EXL 1000

Distribution
Cabinet
Installation
Manual
IMPORTANT SAFETY INSTRUCTION
SAVE THESE INSTRUCTIONS — This manual contains important instructions for Distribution
Cabinet that must be followed during installation, operation and maintenance of the
equipment.

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

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

WARNING
Changes or modifications to this unit not expressly approved by the
party responsible for compliance could void the user's authority to
operate the equipment.

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 commu-
nications. Operation of this equipment in a residential area is likely to
cause harmful interference in which case the user will be required to
correct the interference at his own expense.

86-153158-00
 EXL 1000 Distribution Cabinet

Installation Manual

For service call

1-800-438-7373

86-153158-00 B00 11/97

Copyright © 1997 MGE UPS Systems, Inc. All rights
reserved. Printed in U.S.A.

MGE UPS Systems

1660 Scenic Avenue
Costa Mesa, CA 92626
(714) 557-1636

86-153158-00
 EXL 1000 Distribution Cabinet
Installation Manual

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. 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 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, or 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 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 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.

Service and Factory Repair - Call 1 - 800 - 523 - 0142

Direct questions about the operation, repair, or servicing of this equipment to MGE UPS Systems, Inc. Technical
Support Services. Include the part number and serial number of the unit in any correspondence. Should you require
factory service for your equipment, contact MGE UPS Systems, Inc. Technical Support Services and obtain a Return
Materials Authorization (RMA) prior to shipping your unit. Never ship equipment to MGE UPS Systems, Inc. without first
obtaining an RMA.

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.

Revision History
EXL 1000 Distribution Cabinet Installation Manual
86-153158-00
Copyright © 1997 MGE UPS Systems. All rights reserved. Printed in U.S.A.
Revision: A00 New Release 01/97
B00 ECN# 289-93 11/97

86-153158-00
 Contents

Sections
section description page number
1.0 . . . . . . . . . .
Scope . . . . . 1—1
1.1 . . . . . . . . . . . .
Introduction . . . 1—1
1.2 . . . . . . . . . . .
Unpacking . . . . 1—2
1.3 . . . . . . . . . . . . . . .
Receptacle panel installation 1—3
1.4 . . . . . . . . . . . . . . .
Lashing distribution cabinet
to UPS 1—3
1.5 . . . . . . . . . . . . . . . Wiring connections 1—4
1.5.1 Wiring from UPS
to distribution cabinet 1—5
1.5.2 Wiring from
distribution cabinet to load 1—5

Illustrations
figure description page number
1-1 . . . . . . . . . . . . . . . Location of bolts holding
distribution cabinet to
shipping base, and
EXL 1000 ramp for lowering 1—2
1-2 . . . . . . . . . . . . . . . Lashing distribution cabinet
to EXL 1000 UPS 1—4
1-3 . . . . . . . . . . . . . . . Typical ocnduit and wiring,
5 kVA model 1—6
1-4 . . . . . . . . . . . . . . . Typical conduit and wiring,
7.5 & 10 kVA models 1—7
1-5 . . . . . . . . . . . . . . . Terminal block connections
for various voltage outputs for
distribution cabinets
with transformer 1—7

Tables
table description page number
1-1 . . . . . . . . . . . . . . . Distribution cabinet
model numbers 1—1

86-153158-00 iii
EXL 1000 UPS Distribution Cabinet

This manual has been designed to provide you with all the information you need to install your
EXL 1000 UPS distribution cabinet.

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

This manual uses Noteboxes to convey important

information. Noteboxes come in four varieties:

WARNING CAUTION
A WA R N I N G n o t e b o x A CAUTION notebox
indicates information indicates information
provided to protect provided to protect
the user and service the user and service
personnel against safety personnel against
hazards and/or possible possible equipment
equipment damage. damage.

IMPORTANT NOTE
An IMPORTANT notebox A NOTE notebox
indicates information indicates information
provided as an operating provided as an operating
instruction or as an tip or an equipment
operating tip. feature.

Safety If you encounter a problem while following the instructions

in this manual, we recommend that you contact our
Recommendations Customer Support Services. On request, our customer
support personnel can carry out the complete installation of
your equipment.

iv 86-153158-00
 1.0 Scope This manual provides installation instructions for the EXL
1000 distribution cabinet. Please retain this manual for
future reference.

1.1 Introduction The EXL 1000 series UPSs are phase-to-phase uninterrupt-
ible power systems that typically use 208 or 240 VAC input.
The output of the EXL 1000 is configured in the distribution
cabinet per the customer’s needs. Installation of the distrib-
ution cabinet is integral with the EXL 1000 UPS, and with
any optional battery cabinets.

There are nine configurations of the distribution cabinet

available, depending on your UPS and the type of load
attached.

Table Distribution cabinet model numbers

1-1
5 kVA model 7 or 10 kVA models
description part number output rating part number output rating

transformer with no hard-wire output 72-153158-01 ≤ 10 kVA,

configured for 208 VAC input 46 Arms max.
transformer with hard-wire output 72-153158-08 ≤5 kVA 72-153158-02 ≤ 10 kVA,
configured for 208 VAC input 26 Arms max. 46 Arms max.
transformer with no hard-wire output 72-153158-10 ≤5 kVA 72-153158-03 ≤ 10 kVA,
configured for 240 VAC input 26 Arms max. 46 Arms max.
transformer with hard-wire output 72-153158-09 ≤5 kVA 72-153158-04 ≤ 10 kVA,
configured for 240 VAC input 26 Arms max. 46 Arms max.
no transformer, no hard-wire output 72-153158-05 ≤ 10 kVA,
208 or 240 VAC input* 46 Arms max.
no transformer, with hard-wire output 72-153158-06 ≤ 10 kVA,
208 or 240 VAC input* 46 Arms max.

*depending on output of UPS

86-153158-00 1—1
EXL 1000 UPS Distribution Cabinet

1.2 Unpacking The distribution cabinet is shipped attached to a wooden

base with a box strapped to the wood. Move the crated
distribution cabinet near the installation area of the UPS
using a pallet jack. Remove straps and lift the box from the
base, then remove the bolts from beneath the base that
fasten the cabinet to the base.

Items needed for the connection of the distribution cabinet to

the EXL 1000 UPS are contained within the distribution
cabinet housing. Remove top cover of distribution cab and
take out all loose items such as boxed, receptacle panels. Be
sure there are no loose parts remaining inside the cabinet
before installation.

Figure Location of bolts holding distribution cabinet

1-1 to shipping base, and EXL 1000 ramp for lowering

Ramp supplied
with EXL 1000 UPS

1—2 86-153158-00
 Installation manual

A ramp is included with the EXL 1000 UPS to facilitate

bringing that unit from it’s shipping base to floor level. Use
this same ramp to move the distribution cabinet off its
shipping base.

CAUTION
Do not let the distribution cabinet fall off the base or roll unattended.

1.3 Receptacle panel The 5 kVA distribution cabinet has 4 slots available to
accommodate up to 4 receptacle panels. The 7.5 and
installation 10kVA distrubition cabinets have 7 slots available to
accommodate up to 7 receptacle panels. The customer can
choose any one of eleven different receptacle panels to
mount into any of these slots. The receptacle panels must
be user-installed on the back of the distribution cabinet. A
separate guide for receptacle panel installation is included
with the distribution cabinet.

1.4 Lashing distribution Both the UPS and the distribution cabinet are on casters;
the two cabinets can be lashed together, wiring attached,
cabinet to UPS and then pushed into final position. A symmetrical distribu-
tion lash bracket is provided allowing the distribution
cabinet to lash on either side of the EXL1000 UPS.

The distribution lash bracket (figure 1-2) should be mounted

on the bottom edge of the left side of the distribution cabinet,
as viewed from the front. There are two pem nuts facing
downward on the bottom of the cabinet. These pem nuts hold
1/4 20 x 3/8” self-locking screws that attach the lash bracket
to the distribution cabinet. Position the lash bracket and hand
thread the bolts into the bottom of the cabinet, then tighten
with a wrench. The lash bracket can also be mounted to the
right side of the distribution cabinet if the cabinet will be
installed to the left of the EXL 1000 UPS.

The notch at the back of the lash bracket fits around the
leveling leg of the EXL 1000 UPS. At an angle, push the
distribution cabinet back until the leveling leg is in the notch,
then push the distribution cabinet flush with the UPS. Insert
the M8 x 16 mm bolt through the front notch in the lash
bracket and into the pem nut in the UPS. Some adjustment
in the gap between the cabinets may be needed to begin the
bolt. Tighten with a wrench.

86-153158-00 1—3
EXL 1000 UPS Distribution Cabinet

Figure Lashing distribution cabinet to EXL 1000 UPS

1-2
EXL 1000 UPS
Distribution Cabinet

Optional right
side mounting

1.5 Wiring connections The distribution cabinet installation to the EXL 1000 UPS
should be performed by a trained electrician. If the UPS is
already connected to utility, power down the UPS by
shutting off the upstream circuit breaker and shutting off the
battery circuit breaker on the UPS. Wait at least 5 minutes
before installing distribution cabinet to UPS.

There are landings on both the UPS and the distribution

cabinet for 3/4 inch flexible conduit, which should be used to
house cable wiring. All wire gauges and installation should
be performed as per local and NEC codes. EXL 1000 UPSs
output 208 or 240 phase to phase. There is no neutral. The
three terminal blocks closest to the right of the 7.5 and 10
kVA UPS and the top three terminal blocks on the back of the
5 kVA UPS are for wiring the UPS to the distribution cabinet.
See Fig 1-3 and 1-4 for wiring connections.

1—4 86-153158-00
 Installation manual

1.5.1 Wiring from UPS to Connect 3/4 inch flexible conduit of appropriate length and
slack, as per local and NEC code, to the conduit landings of
distribution cabinet the EXL 1000 UPS and the distribution cabinet. Using the
rightmost hole on the UPS landing and the leftmost landing
on the distribution cabinet will allow for the most direct path
for wires. Secure the conduit to the landings with flexible
metal conduit fittings.

Run three cables (6 AWG 75°C minimum on 7.5 and 10 kVA

models, 10 AWG on 5kVA models) through the conduit. Red,
black and green cable should be used to properly identify the
ground from the “hot” wires. Run the ground (green) cable
from the ground terminal (labeled with the symbol) of the
UPS AC Output terminal block to the input ground of the
distribution cabinet. This terminal is marked with the
symbol and is colored green and yellow.

The black cable should be connected from the L1 terminal of

the AC output of the UPS to L1 of the distribution cabinet.

The red cable should run between the L2 terminal of the UPS
to the L2 terminal of the distribution cabinet.

NOTE
Terminal blocks for connection of the EXL 1000 UPS to the distribution
cabinet are in a different order on each of these cabinets.

1.5.2 Wiring from If the distribution cabinet has 6 or 9 terminals on the

terminal block, cable can be used to hard wire a load to the
distribution cabinet distribution cabinet. Use figure 1-4 to determine which
terminals to use for various voltage outputs of a 9 terminal
to load block. A 6 terminal block indicates that the distribution
cabinet has no transformer. This 6 terminal configuration
supplies the load only at the output voltage of the EXL 1000
UPS. If the distribution cabinet has 3 terminals on the
terminal block, the terminals are for connection of the UPS
to the distribution cabinet; power distribution is through the
user-installed receptacle panels only.

Cable gauge for wiring a load to the distribution cabinet for

the 5kVA model is 10AWG minimum and is 6 AWG 75°C
minimum for the 7.5 and 10 kVA models. Factors to consider
in deciding wire gauge include the current draw of the load
and the length of wire used; given cable of equal diameter,

86-153158-00 1—5
EXL 1000 UPS Distribution Cabinet

longer cables will have more resistance than shorter ones. In

all cases, observe local and NEC codes when deciding on
the gauge of wire to use in your installation.

Install flexible conduit between the load and the distribution

cabinet. 3/4 inch conduit should be used, and should be
attached to the conduit landing using flexible metal conduit
fittings. A ground (green), and two “hot” wires (black and red)
can then be run through the conduit. Properly ground the
load using the green wire, and attach this wire to the
rightmost terminal (as viewed from the back) of the distribu-
tion cabinet terminal block. This terminal is colored green
and yellow and is labeled with the symbol.

Figure Ty p i c a l c o n d u i t a n d w i r i n g , 5 k VA m o d e l
1-3 UPS
Cabinet

Distribution Red
Output

Cabinet
L1 L2

Black
INPUT OUTPUT G
r e en
120
104

104
120

L2 L1 N

G
Green

Bl
Red

ck

Bl a c

reen

ac
B la

k
k

Red
L1 L2
Input

Black From Utility

G
r e en

To Load

1—6 86-153158-00
 Installation manual

Figure Ty p i c a l c o n d u i t a n d w i r i n g , 7 . 5 & 1 0 k VA m o d e l s
1-4 Distribution UPS
Cabinet Cabinet
INPUT OUTPUT
L1 L2 L1 L2
120
104

104
120
L2 L1 N

Gre n
G

B la ck
Bla
G re e n
Green

Red

Red
Bl
Bl a c
ck
Red

ac reen

e
ck
Bl a

k
k

To Load From Utility

Figure Te r m i n a l b l o c k c o n n e c t i o n s f o r v a r i o u s v o l t a g e o u t p u t s
1-5 for distribution cabinets with transformer

104 VAC

104 VAC

120 VAC 120 VAC

120

104

104

120

N
OUTPUT

208 VAC

240 VAC

Phase A Phase B

86-153158-00 1—7
EXL 1000 UPS Distribution Cabinet

A nine terminal block indicates the presence of a transformer

in the distribution cabinet. The transformer provides a
neutral, 120 VAC phase A, 120 VAC phase B (these two
phases are used for 240 VAC), 104 VAC phase A and 104
VAC phase B (these two phases are used for 208 VAC).
While some of the possible voltages this provides will
typically not be used, this flexibility is available. See figure
1-5 for more complete information on which terminals of the
distribution cabinet to connect to the load for particular
available voltages.

The ground (green) wire should already be connected as per

the above instructions. Connect the red and black wires to
the load, and to the appropriate output terminals of the distri-
bution cabinet.

A 6 terminal block indicates no transformer within the distrib-

ution cabinet. There will be only two “hot” terminals
remaining to be connected. They are above the two “120”
labels. These two terminals provide 208 VAC or 240 VAC
phase-to-phase, depending on the output of the UPS. If the
UPS is outputting 208 VAC, these terminals will provide 208
VAC phase-to-phase even though they are positioned near
the “120” labels. If the UPS is outputting 240 VAC, these
terminals will provide 240 VAC phase-to-phase.

NOTE
On distribution cabinets with six terminals on the terminal block, the
output VAC is always the same as the EXL 1000 UPS output. While the
output terminals of the distribution cabinet are near the "120" labels,
the output will be 208 VAC, not 240 VAC, if that is the voltage supplied
by the UPS.

Connect the red and black wires to the terminal blocks

labeled “120” on the distribution cabinet, then connect these
wires to the load.

When all connections have been made, the UPS, distribution

cabinet and any additional battery cabinets can be moved
into their final position.

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