safety of Persons

iii

EX 5/7/11 RT System

CAUTION: Record All Serial Numbers!
RECORD ALL SERIAL NUMBERS FOR EX 5/7/11 RT AND ACCESSORIES.
THESE SERIAL NUMBERS WILL BE REQUIRED IF YOUR SYSTEM NEEDS SERVICE.
KEEP THIS MANUAL IN A PLACE WHERE YOU CAN REFERENCE THE SERIAL
NUMBERS IF SERVICE IS REQUIRED!
EX 5RT System

EX 7RT System

EX 11RT System

Power Module SERIAL NUMBER: ___________________________________________________
Battery Module SERIAL NUMBER: ____________________________________________________
Transformer SERIAL NUMBER: ______________________________________________________

ADDITIONAL MODULES SERIAL NUMBERS:

iv

____________________________

______________________________

____________________________

______________________________

____________________________

______________________________

____________________________

______________________________

____________________________

______________________________

____________________________

______________________________

____________________________

______________________________

____________________________

______________________________

____________________________

______________________________

____________________________

______________________________

CAUTION: Record all serial numbers!

86-86000-00 A01

Installation and User Manual

EX 5/7/11 RT System
Installation and User Manual

Revision History
E X 5 RT / E X 7 RT / E X 1 1 RT S y s t e m I n s t a l l a t i o n a n d U s e r M a nu a l
R ev i s i o n :

A00

Initial Release

86-86000-00

07/2004

Copyright © 2004 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

For Service Call:
1 (800) 438-7373

86-86000-00 A01

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EX 5/7/11 RT System

(This page left blank intentionally)

vi

86-86000-00 A01

Contents

section

description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .ii
Certification Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
Safety of Persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
How to use this manual and Symbol Usage . . . . . . . . . . . . . . . . . . . .iii
CAUTION: Record All Serial Numbers! . . . . . . . . . . . . . . . . . . . . . . .iv
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

Section 1

Introduction
section

description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page

1.0
1.1
1.2

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 1
System Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . .1 — 4
Standard Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 4
Tower Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 4
Rack Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 5
Rear Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 6
Power Module EX 5/7/11 RT . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 6
Battery Module EXB 5/7/11 RT With Emergency
Power Off (EPO) Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 6
EX RT Transformer Module . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 7
Display and Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 7
Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 8
Power Module Rail Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 8
Battery/ Transformer/CLA Module Rail Kit . . . . . . . . . . . . . . . . . .1 — 8
Battery Module with Remote Emergency
Power Off (REPO) Function . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 9
Battery Extension Cable Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 9
Battery Integration Kit with Casters . . . . . . . . . . . . . . . . . . . . . .1 — 10
Input/Output Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 10
Transformer Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 11
CLA Module (Long backup time charger) . . . . . . . . . . . . . . . .1 — 12

1.2.1
1.2.2
1.3
1.3.1
1.3.2
1.3.3
1.4
1.5
1.5.1
1.5.2
1.5.3
1.5.4
1.5.5
1.5.6
1.5.7
1.5.8

86-86000-00 A01

Contents

ci

EX 5/7/11 RT System

Section 2

Setup and Installation
section

description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page

2.0
2.1
2.2
2.3
2.4

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 1
Unpacking and Parts Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 1
Contents of EX 5/7/11 RT System . . . . . . . . . . . . . . . . . . . . . . .2 — 2
Installation in Tower Configuration . . . . . . . . . . . . . . . . . . . . . . . .2 — 4
Installation in Rack Mounting Configuration . . . . . . . . . . . . . . . .2 — 5
Adjustment of Front Panel Logo and control panel for
Rack Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 5
Prepare Battery Module for Rack Mounting . . . . . . . . . . . . . . . .2 — 6
Power or Battery Module Rack Mounting . . . . . . . . . . . . . . . . . .2 — 7
Rear Support Brackets Installation . . . . . . . . . . . . . . . . . . . . . . .2 — 8
Input/Output Box Bracket System Installation . . . . . . . . . . . . . . .2 — 8
Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 9
Connecting the RS232 Communication Port . . . . . . . . . . . . . . .2 — 9
Connecting the Dry (Relay) Contact Communication Port . . . .2 — 10
Installation of Optional Network Management Card . . . . . . . .2 — 10
Remote Emergency Power Off (REPO) Communication Port .2 — 12
Connecting the Input and Output Power Cables to the
Input/Output Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 13
Flexible Cordage and Conduit Installations . . . . . . . . . . . . . . .2 — 13
System Connections with Common Normal and
Bypass AC Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 15
Connecting EX RT Transformer . . . . . . . . . . . . . . . . . . . . . . . .2 — 16
System Connections with Separate Normal and
Bypass AC Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 17
System Connections as Frequency Converter
(without Bypass AC Source) . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 18
Connection of Battery Module, EXB . . . . . . . . . . . . . . . . . . . . .2 — 19
Connection of CLA Module . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 20

2.4.1
2.5
2.6
2.6.1
2.6.2
2.7
2.7.1
2.7.2
2.7.3
2.7.4
2.8
2.8.1
2.8.2
2.8.3
2.8.4
2.8.5
2.9
2.10

Section 3

Operation
section

description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page

3.0
3.1
3.2

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
UPS Personalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Accessing personalization with front panel buttons . . . . . . . . . .3
Accessing personalization through external software . . . . . . . . .3
Final startup sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Normal (double conversion) Mode . . . . . . . . . . . . . . . . . . . . . . .3
ECO Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Operation on battery power . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Transfer to Battery Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Return of Normal AC source . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

3.2.1
3.2.2
3.2.3
3.3
3.3.1
3.3.2
3.4
3.4.1
3.5
3.6

c ii

Contents

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1
1
2
2
4
4
5
5
6
7
7
8
8

86-86000-00 A01

Installation and User Manual

Section 4

Maintenance
section

description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page

4.0
4.1

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Information Technology (IT) Network and Industrial
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Hot Swapping the Power Module . . . . . . . . . . . . . . . . . . . . . . . .4
Re-connecting the power module . . . . . . . . . . . . . . . . . . . . . . . .4
Hot Swapping the Battery Module . . . . . . . . . . . . . . . . . . . . . . . .4
Disconnecting the Battery Module . . . . . . . . . . . . . . . . . . . . . . .4
Re-connecting the Battery Module . . . . . . . . . . . . . . . . . . . . . . .4

4.2
4.3
4.4
4.5
4.5.1
4.5.2

Section 5

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1
2
4
5
6
6
6

Appendix
section

description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page

5.0
5.1
5.2
5.3
5.4
5.5
5.6
5.7

Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
System Input/Output Power Ratings . . . . . . . . . . . . . . . . . . . . . .5
System Overload Characteristics . . . . . . . . . . . . . . . . . . . . . . . .5
System Backup Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . .5
System Short Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . .5
Accessories Electrical Characteristics . . . . . . . . . . . . . . . . . . . . .5
Heat Rejection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Environmental Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . .5

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1
1
1
1
2
2
2
2

MGE Warranty & Propriety Rights
MGE Warranty
Proprietary Rights Statement

Warranty and Product Registration
User Information
Product information
Warranty Extension (Warranty+) not available on products

Technical Support and Field Service
MGE Service and Repair
Who to Contact
Scheduling Field Service Engineer Support
Return for Repair (RMA)

Glossary

G—1

Reorder Form RO — 1

86-86000-00 A01

Contents

c iii

EX 5/7/11 RT System

Figures
figure description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page
1-1:

Tower Configurations with Power Module, Battery Module,
and optional Transformer Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 4
1-2: Rack Configurations with Power Module, Battery Module, and
Transformer Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 5
1-3: Rear panel of the Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 6
1-4: Rear Panel of the Battery Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 6
1-5: Rear Panel of the optional Transformer Module. (PN 86003) . . . . . . . . .1 — 7
1-6: View of typical control panel interface. . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 7
1-7: Power Module Rack Mounting Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 8
1-8: Telescopic rails for the Battery/Transformer/CLA module
Rack mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 8
1-9: Typical back-up time with multiple EXB’s at full load. . . . . . . . . . . . . . . . .1 — 9
1-10: Typical Battery Integration kit with casters setup. . . . . . . . . . . . . . . . . .1 — 10
1-11: Typical Transformer Module contents and connections. . . . . . . . . . . . .1 — 11
1-12: Connection for CLA Module and EX 5/7/11 RT. . . . . . . . . . . . . . . . . . .1 — 12
2-1:

Contents of Standard HV EX 5RT (PN 86050)
/ EX 7RT (PN 86070) / EX 11RT (PN 86110) System. . . . . . . . . . . . . .2 — 3
2-2: Tower Configuration of Standard System and Optional
Transformer Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 4
2-3: Typical orientation of the logo and control panel.
(Power Module shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 5
2-4: Accessing Battery Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 6
2-6: Rack mounting of the power module onto the rails. . . . . . . . . . . . . . . . .2 — 7
2-7a: Rear Support Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 8
2-7b: Input/Output Box Bracket System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 8
2-8: RS232 Communication Cable Connection. . . . . . . . . . . . . . . . . . . . . . . .2 — 9
2-9: Relay Pin Connections for Communication Port. . . . . . . . . . . . . . . . . .2 — 10
2-10: Communication Card Slot with SNMP/Web Network
Management Card installed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 10
2-10a: Activation of remote power off function using a contact
normally open switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 12
2-10b: Activation of remote power off function using a contact
normally closed switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 12
2-12a: Step 1 & 2; Typical plastic and metal coupling installations. . . . . . . . . .2 — 13
2-12b: Step 3; Typical Straight Metal Conduit installation. . . . . . . . . . . . . . . .2 — 14
2-12c: I/O Box Terminal Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 — 14
2-13: Normal AC Input and Output Cables installation. . . . . . . . . . . . . . . . . .2 — 15
2-14: View of EX RT transformer connected downstream for
120/208/240 Vac outputs (shown with one EXB). . . . . . . . . . . . . . . . . .2 — 16
2-15: Normal AC Input, Bypass AC, and Output Cables Installation. . . . . . .2 — 17
2-16: Accessing Terminal Blocks for Input and Output power cables. . . . . . .2 — 18
2-17: Rear view of battery module cable connections. . . . . . . . . . . . . . . . . .2 — 19
2-18: Rear view of CLA module cable battery and AC input connections. . .2 — 20

c iv

Contents

86-86000-00 A01

Installation and User Manual

Figures

(continued)

figure description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page
3-1:
3-2:
3-3:
3-4:
3-5:
3-6:
3-7:

Initial Startup Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 1
Control Panel with scroll up and down buttons. . . . . . . . . . . . . . . . . . . .3 — 2
Configuration used to provide full redundancy (2N) to critical loads. . . .3 — 3
Normal (double conversion) mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 5
ECO mode display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 — 6
Transfer, Threshold and End of backup time. . . . . . . . . . . . . . . . . . . . . .3 — 7
Shutdown display, circuit breaker, and AC source switch. . . . . . . . . . . .3 — 8

4-1:
4-2:
4-3:

Disconnecting the power module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 4
Reconnect the power module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 5
Rear view of the battery module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 — 6

5-1:

Power supplied as a function of input voltage (left), and
Permissible UPS overloads as a function of time (right). . . . . . . . . . . . . .5— 1

Tables
table description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page
1:
2:
3:
4:
5:

EX RT Model Descriptions and Contents . . . . . . . . . . . . . . . . . . . . . . . .1 — 2
Optional Accessories (See section 1.5 for description) . . . . . . . . . . . . .1 — 3
Power Module Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 4
Battery Module Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 4
Battery backup time chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 — 12

3-1:
3-2:
3-3:
3-4:

Local Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Output features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
ON/OFF features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Battery features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

4-1:
4-2:
4-3:

Network and Industrial Modes of Operation. . . . . . . . . . . . . . . . . . . . . . .4 — 1
Troubleshooting not requiring MGE after-sales support. . . . . . . . . . . . . .4 — 2
Troubleshooting requiring MGE after-sales support. . . . . . . . . . . . . . . . .4 — 3

5-1:
5-2:
5-3:

EX 5/7/11 RT Input and Output Characteristics. . . . . . . . . . . . . . . . . . . .5 — 1
Back-up Time ( in minutes). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 — 1
Battery Recharge time to recover 90% of the rated backup time
after discharge at full load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 — 2
Full load heat rejection in BTU’s/hr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 — 2

5-4:

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Contents

—
—
—
—

3
3
4
4

cv

EX 5/7/11 RT System

(This page left blank intentionally)

c vi

86-86000-00 A01

Introduction

1.0

Scope
Thank you for selecting an MGE UPS SYSTEMS, INC. (MGE) product to protect your electrical equipment.
The product you selected is a part of the EX RT series. The EX RT series is a family of Uninterruptible Power Supply
(UPS) designed to provide safe, and reliable AC power backup for sensitive electrical equipment. To discover the
entire range of MGE products, we invite you to visit our website at www.mgeups.com or contact your representative
at (800) 523-0142.
This manual describes the installation and operation of standard HV EX 5/7/11RT systems within the EX RT product
family. For a complete description of the EX RT product family and its available options, please refer to the tables
below:
1

Introduction

Introduction is a general description of system configurations of the EX 5/7/11 RT, and its mechanical
,electrical characteristics. Additionally there is an optional accessories section with important information on MGE
products that will enhance the performance of the EX 5/7/11RT. Please contact your MGE representative for
detailed information on these options.
2

Setup and Installation

Setup and Installation guides the user through tools and equipment required for connecting the EX 5/7/11 RT and
battery installation or replacement. Included are assembly instructions, power cable connections with wire diagrams
for configuring the product to hardware specifications.
3

Operation

Operation describes the EX 5/7/11RT system characteristics of indicators and controls, modes and specifications.
The user procedures include performing software programming that will maintain optimal performance.
4

Maintenance

Maintenance includes a troubleshooting guide of symptoms and possible solutions, hot swapping the power module,
battery module, and testing scenarios.
5

Appendix

Electrical and Mechanical specifications for the EX 5/7/11 RT.
A Glossary provides definitions of abbreviations and terms used in this manual.

86-86000-00 A01

Introduction

1—1

EX 5/7/11 RT System

Table 1: EX RT Model Descriptions and Contents
System Description
Model

Part

Number

Contents
Power Module

Battery Module

Transformer

Power Module

Battery Module

SNMP/Web

86055 86075 86115

86079

Module

Rail Kit 86001

Rail Kit 86002

Network

86119

(120/208/240Vac)

Mgt. Card

86003

66074

5kVA
HV EX 5RT

86050

X

X

5kVA
HV EX 5RT
Network Pack

86052

X

X

5kVA
LV EX 5RT

86050-01

X

X

X

5kVA
LV EX 5RT
Network Pack

86052-01

X

X

X

7kVA
HV EX 7RT

86070

X

X

7kVA
HV EX 7RT
Network Pack

86072

X

X

7kVA
LV EX 7RT

86070-01

X

X

X

7kVA
LV EX 7RT
Network Pack

86072-01

X

X

X

11kVA
HV EX 11RT

86110

X

X

11kVA
HV EX 11RT
Network Pack

86112

X

X

11kVA
LV EX 11RT

86110-01

X

X

11kVA
LV EX 11RT
Network Pack

86112-01

X

X

1—2

Introduction

X

X

X

X

X (x2)

X

X

X

X

X

X (x2)

X

X

X

X

X

X (x2)

X

X

X

86-86000-00 A01

Installation and User Manual

Table 2: Optional Accessories (See section 1.5 for description)
Part Number

Description

86001

Rail Kit for Power Module EX 5/7/11 RT

86002

Rail Kit for Battery/Transformer/CLA Module

86005

Battery Integration Kit with Casters

86006

Battery Extension Cable Kit

86008

Battery Chassis Empty EXB RT W/EPO

86009

I/O Box 5/7kVA UL/US

86010

I/O Box 11kVA UL/US

86012

I/O Box Bracket System

86013

Rear Bracket Supports

86-86000-00 A01

Introduction

1—3

EX 5/7/11 RT System

1.1

System Electrical Characteristics

Table 3: Power Module Ratings
Part Number

86055

86075

86115

Apparent Power, kVA

5

7

10@ 200/208/250 VAC Output
11@ 220/230/240 VAC Output

Active Power, kW

4

4.9

8@ 200/208/250 VAC Output
7.3@ 220/230/240 VAC Output

Input Current, A

25/24/23/
22/21/20

35/34/32
31/30/28

50/48/50/48/46/40

Input Voltage, VAC

200/208/220/
230/240/250

200/208/220/
230/240/250

200/208/220/230/240/250

Output Current, A

25/24/23/
22/21/20

35/34/32
31/30/28

50/48/50/48/46/40

Output Voltage, VAC

200/208/220/
230/240/250

200/208/220/
230/240/250

200/208/220/230/240/250

CAUTION

Power Module is factory configured at 208Vac, 60 Hz input and output.
Input and Output of the UPS must always be the same.

Table 4: Battery Module Ratings

1.2

Part Number

86079

86119

Battery Type

12VDC/7Ah

12VDC/9Ah

Battery Output Voltage

240VDC

240VDC

Standard Configurations
The EX 5/7/11 RT systems can be set up in tower and rack configurations.

1.2.1

Tower Configuration

Figure 1-1: Tower Configurations with Power Module, Battery Module, and optional Transformer Module.

Standard Configuration

Configuration with Transformer

BATTERY MODULE
(EXB 5/7/11 RT)

BATTERY MODULE

EXB RT
EXB

EX

11

RT

EX 11

RT

EX RT

RT

ormer
Transf
ON
OFF

ON
OFF

m
eups.co
www.mg

m
eups.co
www.mg

eups.co

m

www.mg

eups.co

m

www.mg

om
eups.c
www.mg

POWER MODULE
(EX 5/7/11 RT)

1—4

EX RT Transformer

Introduction

POWER
MODULE

86-86000-00 A01

Installation and User Manual

1.2.2

Rack Configuration

Figure 1-2: Rack Configurations with Power Module, Battery Module, and Transformer Module.

Standard Configuration

Configuration with Transformer

POWER MODULE
(EX 5/7/11 RT)
EX RT Tran

www.mgeu

sformer

EX RT Transformer

ps.com

EX 11 RT

ON

POWER MODULE
(EX 5/7/11 RT)

OFF

www.mgeu

ps.com

EXB RT

www.mgeu

BATTERY MODULE
(EXB 5/7/11 RT)

ps.com

BATTERY MODULE
(EXB 5/7/11 RT)

Model

Dimensions

EX 5RT/7RT

(3U) 5.16” x 17.49” x 25”
(131 x 444 x 635mm)

49.6 lbs (22.5 kg)

EX 11RT

(3U) 5.16” x 17.49” x 25”
(131 x 444 x 635mm)

60.6 lbs (27.6 kg)

EXB 5 RT/ 7 RT

(3U) 5.16” x 17.49” x 25”
(131 x 444 x 635mm)

142 lbs (64.5 kg)

EXB 11RT

(3U) 5.16” x 17.49” x 25”
(131 x 444 x 635mm)

151 lbs (68.5 kg)

EX RT
Transformer

(3U) 5.16” x 17.49” x 25”
(131 x 444 x 635mm)

173 lbs (78.5 kg)

86-86000-00 A01

Weights

Introduction

1—5

EX 5/7/11 RT System

1.3

Rear Panels

1.3.1

Power Module EX 5/7/11 RT
EX 5RT Power Module part number 86055
EX 7RT Power Module part number 86075
EX 11RT Power Module part number 86115

Figure 1-3: Rear panel of the Power Module.

1

Slot for optional communication cards.

2

2

Communication port by relays (Dry contacts).

3

3

Remote Emergency Power Off communication port
(REPO).

4

Connectors for automatic detection of battery module(s).

5

RS232 communication port.

6

Battery/CLA module power connector.

7

Manual Bypass switch.

8

Normal AC source circuit breaker.

9

Knockout for entry of AC Output conduit.

10

Knockout for entry of Normal AC source conduit.

11

Knockout for entry of Bypass AC source conduit.

1
4
5

6

9

7

10
8
11

1.3.2

Battery Module EXB 5/7/11 RT With Emergency Power Off (EPO) Function

Figure 1-4: Rear Panel of the Battery Module.

12

12

Connectors for automatic detection of additional battery
module(s) (to the UPS or to other battery modules).

13

Battery power connectors (to the UPS or to other
battery modules).

14

Battery Circuit Breaker with Remote Emergency Power
Off (REPO) shunt trip.
EXB 5RT with EPO part number 86079

13

EXB 7RT with EPO part number 86079
EXB 11RT with EPO part number 86119

14

1—6

Introduction

86-86000-00 A01

Installation and User Manual

1.3.3

EX RT Transformer Module

Figure 1-5: Rear Panel of the optional Transformer Module. (PN 86003)

Load 3: 1 NEMA L6-30R

Load 2: 4 NEMA 5-15/20R

Load 4: 4 NEMA 5-15/20R

Load 3 Circuit Breaker
Load 4 Circuit Breaker

Load 2 Circuit Breaker

Main Output Circuit Breaker

AC Input
Transformer I/O Box
AC Output

Load 1 Circuit Breaker
Load 1: 1 NEMA L6-30R

Transformer Protect
Breaker

1.4

Display and Control Panel

Figure 1-6: View of typical control panel interface.
15

16

17

18

EX 11 RT

19

OFF

15

Load protected / On-line Operation LED.

16

Operation on battery LED.

17

Operation on bypass LED.

18

Fault LED.

19

Alphanumeric display.

20

UPS OFF button.

ON

21
23

20

86-86000-00 A01

21

22

22

Function buttons (scroll up / scroll down).

UPS ON button (or function button in personalization
mode).

23

Introduction

1—7

EX 5/7/11 RT System

1.5

Optional Accessories
Optional Accessories describes the options available for upgrades and enhancement of the EX 5/7/11RT system.
Detailed installation of the unit is described in following sections.
To ensure a successful installation, all procedures should be followed in their correct sequence. Note that any
unauthorized installation may cause damage to the UPS(s) and void the MGE warranty.

1.5.1

Power Module Rail Kit
(Part Number 86001)
This kit is for rack mounting the power module in a 19" enclosure. See section 2.6 for rack installation of power
module.

Figure 1-7: Power Module Rack Mounting Kit.

24

27

25

24

Front mounting brackets.

25

Rear support brackets, part number
86013.

26

Telescopic rails, 695 mm to 1015 mm

26

length (27.36" to 39.96").

Input/Output Box bracket system, part

27

number 86012.

1.5.2

Battery/ Transformer/CLA Module Rail Kit
(Part number 86002)
This kit is for rack mounting of the battery/step-down transformer/CLA module in 19" enclosure. See section 2.6 for
rack installation of power module.

Figure 1-8: Telescopic rails for the Battery/Transformer/CLA module Rack mounting.

24

25

24

26

1—8

Introduction

Front mounting brackets.

25

Rear support brackets, part number
86013.

26

Telescopic rails, 695 mm to 1015 mm
length (27.36" to 39.96").

86-86000-00 A01

Installation and User Manual

1.5.3

Battery Module with Remote Emergency Power Off (REPO) Function
(EXB 5/7 RT; PN 86079, EXB 11RT; PN 86119)
Standard HV EX 5/7/11RT system (one Power Module, EX 5/7/11 RT, and one Battery Module, EXB 5/7/11RT)
offers a standard backup time of 5 to 12 minutes at full load.
To increase backup time, it is possible to connect up to 5 additional EXB 5/7/11 RT modules to the EX 5/7/11 RT
module. See section 2.10 for connections between Power Module (EX 5/7/11 RT) and Battery Module (EXB 5/7/11
RT)

Figure 1-9: Typical back-up time with multiple EXB’s at full load.

Optional
Configurations

Standard
HV EX 5/7/11RT system

EX 5/7/11RT EXB 5/7/11RT

+

EXB 5 RT
EXB 7 RT
/
EXB 11 RT

5 kVA :
7 kVA :
11 kVA:

12 min
7 min
5 min

30 min
20 min
14 min

+

EXB 5 RT
EXB 7 RT
/

+

EXB 11 RT

EXB 5 RT
EXB 7 RT
/
EXB 11 RT

55 min
32 min
22 min

75 min
45 min
30 min

+

EXB 5 RT
EXB 7 RT
/
EXB 11 RT

98 min
57 min
42 min

+

EXB 5 RT
EXB 7 RT
/
EXB 11 RT

118 min
70 min
53 min

See Appendix for additional Back-up time information.
1.5.4

Battery Extension Cable Kit
( 6 ft / 1.8 m, Part number 86006)
This extended battery cable kit will be used instead of the standard battery cable when battery modules (EXBs) are
distant from each other (located in two different enclosures, for instance).
The battery extension cable kit includes a 6 ft long, straight connector battery power cable and a 6 ft. long battery
detection cable.

86-86000-00 A01

Introduction

1—9

EX 5/7/11 RT System

1.5.5

Battery Integration Kit with Casters
(Part number 86005)
Battery Integration Kit is a cart, designed to hold up to 8 modules. It has swivel wheels with brakes, leveling feet,
seismic floor mount panels, plates to lock modules and hardware included. Modules not included.

Figure 1-10: Typical Battery Integration kit with casters setup.

TRANSFORMER MODULE
(optional)
POWER MODULE

BATTERY MODULES
(up to 6)

(Modules Not Included In Kit)

1.5.6

Input/Output Box
Shipped with ferrules for stranded wire application.

OFF
O

- I/O Box 5/7kVA Part number 86009
- I/O Box 11kVA Part number 86010

1 — 10

Introduction

86-86000-00 A01

Installation and User Manual

1.5.7

Transformer Module
This module provides isolated 120/208/240Vac output.

Figure 1-12: Typical Transformer Module contents and connections.

EX RT Transformer Module Contents

Transformer User Manual

EX

RT

Tower Stand Expanders

mer
Transfor

Stabilizer Bracket
(4 screws included)
ps.com
mgeu
www.

BATTERY MODULE
EXB RT

POWER MODULE
EX 5/7/11 RT

TRANSFORMER
MODULE EX RT

AC NORMAL
INPUT

86-86000-00 A01

STEP-DOWN
TRANSFORMER
OUTPUT TO LOAD

Introduction

1 — 11

EX 5/7/11 RT System

1.5.8

CLA Module (Long backup time charger)
(Part number 86004)
Extended back-up time (up to 8 hours at full load) requires a high power battery cabinet connected to the EX
5/7/11RT via the CLA module.
IMPORTANT

The CLA can not be used to charge the battery module (EXB). It is designed to charge the
customer provided high power battery cabinet.

Figure 1-12: Connection for CLA Module and EX 5/7/11 RT.

CLA Module Contents

CLA Documentation

Tower Stand Expanders

Battery Power Cable
EX

RT

forme
Trans

r

Stabilizer Bracket
(4 screws included)

Battery Detection Cable

m
eups.co
www.mg

Typical High Power
Battery Cabinet

CLA

(not included)

EX 5RT /
EX 7RT /
EX 11RT
50A

Utility
AC Source

~

(cable not included)
(see section 2.10 for cable
connection information)
(cable not included)

Table 5: Battery backup time chart.

Battery Backup Time

Recommended Batteries
EX 5RT

EX 7RT

EX 11RT

2 hours

50 Ah

65 Ah

100 Ah

4 hours

100 Ah

130 Ah

200 Ah

8 hours

200 Ah

200 Ah

400 Ah

Total battery voltage : 240 VDC (20 x 12VDC, one string).
The battery capacity must be set within the UPS (5 Ah increment possible, see UPS Personalization section 3.2.

1 — 12

Introduction

86-86000-00 A01

Setup and Installation

2.0

Scope
Installation guides the user through tools and equipment required for making input/output power and communication cable connections, and battery installation and replacement. It provides assembly instructions, power cable
connections with wire diagrams for configuring the product to hardware specifications.

2.1

Unpacking and Parts Check
Once the EX 5/7/11RT system has been inspected and received from the shipping courier, the unit should be moved
to a position as close to the final installation location as possible. See Figures 2-1on page 2-3.
All Modules are shipped in separate boxes.
Prior to any installation, the following items should be observed upon receipt of the EX 5/7/11 RT.
1.

Inspect shipment for any damage prior to receipt. Damage claims should be filed directly with the courier.
Replacements for damaged components should be ordered through MGE Customer Support Services at
1-800-438-7373.

2.

Remove wrapping and foam corners to verify that the equipment nameplate (located on the rear of the units)
details a system that corresponds with the equipment ordered.

86-86000-00 A01

Installation

2—1

EX 5/7/11 RT System

2.2

Contents of EX 5/7/11 RT System
Contents of Power Module:

Contents of Battery Module:

30

EX 5RT /EX 7RT/ EX 11RT.

29

Stabilizer Bracket and hardware.

31

Two sets of tower stands.

38

EXB 5/7/11 RT.

32

RS232 communication cable.

39

Tower stand expanders.

33

Product documentation.

40

Battery Power cable.

34

Input/Output Box. (With 9 insulated ferrules for

41

stranded wires.)

Battery/EX RT transformer/CLA
module rack mounting kit, PN 86002.

(PN 86009 for EX 5/7RT; 86010 for EX 11RT)

42

Battery detection cable.

35

Solution-Pac CD.

43

EXB Documentation.

36

Power Module rack mounting kit, PN 86001

44

Bezel hex drive.

(optional, but standard with Network Pack version).

37

SNMP/Web Network Management Card, PN 66074.
(optional, or standard with Network Pack version)

IMPORTANT

2—2

Packaging must be destroyed according to waste management standards.
Recycling icons are displayed for easy selection.

Installation

86-86000-00 A01

Installation and User Manual

Figure 2-1: Contents of Standard HV EX 5RT (PN 86050) / EX 7RT (PN 86070) / EX 11RT (PN 86110) System.
- EX 5RT Power Module Part number 86055
- EX 7RT Power Module Part number 86075
- EX 11RT Power Module Part number 86115

30

31

32

34

OFF
O
EX

11

RT

33

35

- I/O Box 5/7kVA Part number 86009
- I/O Box 11kVA Part number 86010

37
36

(see 1.5.1)

IP=
MAC=00E0D8FF855E

100

10

Reset

Card Settings
UPS
data

1 2
ON

RS232 Download

ETHERNET

RS232

66074

Standard only with Network Pack option.
- EX 5RT network Pack Part number 86052-01
- EX 7RT network Pack Part number 86072-01
- EX 11RT network Pack Part number 86112-01

38

39

EXB

40

42

RT

29

41

43

44
(not to scale)

- EXB 5RT Battery Module Part number 86079
- EXB 7RT Battery Module Part number 86079
- EXB 11RT Battery Module Part number 86119

86-86000-00 A01

Standard only with
Network Pack version.
See 1.5.2.

Installation

2—3

EX 5/7/11 RT System

2.3

Installation in Tower Configuration
Follow the numerical sequence to assemble tower stands and tower stand expanders, shown in Figure 2-2.

Figure 2-2: Tower Configuration of Standard System and Optional Transformer Module.
Tower Configuration with Standard System
5

EXB

EX

11

RT

RT

Battery Module

ON
OFF

Power Module
s.com
www.mgeup

s.com
www.mgeup

3

4

3

4
4

4

2
1

2
1

Tower Configuration with Optional Transformer Module
Use the same procedure
for tower mounting multiple
battery modules, if applicable.

5

EXB

EX

11

RT

Battery Modules

RT

ON
OFF

Power Module
Transformer Module

s.com
www.mgeup

s.com
www.mgeup

s.com
www.mgeup

3

4

3

4
4

4

2
1

2
1

2—4

Installation

86-86000-00 A01

Installation and User Manual

2.4

Installation in Rack Mounting Configuration

2.4.1

Adjustment of Front Panel Logo and control panel for Rack Orientation.
NOTE

If system includes the transformer module, we recommend to mount the battery module
on the bottom, then mount the power module above the battery module and mount the
transformer on top for optimum stability.

To prepare the front panel logo and LCD display for rack orientation, of all modules. (including transformer or CLA
module, if equipped).
Proceed as follows:
1.

Unclip logo plate, and pull the LCD display from front panel.

2.

Rotate them 90 degree counter clockwise as shown.

3.

Place items back onto the panel.

Figure 2-3: Typical orientation of the logo and control panel. (Power Module shown)

1 RT
EX 1

EX
11

OFF

RT
ON
OFF
www.mgeups.com

www.mg

eups.com

ON

FINISHED PANEL
(rack orientation)
EX
11

OFF

RT

1

ON

www.mgeups.com

1
2

www.mg

3

86-86000-00 A01

2

1 RT
EX 1

eups.com

ON
OFF

3

Installation

2—5

EX 5/7/11 RT System

2.5

Prepare Battery Module for Rack Mounting
(optional rails required, part number: 86002)
The battery module is very heavy. To ease its rack mounting, we strongly recommend to remove the battery pack
from the battery module, as explained below. See Section 1.2.2 for battery module weight.
Proceed as follows:
1.

Unscrew the six screws securing front panel using Bezel Hex Driver 44 .

2.

Unscrew the brackets securing the battery connectors.

3.

Disconnect Battery plugs.

4.

Unscrew the brackets securing the battery pack. Remove battery bracket pack covers.

5.

Pull the left and right battery packs out and set aside for reinstalling after the battery module cabinet has been
rack mounted.

6.

Mount battery module cabinet on rack.

7.

Re-install the battery pack in reverse order.

Figure 2-4: Accessing Battery Pack.

3

3

2
2

RT
EXB

www.mge

4

ups.com

1

x6
1

4

1

44
(not to scale)

5

2—6

Installation

86-86000-00 A01

Installation and User Manual

2.6

Power or Battery Module Rack Mounting
(optional rack mounting kits required, part number: 86001 and 86002)
The rails and necessary mounting hardware are supplied by MGE UPS SYSTEMS, INC.
Proceed as follows:
1.

Attach both front mounting ear brackets 24 to power module or battery module with supplied screws. (For this
step, it is possible to adjust the position of both front mounting ears.)

2.

Attach rails 26 together and secure with wing nuts, and finger tighten.

3.

Attach both rails to rear and front of rack chassis with supplied screws (as shown).

4.

Use caution when sliding unit into rack mount, secure unit to rack with supplied screws. (For this step, it is
possible to adjust the position of both front mounting brackets.)

Figure 2-6: Rack mounting of the power module onto the rails.

3
3
3
3
1
2

4
1

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4

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EX 5/7/11 RT System

2.6.1

Rear Support Brackets Installation
(Part number 86013, included with rack mounting kits, part numbers: 86001 and 86002)
These brackets prevent the power module from moving when the entire rack enclosure is moved.
Proceed as follows:
1.

Attach the brackets 25 to the I/O Box and power module.

2.

Secure brackets to rails.

Figure 2-7a: Rear Support Brackets.

1
2
2
1

2.6.2

Input/Output Box Bracket System Installation
(Part number 86012 included with power module rack mounting kit, part numbers: 86001)
This bracket system keeps the I/O Box stationary while hot swapping the power module. It will then be easier to slide
the replacement module into the connectors of the I/O Box.
NOTE:
1.

The rear support brackets must be removed prior to
installing I/O Box bracket system.

Secure small bracket to larger bracket from the underside 27 .

2 & 3. Secure large bracket 27 (with supplied screws) to rails at the rear of module.
4.

Secure small attached bracket (with supplied screws) to the I/O Box.

Figure 2-7b: Input/Output Box Bracket System.

1
2

4
OFF

3
3
4

2—8

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Installation and User Manual

2.7

Communication Ports
EX 5/7/11RT provides 3 communication methods that can be used simultaneously:

2.7.1

◗

The COM port 5 provides RS232 communications using MGE Serial HID UPS Transfer (SHUT)protocol.
This COM Port is compatible with Personal Solution Pac (PSP) to shutdown one computer. Personal Solution
Pac is included in the Solution Pac CD-Rom. For Network Management or multiple computer shutdowns an
optional network card must be purchased.

◗

The Dry Contact Port
AS400) and more.

◗

The slot 1 is compatible with any MGE UPS SYSTEMS, INC. communication card (check www.mgeups.com
web site for the complete list of compatible cards)

2

is used for basic signaling or for protection of IT systems like IBM iSeries (formerly

Connecting the RS232 Communication Port
32 communications cable to the serial port on the computer.

1.

Connect the RS 232

2.

Connect the other end of the communications cable
EX 5/7/11 RT.

32 to the RS 232

5

communications port on the

The EX 5/7/11 RT System can now communicate with Personal Solution Pac for power management. UPS configuration settings are done by Personal Solution Pac for Windows.

Figure 2-8: RS232 Communication Cable Connection.
32

5

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EX 5/7/11 RT System

2.7.2

Connecting the Dry (Relay) Contact Communication Port

2

The system status is indicated by the connection of common pin (Pin 5) to the appropriate pins. Refer to the pin
explanations below for details.

Figure 2-9: Relay Pin Connections for Communication Port.
Pin 1, 2: not used.

5

4
9

NO

NC

3
8

2
7

NO

1
6

NO

NO

Remote Power Off signal (5 to 27 VDC, 10 mA max).

Pin 4:

Operation on mains (not on battery). (48VDC, 2A max.)

Pin 5:

User common.

Pin 6:

Operation on automatic bypass.

Pin 7:

Low battery.

Pin 8:

Load protected

Pin 9:

Operation on battery.

Legend:

common

2.7.3

Pin 3:

NO:

contact normally open.

NC:

contact normally closed.

Installation of Optional Network Management Card
It is not necessary to shut down the UPS to install the optional communications card, except for USB card. Following
is a typical installation of the Network Management Card, (PN 66074, standard with the network pack option.)
Proceed as follows:
1.
2.
3.

Remove the slot cover secured by two screws.
Insert the card

37 into the slot.

Secure the card with both screws.

Figure 2-10: Communication Card Slot with SNMP/Web Network Management Card installed.

37

2 — 10

Installation

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Installation and User Manual

A wide range of optional cards will allow your UPS to talk to nearly all equipment management systems, making
integration faster and easier. All these cards can plug directly into the UPS, saving time and money on your next
UPS project. (Meta UPS Card and U-Talk /Basic Acquisition Cards are used exclusively with Multi-slot.)
Dual U-Talk/Basic Card

(66060) Provides two communications ports that may be configured
for serial link or AS/400 type dry contacts.

ModBus Card

(66061) Interface your UPS with a Building Management System.

Dual COM Ports Card

(66066) This card has two independent RS232 communication ports
on which it can be connected. One for connecting monitoring software
(included) and one for remote control panel UPS control.

USB Card

(66067) Take advantage of the latest and fastest communication
protocol for Microsoft Windows 2000/XP or Mac OSX.

Dual Volt Free Contacts

(66068) The two ports are used to supply UPS status information

Card for AS/400

or one port can be used as a Remote Power Off (REPO) port.

Alarm Relay Card

(66069) Six output relays show UPS status and two status inputs are
used with the Galaxy 3000 UPS.

XML-Web Card

(66073) XML-Web Card acts as a web page for your UPS information.
Used along with XML-ClientTM software, up to 50 servers or workstations will
be protected and can monitor the UPS with a simple web browser.
Security is handled with the SSL protocol, used by many websites to
safeguard sensitive password information.

SNMP-Web Card

(66074) The SNMP/Web 10/100BT communications card is
both an SNMP agent and an HTTP/Web server. Therefore, it
enables UPS supervision from any Network Monitoring
System using SNMP traps or simply from any web
browser (Internet Explorer, Netscape Navigator, etc.)
Orderly system shutdown of up to 32 protected servers can
be established using MGE’s Solution-Pac/WAN software
suite.

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Installation

2 — 11

EX 5/7/11 RT System

2.7.4

Remote Emergency Power Off (REPO) Communication Port

3

The end user is responsible for the installation of an emergency power off function. Installation must be carried out
in compliance with local code regulations.
To shutdown the entire system completely in case of emergency:
Disconnect the AC input to the power module.
Turn off the circuit breaker of the battery module connecting to the power module.
Turn off the circuit breaker of the subsequent battery modules, if applicable.
All these steps above should be performed via a single device.
To simplify the last two steps above, the power module provides an RJ-45 connector on the back panel, called
Remote Emergency Power Off (REPO) port. Upon applying a voltage source (5-27VDC, 10mA max.) to pins 2, 4 of
this port, the power module will send a signal to trip off the shunt trip on each circuit breaker of all battery modules
via the battery detection cable simultaneously. Refer to the diagram below for details.

Figure 2-10a: Activation of remote power off function using a contact normally open switch.

RJ11

3
654321

Figure 2-10b: Activation of remote power off function using a contact normally closed switch.

RJ11

3
654321

Signal:
Activation voltage: 5VDC to 27VDC
Current 10 mA (max)

NOTE

2 — 12

Both AC and DC sources must be present for normal start-up of EX 5/7/11RT
system. If the system is configured for cold start, the AC and DC sources are
required for initial start-up only.

Installation

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Installation and User Manual

2.8

Connecting the Input and Output Power Cables to the Input/Output Box
WARNING

This type of connection must be carried out by qualified electrical personnel.
Before carrying out any connections, check that battery circuit breaker
and that the upstream protection devices (Normal and Bypass AC
sources) are open (OFF).

14

is OFF

EX 5/7/11 RT UPS always comes from factory with Normal and Bypass AC inputs
already connected together, using a shunt.

2.8.1

Flexible Cordage and Conduit Installations

Figure 2-12a: Step 1 & 2; Typical plastic and metal coupling installations.
1.

1

Knockout die stamp circles.
NOTE

Outer circle is for
Plastic strain relief

OFF
O

I/O BOX

Inner circle is for
Metal strain relief

Terminal cable capacity:
Max. 4 AWG (11kVA), 6 AWG
(5/7kVA).
Knockout die stamp
circles (on terminal block
cover) have two sizes that fit
either plastic or metal
coupling. Plastic coupling is for
flexible cordage
and metal coupling is for solid
wires. Knock out appropriate
circle for your application.

Terminal Block Cover

OFF
O

2

2.

Remove bottom cover plate as shown.

3.

Typical plastic strain relief installation:
a) Secure strain relief body onto the
knockout plate.

3. Typical Flexible Cordage Installation

b) Strip the jacket back to expose the
three wires. Strip the insulation of
each wire back 1/2”. Insert the
ferrules as shown to each wire.

OFF
0
OFF
0

(b)
OFF
O

(c)
(a)

CAUTION:

(d)

c)

NOTE: Place lug ring inside
the terminal block cover.
Screw coupling into lug ring.

4. Typical 90° Metal Conduit Installation

Always connect the
earth ground wire first.

Slide the cordage into the strain relief
and secure the wires into the
terminal blocks using the guide
printed on bottom of I/O box.

d) Secure the cordage retainer nut.
OFF
O

OFF
O

4.
(c)
(a)

(b)

(d)

Typical 90° metal conduit installation.
a) Secure strain relief body to knockout
plate as shown.
b) Insert three wires through flexible
conduit and bend 90°.

NOTE: Place lug ring inside
the terminal block cover.
Screw coupling into lug ring.

c)

Strip the insulation back 1/2” to
expose solid wire and secure three
wires into the terminal block using
guide printed on bottom of I/O box.

CAUTION:

d)

86-86000-00 A01

Installation

Always connect the
earth ground wire first.

Install strain relief cover using two
screws.

2 — 13

EX 5/7/11 RT System

Figure 2-12b: Step 3; Typical Straight Metal Conduit installation.
5.

5. Typical Straight Conduit Installation

Typical straight metal conduit
Installation.

OFF
O

a) Secure strain relief onto the
terminal block cover as shown.

OFF
O

(c)

(e)

b) Insert three wire through flexible
conduit.

(d)

(a)

(b)

c)

NOTE: Place lug ring inside
the terminal block cover.
Screw coupling into lug ring.

Strip the insulation of each wire
back 1/2” to expose solid wire.

CAUTION:

Always connect the
earth ground wire first.

d) Secure three wires into the terminal
block using guide printed on bottom
of I/O box.
e) Twist the conduit onto the coupling
body as shown.

Figure 2-12c: I/O Box Terminal Block Diagram.
Output
200/208/220/230/240Vac

L6

L5

Normal AC Source
200/208/220/230/240Vac

L2

L1

Bypass AC Source
200/208/220/230/240Vac

L1

L4

L3

Jumper

2 — 14

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Installation and User Manual

2.8.2

System Connections with Common Normal and Bypass AC Sources

Figure 2-13: Normal AC Input and Output Cables installation.
Proceed as follows:
1.
OFF
O

1

Remove the I/O box from EX 5/7/11RT by
loosening three screws. Knockout appropriate circle for your wire style.
CAUTION:

Always connect the
earth ground wire first.

1.

See section 2.8.1 to install normal AC
source and output wires per I/O Box
Terminal diagram. Re-install the cover plate
under the I/O Box.

2.

Install the I/O Box with three screws.

2

10
100
Reset
1 2
ON

IP=
MAC=00E0D8FF855E

RS232 Download

ETHERNET

UPS
data

Card Settings

66074

OFF
O

To Step-Down
Transformer
(if applicable)

Simplified Connection Diagram
UPSTREAM
CIRCUIT
BREAKER
AC INPUT

(NOT SUPPLIED)

8

NOTE:

86-86000-00 A01

Bypass AC
Normal AC

Load to
Transformer Module

The power module factory default is for the common normal and bypass
AC source (single Main). AC input connections must be made to L1, L2,
and
terminals.

Installation

2 — 15

EX 5/7/11 RT System

2.8.3

Connecting EX RT Transformer
(Part number 86003)
This module is to provide isolated 120/208/240 VAC outputs to the protected loads.

Figure 2-14: View of EX RT transformer connected downstream for 120/208/240 Vac outputs (shown with one EXB).
POWER MODULE
EX 5/7/11 RT

BATTERY MODULE
EXB 5/7/11 RT
TRANSFORMER
MODULE EX RT

Follow connection diagram for
appropriate input/output voltages.

AC NORMAL
INPUT

STEP-DOWN
TRANSFORMER
OUTPUT TO LOAD

Terminal Block Transformer Module Connection diagram
(located on bottom of Transformer I/O Box)
L3

L2

L1

Lb

Ld

N

120Vac

208Vac

Lc

La
Terminal Block capability :
AWG 4 solid or stranded wire.

120Vac
208Vac

240Vac

240Vac
AC Output

AC Input

Simplified Connection Diagram
UPSTREAM
CIRCUIT
BREAKER

Bypass AC

Transformer Module

(NOT SUPPLIED)

8

AC INPUT

To Load

Normal AC

2 — 16

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Installation and User Manual

2.8.4

System Connections with Separate Normal and Bypass AC Sources
CAUTION:

This installation requires 2 AC input source with Line, Neutral plus Ground,
(200-240VAC). Neutral points are connected together inside the UPS.

Figure 2-15: Normal AC Input, Bypass AC, and Output Cables Installation.

Proceed as follows:
1.

1

OFF
O

L3

L1

Remove the cover plate under the I/O Box. Loosen
the terminal blocks L1 and L3, and remove the
jumper.
CAUTION:

OFF
O

3

Output

2.

See section 2.8.1 and I/O Box terminal diagram for
installation of Normal AC Input, Bypass AC
source, and Output cable with different wire style.

3.

Reinstall the cover plate under the I/O Box with
four screws.

4.

Secure the I/O Box to the power module using
three screws.

2
Bypass
Normal

Always connect the
earth ground wire first.

See section 2.8.3 for connecting EX RT
Transformer, if applicable.

4

10
100
Reset
1 2
ON

IP=
MAC=00E0D8FF855E

RS232 Download

ETHERNET

UPS
data

Card Settings

66074

OFF
O

To Step-Down
Transformer
(if applicable)

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EX 5/7/11 RT System

2.8.5

System Connections as Frequency Converter (without Bypass AC Source)

Figure 2-16: Accessing Terminal Blocks for Input and Output power cables.

CAUTION:

OFF
O

1.

1

Always connect the
earth ground wire first.

Remove the cover plate under the I/O Box.
Remove the jumper connecting L3 and L1.

CAUTION:

Do not connect anything to the
Bypass AC terminal block.

OFF
O

2

2.

Refer to section 2.8.1 to install normal AC source
and output wires per I/O Box Terminal diagram. Reinstall the cover plate under the I/O Box.

3.

Secure the I/O Box to power module with three
screws.
See section 2.8.3 for connecting EX RT
Transformer, if necessary.

3

10
100
Reset
1 2
ON

IP=
MAC=00E0D8FF855E

RS232 Download

ETHERNET

UPS
data

Card Settings

66074

OFF
O

To Step-Down
Transformer

2 — 18

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Installation and User Manual

2.9

Connection of Battery Module, EXB
1.

Check that the battery circuit breaker 14 is OFF (“0”) position.

2.

Connect the battery power cable
modules.

3.

Connect the battery detection cable 42 between connectors
modules.

40

to the connectors

6

and

4

and

13

of the power and battery

12 of the power and battery

Figure 2-17: Rear view of battery module cable connections.

12
4

42

40

13
6

14

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EX 5/7/11 RT System

2.10

Connection of CLA Module
1.

Connect the battery power cable 40 and battery detection cable 42
between the power module and the CLA module.

2.

Connect the DC Input of the CLA to high power battery cabinet.

(provided with the CLA module)

◗ DC Input Cable cross-section (not provided): maximum 4 AWG solid or stranded wire.
3.

Connect the AC input cable of the CLA module to the utility AC input:
◗ AC input cable cross-section (not provided): maximum 16 AWG solid or stranded wires.

Figure 2-18: Rear view of CLA module cable battery and AC input connections.

Connection Diagram
(inside CLA Module)
42

-

+

DC INPUT
240Vdc

N
(L2)

L
(L1)

AC INPUT
156-280Vac

40

To High
Power Battery
Cabinet
Utility AC Source

2 — 20

Installation

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Operation

3.0

Scope
Operation describes EX 5/7/11RT system characteristics of indicators and controls, modes and specifications and
theory of operating the EX 5/7/11RT. The user procedures include performing software programming that will
maintain smooth performance. Refer to Figure 1.6 for descriptions of circled numbers.

3.1

Initial Startup
7

1.

Check that the manual bypass switch

is on Normal position.

2.

Set the normal AC source circuit breaker

3.

Set the battery circuit breaker 14 to the ON position.

8

to the ON position.

The load is powered via the bypass AC source, but not protected by the UPS.
Batteries are recharging, an eight-hour recharge period is necessary to get full backup time.
LED 17 is ON.

Figure 3-1: Initial Startup Display.
17

OFF

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ON

Operation

3—1

EX 5/7/11 RT System

3.2

UPS Personalization
IMPORTANT

If specific settings are required, it is recommended to
enter the UPS personalization mode at this stage.
It is possible to enter this mode through the front panel
buttons or the Personal Solution-Pac software for
Windows included in the MGE UPS SYSTEMS, INC. SolutionPac power management suite CD-ROM.

3.2.1

Accessing personalization with front panel buttons
◗

Press "scroll up" 20 and "scroll down" 21 function buttons together for more than 3 seconds.

◗

Press the function button 21 placed under the “ENT” word to enter the set up mode and
follow the LCD messages using the buttons now defined as select keys. See Tables: 3-1,
3-2, 3-3, and 3-4 for settings.

Figure 3-2: Control Panel with scroll up and down buttons.

UPS SET UP
EXIT ENT
OFF

ON

20

3—2

21

Operation

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Installation and User Manual

Table 3-1: Local Settings.

Display

Factory setting

Options

Language

English

French, Spanish, German, Italian

Date / time format

International format

US format

(DD-MM-YYYY/HH:MM)

(MM-DD-YYYY/HH:MM AM/PM)

Date / time change

GMT (Greenwich Mean Time)

MM-DD-YYYY/HH:MM adjustable

Audible alarm

Quick beeps

Slow beeps

Table 3-2: Output features.

Display

Factory setting

Options

Comments

Output voltage

208 Volts AC

200/208/220/230/240/250

Frequency converter

Disabled

Enabled

Bypass AC source disabled

Output frequency

Auto ranging

50/60 Hz

User selectable under
frequency converter mode

Eco mode

Disabled

Enabled

See glossary

Hot standby

Disabled

Enabled

Full redundancy (see Figure 3-3)

Operating mode

IT Network

Industrial

(*) See Section 4.1

Bypass
Transfer

When bypass OK (**)

When bypass NOK (**)

(*)

Interrupt time

10 ms

10 to 200 ms
(by steps of 10 ms)

Interrupt time calibration during
during load transfer on
Bypass AC source
out of tolerances

Overload level

102%

50/70%

(*) : - Select "IT Network" for computer loads.
- Select "Industrial" when bypass NOK in case of absolute need for service continuity (with potential
10 ms interrupt).
(**) UPS will switch to Bypass AC Source if it is within the set tolerances.

Figure 3-3: Configuration used to provide full redundancy (2N) to critical loads.
BYPASS AC

Full redundancy configuration
offers better protection to
critical load, whereas the first
UPS acts as the Bypass AC
Source for the second UPS.

Protective Device
NORMAL AC

Utility
AC Source

Protective Device

NORMAL AC
LOAD

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EX 5/7/11 RT System

Table 3-3: ON/OFF features.

Display

Factory setting

Options

Comments

Cold start

Disabled

Enabled

Start on battery.

Forced reboot

Enabled

Disabled

Enables automatic restart of
the system even if normal AC
source is restored before the
end of the shutdown sequence.

Automatic restart

Enabled

Disabled

UPS restarts automatically
when normal AC source
is restored.

Sleep mode

Disabled

Enabled

Automatic shutdown on battery
if output load level <10%

Remote Command

Enabled

Disabled

Enables shutdown or restart
orders from software.

Comments

Table 3-4: Battery features.

Display

Factory setting

Options

Battery test

Every week

No test/daily/monthly

Pre-Alarm

20%

0 to 100%

Low battery signal;1% increment

Runtime choice

UPS reads # and type
of battery
modules connected.

From 65 to 400 Ah

Requires EX 5/7/11RT CLA if
using options (see section 1.5.4
“Battery extensions cable kit”)

Battery deep discharge
protection

Enabled

Disabled

If disabled, loss of
MGE UPS SYSTEMS,INC.
warranty.

3.2.2

Accessing personalization through external software
Insert the Solution-Pac CD ROM in your CD drive.

◗

At the first Navigator Screen, select "Installation" and follow the instructions to install Personal
Solution-Pac for Windows.

◗

If nothing appears, launch startup.exe

◗

Then go to "Advanced settings" and "UPS settings".

Please note that the Linux/Unix/MacOS versions of Personal Solution-Pac do not include this feature.

3.2.3

Final startup sequence
Press the  button more than 3 seconds.

◗

After UPS internal test sequence, the green LED 15 goes on.

CAUTION

3—4

During the restart, if the Bypass AC source is out of
tolerance, the UPS will generate an output
calibrated 10 msec output interrupt.

Operation

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Installation and User Manual

3.3

Operating Modes

3.3.1

Normal (double conversion) Mode

Figure 3-4: Normal (double conversion) mode.
This is the standard operating mode, set by the
factory.

15

Two possible cases.
1.

15

LOAD LEVEL
4kW / 5 kVA
OFF

15

If Normal AC source available:
LED is ON.

The load is protected by the UPS.
ON

Scroll up 21 and scroll down 22 function buttons
allow you to read the UPS measurements (Normal AC
source voltage, Bypass AC source voltage, operating
mode, battery capacity and UPS Serial Number).

16

2.

If Normal AC source not available:

CAUTION:

REMAINING TIME
10 minutes
OFF

ON

Do not operate the Manual Bypass switch
when the UPS is in Normal mode.

15

LED flashes.

16

LED is ON.

The audible alarm sounds intermittently.
The load is now powered by the UPS battery.
This display shows remaining back-up time.

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Operation

3—5

EX 5/7/11 RT System

3.3.2

ECO Modes

Figure 3-5: ECO mode display.
15

The main advantage of the ECO mode (see glossary)
is that it reduces the consumption of electrical power.

17

Three possible cases:
1.

If Bypass AC source available:

15

OFF

and 17

LED are ON.

The load is supplied with AC power but not protected
in ECO mode.

ON

15
2.

If Bypass AC source not available:

15

LED is ON.

The audio alarm sounds intermittently.

15
OFF

The load is automatically supplied in Normal
mode via the Normal AC input.

16
ON

3.

Both Normal and Bypass AC sources not
available or out of tolerance:

15

LED is ON.

16

LED is ON.

The audio alarm sounds intermittently.
OFF

ON

The load is powered by the battery power from the
UPS.
The display indicates the battery remaining
backup time.

3—6

Operation

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Installation and User Manual

3.4

Operation on battery power

Figure 3-6: Transfer, Threshold and End of backup time.
15

3.4.1

16

Transfer to Battery Power
The load continues to be protected by the UPS when
the Normal AC source is not available. Power is
supplied by the battery.
There are three possible cases:

REMAINING TIME
10 minutes

First Case:

15

LED is ON.

16

LED is ON.

ON

OFF

The audio alarm beeps every 10 seconds.
15

16

◗

This indicate the load is supplied by the battery.

◗

The display indicates the battery remaining
backup time.

Second Case:
REMAINING TIME
2 minutes
OFF

15

LED is ON.

16

LED is ON.

ON

The audio alarm beeps every 3 seconds.
◗
15

16

Low battery warning on display. There is very little
remaining battery backup time. Close all applications because UPS automatic shutdown is
pending.

17

Third Case:

SHUTDOWN DUE
TO DEPLETED BATTERY
OFF

15

LED is OFF.

16

LED is OFF.

The audio alarm is stopped.

ON

◗

The load is transferred to the Bypass AC source if
available. In this case:

17 LED is ON.

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Operation

3—7

EX 5/7/11 RT System

3.5

Return of Normal AC source
After an outage, the UPS restarts automatically when AC power is restored (unless this function has been disabled
via UPS personalization).

3.6

Shutdown

Figure 3-7: Shutdown display, circuit breaker, and AC source switch.
1.

17

Press the OFF button
seconds.

19

more than 3

The load is no longer protected by the UPS. It is
powered via the bypass AC source. If the UPS is
set in frequency converter mode, the load will not
be powered.

OFF

If the bypass AC source is out of tolerance, the
UPS will generate a calibrated 10msec output
interrupt.

ON

2.
19

14

Set the battery circuit breaker(s) 14
OFF position.

3.

Set the Normal AC source circuit breaker

8
8

3—8

to the

4.

Operation

to the OFF position.

For a full shutdown of UPS and connected
load, the upstream circuit breaker (not
included) should be set to the OFF position.

86-86000-00 A01

Maintenance

4.0

Scope
Maintenance includes a troubleshooting guide of symptoms and possible solutions, Hot swapping the power module
and Battery Module, and testing scenarios.

4.1

Information Technology (IT) Network and Industrial Operating Modes

Table 4-1: Network and Industrial Modes of Operation.

Symptoms

IT network mode

Industrial mode

Overload, and Bypass
source in tolerance.

Load is transferred to Bypass AC source.
UPS returns to normal mode if overload
is removed.

Same as I/T network mode, but AC
to the UPS does not return to
normal mode if overload
is removed.

Overload, and Bypass
AC source not in tolerance.

The UPS shuts down and load is not
transferred to Bypass AC source.

Load is transferred to Bypass
AC source with 10 milliseconds output break.
The UPS does not return to
normal mode if overload
is removed.
Load is transferred to Bypass
AC source, the UPS returns to
normal mode if the short circuit
is removed.

Output short circuit and Bypass The load remains powered by the UPS.
AC source in tolerance.
The UPS shuts down after 3 minutes
if the short circuit remains

Output short circuit and Bypass The load remains powered by the UPS.
AC source not in tolerance.
The UPS shuts down after 3 minutes
if the short circuit remains.

86-86000-00 A01

Maintenance

The load is transferred to
Bypass AC source with
10 milliseconds output break.
The UPS does not return to
normal mode if the short circuit
is removed.

4—1

EX 5/7/11 RT System

4.2

Troubleshooting
◗

If any of LED's

◗

Use "scroll up" or "scroll down" function button to reset the audible alarm.

◗

Troubleshooting not requiring MGE UPS SYSTEMS, INC. after-sales support:

17 or

18 is on, there is an operating anomaly or an alarm.

Table 4-2: Troubleshooting not requiring MGE after-sales support.
Symptom

Indication

Correction

LED 17 is on, and Bypass AC
source is present
the alphanumeric display shows
BAD CONNECTION
REWIRE AC NORMAL

AC source is not connected
to the correct terminals.

Rewire correctly the normal AC
source.

LED 17 is on,
the alphanumeric display shows:
LOAD LEVEL
XX kW / XX KVA

Load supplied by bypass AC source.

Push the ON button for more than 3
seconds.

LED 17 is on, and Bypass AC
source is present
the alphanumeric display shows:
THERMAL OVERLOAD
1XX%

UPS overload

Check if any device is shorted or failed.

Short circuit conditions on output
devices.

Check if any device is shorted or
failed.

180° degree phase shift between
bypass and normal AC source.

Check if bypass source is correctly
wired
(in case of upstream transformer use).

Input/Output box not
installed correctly.

Check if the Input/Output box
is correctly installed. See section 2.8.

LED

18 is on,

the alphanumeric display shows:
CURRENT OVERLOAD
LED

15 is on,

but the alphanumeric display shows:
BYPASS REVERSE
REWIRE BYPASS
Audible alarm is on,
the alphanumeric display shows:
I/O BOX REMOVED

4—2

Maintenance

86-86000-00 A01

Installation and User Manual

Table 4-3: Troubleshooting requiring MGE after-sales support.
Symptom

Indication

Correction

LED 17 and 18 are on,
Bypass AC Source is present
and audible alarm is on.
the alphanumeric display shows:
xxx FAULT

Internal fault
and transfer of load
on bypass AC source

Call the after sales support department.

LED 17 is on, and audible alarm
is on, the alphanumeric display
shows
BATTERY FAULT

Battery fault during the battery test.

Call the after sales support department.

LED 17 is on,
the alphanumeric display shows:
SHUTDOWN
STATIC SW FAILED

Static switch failure

Call the after sales support department.

Audible alarm is on,
the alphanumeric display shows:
END OF WARRANTY

Batteries may have exceeded
their rated life period. Battery
capacity is severely reduced.

Follow the battery replacement procedure
in section 4.5.

NOTE: To reset the alarm permanently, press both function buttons 21 and 22 for more than 3 seconds.

86-86000-00 A01

Maintenance

4—3

EX 5/7/11 RT System

4.3

Hot Swapping the Power Module
This operation can be performed without interrupting the load.

Figure 4-1: Disconnecting the power module.
17

1.

Stop the UPS with the OFF button 19 (press
more than 3 seconds).
Check if UPS is on bypass AC source:
LED 17 is on (If LED 17 is not on, do not
turn the manual bypass and call the after sales
support department).

XXX FAULT
1CXXXXXXX
OFF

ON

19

Turn the manual bypass switch
BYPASS position.

3.

Switch the battery circuit breaker(s) 14 to the
OFF position.

Tower configuration

Card

5E
8FF85
IP= 00E0D
MAC=

10
100

CAUTION:

gs
Settin

UPS
data

to the

Do not switch the Normal AC

66074
RS232

Reset

1 2
ON

RS232

7

2.

RNET
ETHE

load
Down

8

42

source circuit-breaker

to

40

the OFF position. Doing so
will disconnect power to the

7

load.
φ

Loosen three screws to remove the
Input/Output box.

5.

Disconnect the battery cables
from the power module.

BY
PASS

4.
8

12

Rack configuration

40 and

42

The power module can be replaced.
The connected equipment is powered by the
Bypass AC source.

4—4

Maintenance

86-86000-00 A01

Installation and User Manual

4.4

Re-connecting the power module
This operation can be performed without interrupting the load.

Figure 4-2: Reconnect the power module.
15

17

1.

Secure the Input/Output junction box using the
three screws.

2.

Reconnect the cables

40 and

42 to the

power module.
LOAD LEVEL
4 kW/ 5 kVA
OFF

ON

3.

Switch the battery circuit breaker(s) 14 to the
ON position.

4.

Check if Normal AC source circuit breaker

8
22

is on the ON position.

5.

Check that the LED 17 is on.

6.

Turn the manual bypass switch from the
BYPASS to the NORMAL position.

7.

Follow initial start up sequence (see section
3.1) in order to personalize the UPS.

8.

Push the ON button
seconds.

22

for more than 3

The green LED 15 is on, and the connected
equipment is now protected by the UPS.

86-86000-00 A01

Maintenance

4—5

EX 5/7/11 RT System

4.5

Hot Swapping the Battery Module

Figure 4-3: Rear view of the battery module.

Battery Module
42

Power Module

4.5.1

40

Disconnecting the Battery Module
1.

Switch the battery circuit breaker(s) 14 to the
OFF position.

2.

Disconnect the cables 40 and 42 from the
power module.

The battery module can be replaced.
The connected equipment is powered by the UPS,
but not protected.
It is also possible to replace battery pack instead of
battery module.
Contact your nearest after sales support service.
CAUTION:

Always replace both battery
packs with new ones.

To remove battery pack:
1.

First, switch the battery circuit breaker(s) to the
OFF position.

See section 2.5 and follow instructions for battery
pack replacement.

14

4—6

4.5.2

Maintenance

Re-connecting the Battery Module
1.

Reconnect the battery cables 40 and 42
the power module.

2.

Switch the battery circuit breaker(s) 14 to the
ON position.

to

86-86000-00 A01

Appendix
5.0

Electrical Specifications

5.1

System Input/Output Power Ratings

Table 5-1: EX 5/7/11 RT Input and Output Characteristics.

Source

Voltage

Frequency

Normal AC Source

208 to 240 Volts AC

40 to 70 Hz

Bypass AC Source

208 to 240 Volts AC*

48 to 52 Hz**

Load Output

120/240Vac Volts AC
(120/208/240Vac
are possible with
transformer module)

50/60 Hz autoranging
(or frequency converter)

(*): depends on output voltage setting, can be modified by software.
(**): set to +/- 4% by default, (1,2,4,8% are possible values), can be modified by software.

5.2

System Overload Characteristics

Figure 5-1: Power supplied as a function of input voltage (left), and Permissible UPS overloads as a function of time (right).
Load Percentage

Load Percentage
1.5
100%

70%
1.25

1.1
1.02
U
120V 160V

5.3

0.5s

280V

t
30s

60s

120s

System Backup Characteristics

Table 5-2: Back-up Time ( in minutes).
System
Standard 11kVA
Standard 11kVA + 1 EXB
Standard 11kVA + 2 EXB
Standard 11kVA + 3 EXB
Standard 11kVA + 4 EXB
Standard 11kVA + 5 EXB
Standard 7kVA
Standard 7kVA + 1 EXB
Standard 7kVA + 2 EXB
Standard 7kVA + 3 EXB
Standard 7kVA + 4 EXB
Standard 7kVA + 5 EXB
Standard 5kVA
Standard 5kVA + 1 EXB
Standard 5kVA + 2 EXB
Standard 5kVA + 3 EXB
Standard 5kVA + 4 EXB
Standard 5kVA + 5 EXB

86-86000-00 A01

30%
25
61
96
135
172
201
37
80
124
185
245
287
37
90
140
185
255
306

Load Percentage
50%
70%
14
9
30
20
53
34
84
51
102
67
113
87
21
12
53
30
83
55
108
75
132
98
164
118
31
21
70
53
112
83
156
108
207
132
260
164

Appendix

100%
5
14
22
30
42
53
7
20
32
45
57
72
12
30
55
75
98
118

5—1

EX 5/7/11 RT System

Table 5-3: Battery Recharge time to recover 90% of the rated backup time after discharge at full load.
Configuration for
2 hours backup time

Configuration for
4 hours backup time

Configuration for
8 hours backup time

EX 5

7 hours

15 hours

24 hours

EX 7

5 hours

12 hours

20 hours

EX 11

7 hours

15 hours

24 hours

5.4

System Short Circuit Protection
Short circuit current provided by EX 5/7/11RT in normal or battery mode:
EX5/7 RT
110A for 80ms
EX11 RT
190A for 80ms

5.5

Accessories Electrical Characteristics
EX RT Transformer
Nominal power
Nominal current
Input voltage
Output Voltage
Frequency
Isolation (EN 61558-1-2-4)
Operating temperature
Max. operating rel. humidity
Derating / altitude
Dimensions HxWxD (tower)
Dimensions HxWxD (rack 3U)
Weight

11 kVA
63 A
208-240Vac
120/208/240Vac
50/60 Hz (+/-10%)
3.75 kV / 5 M ohms
From 0° to +40°C
95%
Pn-10% > 1000 m
17.5 x 5.15 x 25 inches (444 x 131 x 635 mm)
5.15 x 17.5 x 25 inches (131 x 444 x 635 mm)
151 lbs. (68.5 kg)

EX RT CLA module
AC input voltage
Input frequency
Battery charge current

5.6

156-280 Volts AC
40-70 Hz
6 A DC

Heat Rejection

Table 5-4: Full load heat rejection in BTU’s/hr.

System

Operation Mode
On-line

On Battery

5kVA

1327

1944

7kVA

1858

2722

11kVA

2919

4278

5.7

5—2

Environmental Characteristics
◗

The operating temperature is 0 to 40°C (8 hours at 45°C), however optimum operation is within the +20 to +25°C
range and at 5-95% humidity, non-condensing at altitude up to 3280ft without de-rating.

◗

The storage temperature : -20 to 40°C. Humidity : 5-95%, non condensing.

◗

Battery backup time is adversely affected by high and low temperatures. It is significantly reduced at temperatures under 10°C. Above 25°C, battery service life is cut in half every 10°C. Above 40°C, battery manufacturers
no longer guarantee operation due to the risk of thermal runaway.

◗

Air enters through the front air vent grills and exits through the back. Always keep air vent grills unobstructed.

Appendix

86-86000-00 A01

MGE Warranty & Proprietary Rights for Single Phase Products
MGE Warranty
The 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 a period of 24 months from the date of purchase. The MGE UPS SYSTEMS, INC. shall have the sole right
to determine if the parts are to be repaired at the job site or whether they are to be returned to the factory for repair
or replacement. All items returned to MGE UPS SYSTEMS, INC. for repair or replacement must be sent freight
prepaid to its factory. Purchaser must obtain MGE UPS SYSTEMS, INC.’s Return Materials Authorization prior to
returning items. The above conditions must be met 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 of God.
In no event shall the MGE UPS SYSTEMS, INC. be liable for loss, damage, or expense directly or indirectly arising
from the use of the units, or from any other cause, except as expressly stated in this warranty. MGE UPS SYSTEMS,
INC. makes no warranties, express or implied, including any warranty as to merchantability or fitness for 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 UPS SYSTEMS, INC. for any consequential or special damages arising out of any breach of
warranty, and for any damages Purchaser may claim for damage to any property or injury or death to any person
arising out of its purchase of the use, operation or maintenance of the product. MGE UPS SYSTEMS, INC. will not
be liable for any labor subcontracted or performed by Purchaser for preparation of warranted item for return to MGE
UPS SYSTEMS, INC.’s factory or for preparation work for field repair or replacement. Invoicing of MGE UPS
SYSTEMS, INC. for labor either performed or subcontracted by Purchaser will not be considered as a liability by the
MGE UPS SYSTEMS, INC.
This warranty shall be exclusive of any and all other warranties express or implied and may be modified only by a
writing signed by an officer of the MGE UPS SYSTEMS, INC. This warranty shall extend to the Purchaser but to no
one else. Accessories supplied by MGE UPS SYSTEMS, INC., but manufactured by others, carry any warranty the
manufacturers have made 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.
Purchaser agrees to indemnify and hold MGE UPS SYSTEMS, INC. harmless from any liability by virtue of any patent
claims where Purchaser 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 any
oral representation shall not bind MGE UPS SYSTEMS, INC. and shall not be part of any warranty.
There are no warranties which extend beyond the description on the face hereof. In no event shall MGE UPS
SYSTEMS, INC. be responsible for consequential damages or for any damages except as expressly stated herein.

Proprietary Rights Statement
The information in this manual is the property of MGE UPS SYSTEMS, INC., and represents a proprietary article in
which MGE UPS SYSTEMS, INC., retains any and all patent rights, including exclusive rights of use and/or manufacture and/or sale. Possession of this information does not convey any permission to reproduce, print, or manufacture
the article or articles shown herein. Such permission may be granted only by specific written authorization, signed by
an officer of MGE UPS SYSTEMS, INC.
IBM, PC-AT, ES/9000, and AS/400 are trademarks of International Business Machines Corporation. MGE and MGE
UPS SYSTEMS are trademarks of MGE UPS SYSTEMS, INC. Other trademarks that may be used herein are owned
by their respective companies and are referred to in an editorial fashion only.

Warranty and Product Registration
Thank you for choosing MGE UPS SYSTEMS, INC. for your power protection, distribution, and quality
requirements. We are pleased to have you join our increasing family of users.
In order to maximize the value you receive from this product, and to ensure that you are kept informed of
product or software updates, we recommend that you take a few minutes to register your new purchase.
You may register online at the URL noted below. Should you not have Internet access, you may mail or fax
this form back (attn: Warranty Registration) as indicated at the bottom of the page.
Register your UPS at: http://www.mgeups.com/email/warranty/menu.htm
Please be prepared with the following information to register and validate your UPS warranty, keep
informed on software and product updates, and register your extension "Warranty+" if purchased with the
UPS.
User Information
Last name

________________________________________

First name

________________________________________

Company name

________________________________________

Address

________________________________________

Zip code

________________________________________

City

________________________________________

State/Province

________________________________________

Country

________________________________________

Tel

________________________________________

Fax *

________________________________________

Email*

________________________________________

Product information
Model

________________________________________

Serial Number

________________________________________

Date of purchase

________________________________________

Warranty Extension (Warranty+) not available on products
I have purchased a warranty extension (Warranty+)
Reference: _____________________

Contract Number: _________________

Thank you from all of us at MGE.

MGE UPS SYSTEMS, INC., 1660 Scenic Avenue, Costa Mesa, CA 92626, USA
Tel: 714-557-1636
Fax: 714-557-9788
41-000154-53 Rev B00 9/2003

MGE Customer Care Center
Technical Support and Product Services

?

Technical questions? If you encounter a problem while following the instructions in this manual, or have
questions about the operation, repair, or servicing of your equipment, please direct calls to MGE UPS

SYSTEMS, INC. Customer Care Center or visit our web site www.mgeups.com for complete service information.
To insure that your questions are correctly answered, please obtain the part number, assembly number, and serial
number of the unit and include them in any discussions or correspondence.
Part Number:

_____________________________________________________________________

Assembly Number: _____________________________________________________________________
Serial number:

_____________________________________________________________________

Who To Contact
Customer Care Center:

1-800-523-0142, extension 1113

Field Service Engineer:

1-800-438-7373

(USA and Canada Only)

Customer FAQ
or International calls:

1-714-557-1636

(Ask for Technical Support Group, TSG)

(USA and Canada Only)

Commitment: MGE 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 UPS is critical to maintaining your schedule, please call the MGE
toll free telephone number at 1-800-438-7373, to insure a safe installation and startup that will maintain
the MGE warranty and insure smooth performance

Return Policy for Repair (RMA)
Should you require factory service for your equipment, contact MGE’s Customer Support Services and obtain a Return
Materials Authorization (RMA) prior to shipping your unit. Never ship equipment to MGE without first obtaining an RMA.
Date:

______________________________________________________

RMA Number:

______________________________________________________

Contact Name: ______________________________________________________

EX 5/7/11 RT System

(This page left blank intentionally)

W—4

86-86000-00 A01

Glossary

Term used

Definition / Meaning

@

At.

/

And/or.

+/-

Plus or Minus.

≤

Equal to or less than.

#

Number.

°C

Degree Celsius.

°F

Degree Fahrenheit.

Ø

Phase angle.

Ω

Ohm; unit of resistance.

®

Trade Mark.

2nd

Second.

AC or ac

Alternating current, also implies root-mean-square (rms).

Ambient Temp.

Temperature of surrounding air.

Ambient noise

Acoustical noise of surrounding environment.

ANSI

American National Standard Institute.

AWG

American Wire Gauge.

Breaker

Electrical circuit interrupter.

BTU or Btu

British thermal unit. Defined as the amount of heat required to raise the temperature of one pound of water by 1°F.

BYPASS

See “Static Transfer switch”.

BYPASS mode

See “off-line mode”.

Carrier

The company or individual responsible for delivering goods from one location to another.

C

Common.

CB

Circuit breaker.

cm

Centimeter.

dB

Decibels.

DC

Direct current.

Conduit

A flexible or rigid tube enclosing electrical conductors.

C.S.S.

Customer Support Service.

86-86000-00 A01

Glossary

G—1

EX 5/7/11 RT System

G—2

Current rating

The maximum current that a conductor or equipment can carry reliably without damage.

dBA

Decibel Adjusted.

dBrnC

Decibel above reference noise.

DC or dc

Direct current, or voltage.

Digital Meter

The LCD display on the front panel of inverter system.

Earth ground

A ground circuit that has contact with the earth.

ECO Mode

Operating mode by which the load is supplied directly by the AC source if it is within the
tolerances defined by the user. This mode reduces the consumption of electrical power.

Electrician

Refers to an installation electrician qualified to install heavy-duty electrical components in
accordance with local codes and regulations. Not necessarily qualified to maintain or repair
electrical or electronic equipment.

FET

Field effect transistor.

Freq.

Frequency.

Frequency slew rate

The change in frequency per unit of time. Given in term of Hz per second (Hz/sec.).

GND

Ground (safety).

Hz

Hertz, frequency measurement unit, 1Hz is one cycle per second.

Inverter mode

See “on-line” mode.

I

Current.

IEC

International Electrotechnical Commission.

IEEE

Institute of Electrical and Electronic Engineers.

Input branch circuit

The input circuit from the building power panel to the equipment.

Inverter

An electrical circuit that generates an AC voltage source from a DC voltage source.

IGBT

Insulated gate bipolar transistors.

I/O

Input/Output.

I/T or IT

Information Technology.

kVA

KiloVolt-Ampere; is equal to 1000 Volt-Ampere.

L

Line.

LCD

Liquid-Crystal Display unit.

LED

Light Emitting Diode.

Mains or Mains 1

Main AC input source.

Mains 2

Bypass AC input source.

mA

Milliampere.

MAX.

Maximum.

MCM

Thousand circular mil; standard wire sizes for multiple stranded conductors over 4/0 AWG in
diameter. M is from Roman numerical system indicating 1000.

Module

Refers to individual power inverter module.

N

Neutral.

Glossary

86-86000-00 A01

Installation and User Manual
NC

Normally closed.

NO

Normally open.

NEC

National Electrical Code.

NFPA

National Fire Protection Association.

PN

Part number.

On-line mode

Inverter output power is the primary energy source to load.

Off-line mode

Inverter output is off, and the load connected at the inverter output receives power
from utility line via a static transfer switch or maintenance bypass relay.

OSHA

Occupational Safety and Health Agency.

PCA

Printed circuit assembly.

PCB

Printed circuit board.

PWM

Pulse Width Modulation.

SCR

Silicon controlled rectifier.

Shipping damage

Any damage done to an article while it is in transit.

SPDT

Single Pole Double Throw.

Static Transfer

An solid state switching mechanism electronically controlled to pass AC power
directly from the utility to an output load.

Technician

Refers to an electronic technician qualified to maintain and repair electronic
equipment. Not necessarily qualified to install electrical wiring.

Test connector

DB-9 type connector on the LCD panel allowing MGE UPS SYSTEMS Customer
Support Service technician to access programmable and diagnostic features of the
system.

V

Volts

VA

Volt amperes

VA

Volt-amps, unit for apparent power measurement, equal V x I.

VAC or Vac

Voltage of AC type.

VDC or Vdc

Voltage of DC type.

ve

Battery voltage.

Via

By way of.

86-86000-00 A01

Glossary

G—3

EX 5/7/11 RT System

(This page left blank intentionally)

G—4

86-86000-00 A01

Reorder Form

1660 Scenic Avenue
Costa Mesa, CA 92626
Use this form to report any errors, omissions, or other problems you have experienced, or to order
additional hardcopies of this document. A free copy of this document may be downloaded from the
proprietary MGE Rep Web site. Please contact your MGE UPS SYSTEMS,INC. Representative for assistance.

NAME

_____________________________________________________________________________________

COMPANY ___________________________________________________________________________________
STREET ADDRESS ____________________________________________________________________________
CITY ________________________________________ STATE __________________ ZIP ___________________
I would like to order______ (quantity @ $75.00 each) additional copies of the:

EX 5/7/11 RT System
Installation and User Manual

86-86000-00 A01

I would like to report the following problems with this document:

www.mgeups.com

Contact MGE
United States
MGE UPS SYSTEMS
1660 Scenic Ave.
Costa Mesa, CA 92626
Tel: (714) 557-1636
(800) 523-0142
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
(800) 523-0142 ext. 7831
Fax: (714) 434-0199
email: info@mgeups.com
www: mgeups.com

1 6 6 0 S c e n i c Ave n u e, C o s t a M e s a , C a l i fo r n i a 9 2 6 2 6 • ( 7 1 4 ) 5 5 7 - 1 6 3 6



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