GE 225, 300 User Manual

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SGS_225-300_UPS_GE_01

SG Series

225 and 300 kVA

INSTALLATION GUIDE

UNINTERRUPTIBLE POWER SUPPLY

Digital Energy TM

SG Series

225 and 300 kVA

Series 0

General Electric Company

2500 Discovery Blvd.

Rockwall, TX 75032

Telephone: (972)-290-7400

Fax: (972)-290-7500

SG Series UPS Technology for the digital world

Model:

Date of issue: 11/05/2003

File name: OPM_SGS_ISG_M22_M30_0US_V011

Revision: 1.1

Author:

Identification No.:

Up-dating

Revision Concern Date

1.1

SG Series

“3-wire kit” for RPA Parallel System 11/05/2003

225 and 300 kVA / Series 0

The information contained in this publication is intended solely for the purposes indicated.

The present publication and any other documentation supplied with the UPS system is not to be reproduced, either in part or in its entirety, without the prior written consent of GE Industrial Systems.

The illustrations and plans describing the equipment are intended as general reference only and are not necessarily complete in every detail.

The content of this publication may be subject to modification without prior notice.

OPM_SGS_ISG_M22_M30_0US_V011.doc 2/38 Installation Guide

SG Series

225 & 300 kVA

Dear Customer,

We thank you for selecting our products and are pleased to count you amongst our ver valued customers at GE.

We trust that the use of the SG Serie Uninterruptible Power Supply system, developed and produced to the highes standards of quality, will give you complete satisfaction.

Please carefully read the Installation Guide. It contains all the necessary information about the installation of the UPS.

Thank you for choosing

START UP AND COMMISSIONING

A GE Global Services Field Engineer must perform start-up and commissioning of the UPS. Please Contact G.E. Global Services at least two weeks prior to schedule start-up and commissioning at 1-800-637-1738, or by E-mail at gedeservices@indsys.ge.com

Manufactured by: Distributed in the USA by: Your service contact:

GE Industrial Systems

General Electric Company

6595 Riazzino (Locarno) Switzerland

OPM_SGS_ISG_M22_M30_0US_V011.doc 3/38 Installation Guide

SG Series

225 & 300 kVA

Preface

Congratulations on your choice of a It will help eliminate load disturbances due to unexpected power problem.

This manual describes how to prepare the installation site, and it provides weight and dimensions and procedures for moving, installing and connecting the UPS.

Please refer to the Operating Manual, which describes the function of the UPS module, the purpose and location of the switches, the meaning of the system events related to the front panel indication, and provides procedures for starting and stopping the equipment.

While every care has been taken to ensure the completeness and accuracy of this manual, GE Industrial Systems assumes no responsibility or liability for any losses or damages resulting from the use of the information contained in this document.

WARNING!

SG Series 225 and 300 kVA, is a product that needs to be installed by a licensed and knowledgeable contractor.

SG Series

Uninterruptible Power Supply (UPS).

We recommend that this manual be kept next to the UPS for future references. If any problems are encountered with the procedures contained in this manual, please contact your Service Center before you proceed.

This document shall not be copied or reproduced without the permission of GE Industrial Systems.

Some of the information contained in this manual may be changed without notice to reflect technical improvements.

Safety instructions

Read the safety instructions contained on the following pages carefully before the installation of the UPS, options and battery system.

Pay attention to the rectangular boxes included in the text:

They contain important information and warning concerning electrical connections and personnel safety.

Parallel version secured with RPA

When included in the text, this symbol refers to operation needed only for parallel system.

OPM_SGS_ISG_M22_M30_0US_V011.doc 4/38 Installation Guide

SG Series

225 & 300 kVA

Table of contents Page

1 IMPORTANT SAFETY INSTRUCTIONS .................................................................6

2 LAYOUT ...................................................................................................................9

2.1 LAYOUT

SG SERIES

3 INSTALLATION......................................................................................................10

3.1 TRANSPORT ................................................................................................................10

3.1.1 Dimensions and weight .................................................................................................10

3.2 DELIVERY.....................................................................................................................11

3.3 STORAGE.....................................................................................................................11

3.3.1 Storage of the UPS .......................................................................................................11

3.3.2 Storage of Battery .........................................................................................................11

3.4

3.4.1 UPS location..................................................................................................................12

3.4.2 Battery location..............................................................................................................14

3.5 VENTILATION AND COOLING.....................................................................................15

3.6 UNPACKING .................................................................................................................16

3.7 ELECTRICAL WIRING ..................................................................................................17

3.7.1 Utility input connection ..................................................................................................17

3.7.2 Input/output over current protection and wire sizing......................................................18

3.7.3 Battery over current protection and wire sizing .............................................................19

3.8

3.8.1 Power connections ........................................................................................................21

3.8.2 Power connection with common input utility..................................................................23

3.8.3 Power connection separate input utility.........................................................................25

3.8.4 Battery connection.........................................................................................................27

3.8.5 Setup for

3.9 POWER WIRING OF PARALLEL UNITS......................................................................29

3.10 PARALLEL CONTROL BUS CONNECTION ................................................................30

3.11

PLACE OF INSTALLATION ..........................................................................................12

WIRING CONNECTION ................................................................................................21

SG Series

CONTROL BUS CABLE LOCATION ............................................................................32

225 AND 300 KVA ............................................................................9

when functioning as frequency converter.........................................28

4 CUSTOMER INTERFACE......................................................................................34

4.1

4.1.1 Serial Port J3.................................................................................................................35

4.1.2 Output potential free contacts .......................................................................................35

4.1.3 Programmable input free contacts ................................................................................36

4.1.4 Gen Set Signaling (GEN ON)........................................................................................36

4.1.5 AUX external Maintenance Bypass...............................................................................36

4.1.6 Auxiliary Power Supply (APS) 24 VDC / 1A ..................................................................36

4.1.7 EPO (Emergency Power Off) Input contact...................................................................37

CUSTOMER INTERFACE ............................................................................................34

5 NOTES....................................................................................................................38

5.1

OPM_SGS_ISG_M22_M30_0US_V011.doc 5/38 Installation Guide

NOTES FORM ..............................................................................................................38

SG Series

225 & 300 kVA

1 IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

This manual contains important instructions for models SG Series 225 and 300 kVA that should be followed during installation and maintenance of the UPS and battery.

- Move the UPS in an upright position in its original package to the final destination room. To lift the cabinets, use a forklift or lifting belts with spreader bars.

- Check for sufficient floor and elevator loading capacity.

- Check the integrity of the UPS equipment carefully. If you notice visible damage, do not install or start the UPS. Contact the nearest Service Center immediately.

- WARNING! RISK OF ELECTRICAL SHOCK: Do not remove covers; there are no user serviceable parts inside.

- All maintenance and service work should be performed by qualified service personnel. The UPS contains its own energy source (battery).

- The field-wiring terminals may be electrically live, even when the UPS is disconnected from the utility.

- Dangerous voltages may be present during battery operation. The battery must be disconnected during maintenance or service work.

- This UPS contains potentially hazardous voltages.

- Be aware that the inverter can restart automatically after the utility voltage is restored.

INSTALLATION

- This UPS must be installed and connected only by trained personnel.

- Verify accurately during Commissioning and Maintenance of the UPS, for the following: Damaged components, squeezed wires and cables, or not correctly inserted plugs.

- After removing the sidewalls of the UPS, make sure that all earth connections when reassembling, are correctly reattached

- This UPS is intended for use in a controlled indoor environment free of conductive contaminants and protected against animals intrusion.

- HIGH GROUND LEAKAGE CURRENT: Ground connection is essential before connecting to AC input!

- Switching OFF the unit does not isolate the UPS from the utility.

- Do not install the UPS in an excessively humid environment or near water.

- Avoid spilling liquids on or dropping any foreign object into the UPS.

- The unit must be placed in a sufficiently ventilated area; the ambient temperature should not exceed 104°F (40°C).

- Optimal battery life is obtained if the ambient temperature does not exceed 77°F (25°C).

- It is important that air can move freely around and through the unit. Do not block the air vents.

- Avoid locations in direct sunlight or near heat sources.

- Store the UPS in a dry location; storage temperature must be within -13°F (-25°C) to 131°F (55°C).

- If the unit is stored for a period exceeding 3 months, the battery must be recharged periodically (time depending on storage temperature).

GENERAL

STORAGE

BATTERY

- The battery-voltage is dangerous for person’s safety.

When replacing the battery, use the same number, voltage (V) and capacity (Ah).

Proper disposal or recycling of the battery is required. Refer to your local codes for disposal requirements.

- Never dispose of battery in a fire: They may explode.

- Do not open or mutilate battery: Their contents (electrolyte) may be extremely toxic. If exposed to electrolyte, wash immediately with plenty of water.

- Avoid charging in a sealed container.

- Never short circuit battery. When working with battery, remove watches, rings or other metal objects, and only use insulated tools.

OPM_SGS_ISG_M22_M30_0US_V011.doc 6/38 Installation Guide

SG Series

225 & 300 kVA

Safety instructions when working with battery

EXTERNAL BATTERY MUST BE INSTALLED AND CONNECTED TO THE UPS BY QUALIFIED SERVICE PERSONNEL.

INSTALLATION PERSONNEL MUST READ THIS ENTIRE SECTION AND REFER TO THE BATTERY MANUFACTURERS INSTALLATION MANUAL BEFORE HANDLING THE UPS AND BATTERY.

UPS intended to be used with a remote battery supply – All models: “Please refer to the battery manufacturer’s installation manual for battery installation and maintenance instructions”.

DANGER!

Full voltage and current are always present at the Battery Terminals. The Battery used in this system can provide dangerous voltages, extremely high currents and a risk of electric shock. They may cause severe injury if the terminals are shorted together or to ground. You must be extremely careful to avoid electric shock and burns caused by contacting Battery Terminals or shorting terminals during battery installation. Do not touch un insulated Battery Terminals.

A qualified service person that is familiar with Battery systems and required precautions must install and service the Battery. The installation must conform to national and local codes. Keep unauthorized personnel away from Battery.

The qualified service person must take these precautions:

1 Wear protective clothing, such as rubber gloves and boots and protective eye wear.

Batteries contain caustic acids and toxic materials and can rupture or leak if mistreated. Remove rings and metal wristwatches or other metal objects and jewelry. Do not carry metal objects in your pockets where the objects can fall into the Battery Cabinet.

2 Tools must have insulated handles and must be insulated so that they will not short Battery

Terminals. Do not allow a tool to short between individual or separate Battery Terminals or to the cabinet or rack. Do not lay tools or metal parts on top of the Battery, and do not lay them where they could fall onto the Battery or into the cabinet.

3 Install the Battery as shown on the drawing provided with the Battery.

When connecting cables, never allow a cable to short across a Battery’s Terminals, the string of batteries, or to the cabinet or rack.

4 Align the cables on the Battery Terminals so that the cable lug will not contact any part of the

cabinet or rack, even if the Battery is moved. Keep the cable away from any sharp metal edges.

5 Install the Battery Cables so the UPS or Battery Cabinet Doors cannot pinch them.

6 Do not connect the Battery Terminal to Ground.

If any Battery Terminal is inadvertently grounded, remove the source of the ground. Contacting any part of a grounded Battery can cause a risk of electric shock.

7 To reduce the risk of fire or electric shock, install the Battery in a temperature and humidity

controlled indoor area, free of contaminants.

8 Battery System Chassis Ground (earth) must be connected to the UPS chassis ground (earth).

If you use conduit, this ground conductor must be routed in the same conduit as the Battery Conductors.

9 Where conductors may be exposed to physical damage, protect the conductors in accordance with

all applicable codes.

10 If you are replacing Battery or repairing Battery Connections, shut OFF the UPS and remove the

Battery Fuses or open the Battery System disconnect.

OPM_SGS_ISG_M22_M30_0US_V011.doc 7/38 Installation Guide

SG Series

225 & 300 kVA

Safety symbols and warnings

Safety warnings The text of this manual contains some warnings to avoid risk to the persons and to avoid damages

to the UPS system and the supplied critical loads.

The non-observance of the warnings reminding hazardous situations could result in human injury and equipment damages.

Please pay attention to the meaning of the following warnings and symbols.

Throughout this manual the following symbols are defined:

WARNING, if instruction is not followed injury or serious equipment damage may occur!

CAUTION, internal parts have dangerous voltage present. Risk of electric shock!

PE (Earth) – GND (Ground) PROTECTIVE GROUNDING TERMINAL: A terminal which must be connected to earth ground prior to making any other connection to the equipment.

A terminal to which or from which an alternating (sine wave) current or voltage may be applied or supplied.

A terminal to which or from which a direct current or voltage may be applied or supplied.

This symbol indicated the word “phase”.

This symbol indicates the principal on/off switch in the on position.

This symbol indicates the principal on/off switch in the off position.

OPM_SGS_ISG_M22_M30_0US_V011.doc 8/38 Installation Guide

SG Series

225 & 300 kVA

2 LAYOUT

2.1 LAYOUT SG Series 225 AND 300 KVA

SGS_225-300_UPS_GE_02

SGS_225-300_UPS_03

Fig. 2.1-1 SG Series general view

SGS_225-300_UPS_04

XA CR PAXB

Fig. 2.1-3 SG Series general view with optional 5 and removed protection panels

harmonic filter

Fig. 2.1-2

SG Series

general view with open doors

1 Opening for top cable entry

2 Opening for bottom cable

entry

3 Compression lugs for Utility

input and Load output

4 Compression lugs for

external Battery connection

CR Connectivity Rack

PA 24VDC / 1A Auxiliary Power

Supply

XA Terminals for 24VDC

uxiliary Power Supply

connection

XB Terminals for EPO

connection

OPM_SGS_ISG_M22_M30_0US_V011.doc 9/38 Installation Guide

SG Series

225 & 300 kVA

3.1 TRANSPORT

3 INSTALLATION

Forklift

Crane

Fig. 3.1-1 UPS cabinets moving

3.1.1 Dimensions and weight

Transport UPS only in upright position!

The UPS is packaged on a pallet suitable for handling with a forklift.

Pay attention to the center of gravity.

The UPS must be moved in upright position. Do not tilt cabinets more than +/- 10° during handling.

Move the UPS in it’s original package to the final destination site.

Do not stack other packages on top:

This could damage the UPS.

If the UPS must be lifted by crane, use suitable lifting straps and spreader bars. Note of the center of gravity marked on the package.

Check for sufficient floor and elevator loading capacity.

Dimensions

SGS_225-300_UPS dimensions_GE_0 1US

SG Series

225 and 300 kVA

(W x D x H)

64.96 x 31.50 x 70.90 inches

1,650 x 800 x 1,800 mm

Fig. 3.1.1-1 UPS cabinet dimensions

Weight

UPS rating

SG Series

Weight

lbs / kg

225 and 300 kVA

Floor loading

lbs/sq.ft - kg/m

SG Series 225 kVA 2,756 / 1,250 194 / 947 SG Series 300 kVA 3,087 / 1,400 218 / 1,061

P.S.: Weights including the 5th harmonic filter.

OPM_SGS_ISG_M22_M30_0US_V011.doc 10/38 Installation Guide

SG Series

225 & 300 kVA

3.2 DELIVERY

When delivered, inspect the package integrity and the physical conditions of the cabinets

In case of any damage sustained during transport, immediately inform the carrier and contact your local

A detailed report of the damage is necessary for any insurance claim.

3.3 STORAGE

3.3.1 Storage of the UPS

carefully.

Service Center

A DAMAGED UPS MUST NEVER BE INSTALLED OR CONNECTED TO UTILITY OR BATTERY!

The UPS is carefully packed for transport and storage so that it is in perfect condition when installed. Never leave a UPS outside the building and don’t store other packages on the top of the UPS.

It is advisable to store the UPS in its original package in a dry, dust-free room, away from chemical substances, and with a temperature range not exceeding -13°F (-25°C) to 131°F (55°C).

Some important functions of the UPS, such as the customized functions, are defined by parameters stored in a RAM memory. A small backup Battery located on the Control Unit board supplies the RAM. If the storage time of the UPS exceeds authorized Service Center before putting the UPS into operation.

3.3.2 Storage of Battery

When the delivery includes a maintenance free Battery, keep in mind that they are subject to self-discharge and therefore you must recharge the Battery.

The storage time without Battery recharge depends on the temperature of the storage site.

The optimal temperature for Battery storage is 68°F (20°C) to 77°F (25°C).

Recharge stored maintenance free Battery every:

1 year

, these functions

should be verified

by an

6 months when the storage temperature is 68°F (20°C)

3 months when the storage temperature is 86°F (30°C)

2 months when the storage temperature is 95°F (35°C)

OPM_SGS_ISG_M22_M30_0US_V011.doc 11/38 Installation Guide

SG Series

225 & 300 kVA

3.4 PLACE OF INSTALLATION

3.4.1 UPS location

A qualified electrical contractor must carry out the installation and cabling of the UPS. If optional cabinets and accessories are included with the UPS, please refer to those accompanying manuals for installation and operating instructions.

It is important to have a clean, dust-free environment provided with proper ventilation and airconditioning to keep the ambient temperature within the specified operating range.

The recommended air inlet temperature is from 68°F (20°C) to 77°F (25°C) (max. 95°F / 35°C). Refer to section 3.5.

Check for sufficient floor load capacity before installing the UPS and the Battery. Refer to section 3.1.1.

For Battery installation follow the local codes and the recommendation of the battery supplier.

Temperature is very important for valve-regulated batteries (maintenance free). Operation at temperatures higher than 77°F (25°C) will reduce battery life.

SG Series

The Although some RFI filtering is inherent to the UPS there is no guarantee that the UPS will not influence sensitive devices such as cameras and monitors that are positioned close by. If interference is expected, the UPS should be moved away from the sensitive equipment.

A single-phase power outlet (120 VAC) should be provided near the UPS for connection of power tools, test equipment or connectivity devices. This outlet must be grounded.

Positioning of the UPS

Fig. 3.4.1-1 SG Series 225 and 300 kVA clearances

UPS can radiate radio frequency energy.

SG Series

Min.

16" / 400mm

SGS_225-300_UPS dis position_GE_01

The rear panel of the UPS may be mounted flush to a wall or other structure.

Clearance around the front of the unit should be sufficient to enable free passage of personnel with the doors fully open, and to allow sufficient airflow to the door vents.

Check section 110-26(A) of the NEC code for specific requirements.

Recommended minimum clearance between ceiling and top of the UPS should be 16”

(400 mm

) for proper cooling air exhaust.

In case of additional cabinets (external Batteries or input, output transformers) these can be placed on either side of the cabinet.

OPM_SGS_ISG_M22_M30_0US_V011.doc 12/38 Installation Guide

SG Series

225 & 300 kVA

Openings for input and output cable connections

Battery

Utility input Output Load

SG Series openings are provided on the top and

Fig. 3.4.1-2 Opening on top of the cabinet for input and output cables

the bottom of the UPS for the connection of input and output cables.

Pay attention to the

Utility input Output Load

position of these openings, when choosing the placement of the UPS. These openings are

covered with a protective plate.

Fig. 3.4.1-3 Opening on the bottom of the cabinet for input and output cables

Fixing of the UPS cabinet on the floor

The UPS cabinet is free standing and normally does not require to be bolted to the floor. The UPS cabinet can be fixed however to the floor by bolting it with the supporting blocks to the floor.

See Fig. 3.4.1-4.

1.378" 1.378" 35mm

Ø 0.47305" Ø 12mm

SGS_225-300_UPS view bottom_02US

Fig. 3.4.1-4 Fixing of the UPS cabinet on the floor

62.205"

1580mm

Front side

35mm

2.363"

60mm

28.071"

713mm

680mm

26.772"

2.363"

60mm

OPM_SGS_ISG_M22_M30_0US_V011.doc 13/38 Installation Guide

SG Series

225 & 300 kVA

In case of parallel system, try to place the UPS modules in sequence of their numbers (marked on the packing).

If the units are positioned “ by side”, the side panels must be mounted on all units.

3.4.2 Battery location

Batteries require a well-ventilated room with controlled temperature to obtain reliable operation.

The Battery can be install immediately adjacent to the UPS (left or right side) or remotely from the UPS. If the Battery is installed remotely from the UPS, a wall mounted DC disconnect device must be installed within line-of-site to both the UPS and the Battery.

The optimal room temperature for the Battery is 68°F (20°C) to 77°F (25°C).

The life of valve-regulated batteries will be reduced by 50% for each additional 18°F (10°C) that the Battery ambient temperature is above 77°F (25°C).

The Battery System associated with larger UPS is usually either rack mounted or installed in multiple Battery Cabinets.

Installation and assembly must be made according to the local standards and Battery System manufacturer‘s recommendations.

The Battery Circuit Breaker or Battery Fuse Box must be mounted as near as possible to the

Battery.

side

SGS_225-300_RPA disposition_GE_01US

UPS 1

Fig. 3.4.1-5 RPA system disposition

3-4-5-6-7-8

UPS 2

UPS

Battery installation and connection must be performed by qualified personnel only.

Read all safety instructions before proceeding with the installation.

OPM_SGS_ISG_M22_M30_0US_V011.doc 14/38 Installation Guide

SG Series

225 & 300 kVA

3.5 VENTILATION AND COOLING

Fig. 3.5-1 Installation on plain floor Fig. 3.5-2 Installation on raised floor

The heat produced by the UPS is transferred to the environment by its ventilation.

Air inlets for UPS ventilation are located on the front of the UPS, while air outlets are on top of the cabinet.

A suitable ventilation or cooling system must be installed to extract the heat from the UPS room.

Do not put anything on the top of the cabinet.

Air filtration systems could be required when the UPS operates in a dirty environment. Contact your

In order to prevent overheating of the UPS, the available air intake flow rate must exceed the total air exhaust flow rate requirement of the UPS system.

The below table indicates the heat dissipation at full Load at PF = 0.8 lag. and charged

Battery

UPS rating

SG Series 225 kVA

SG Series 300 kVA

Dealer

, up to 3,280 ft (1,000 m) altitude, for cooling air 77°F (25°C) to 86°F (30°C).

or the nearest

BTU / hr kW CFM m3 / h

50,512 14.80 2,541 4,317

64,164 18.80 3,228 5,484

Service Center

Losses Cooling air flow

for appropriate solutions.

OPM_SGS_ISG_M22_M30_0US_V011.doc 15/38 Installation Guide

SG Series

225 & 300 kVA

3.6 UNPACKING

The UPS and Battery Cabinets may be shipped packaged in carton boxes or in wooden crates (if requested).

Move the cabinets as close as possible to the final location before removing from the pallet.

If delivered in a wooden crate, remove the cabinet from the pallet with care, because of the heavy weight of the equipment.

Take care not to damage the UPS when moving by forklift.

For parallel systems, the delivery also includes the bus control cables for inter-connecting the UPS modules.

Packing material recycling

GE Industrial Systems, in compliance with environment protection, uses only environmentally friendly material. UPS packing materials must be recycled in compliance with all applicable regulations.

OPM_SGS_ISG_M22_M30_0US_V011.doc 16/38 Installation Guide

SG Series

225 & 300 kVA

3.7 ELECTRICAL WIRING

UPS installation and connection must be performed by qualified service personnel only. It is the responsibility of the installation technician to ensure that all local and national electric codes are adhered to.

3.7.1 Utility input connection

Ensure that the AC and DC external isolators are OFF and locked out to prevent their inadvertent operation. Do not apply power to the equipment prior to the commissioning by a qualified service engineer. Before any other input connection, connect and check the grounding wire.

The UPS has available input terminations for the Rectifier and Bypass. The unit may be powered from a common input source or separate input sources if desired.

Separate input Rectifier & Bypass (recommended)

The Bypass and Rectifier Inputs are to be powered from different Utility supplies (F1 and F2 inputs).

In this case, when the Rectifier Input Fuses are opened, the Bypass and the Manual Bypass are supplied by the other source.

In this case, remove the interconnection links BR1, BR2 and BR3 on the input terminals or bus bars. See Fig. 3.8.3-2.

Common input Rectifier & Bypass

The

same power source

F3). Bear in mind that when the Utility Fuses are opened there is a supply failure to the Rectifier

as well as to the Bypass and Manual Bypass.

In this case, the interconnection links BR1, BR2 and BR3 on the input terminals or bus bars must remain connected. See Fig. 3.8.3-2.

Separate input Rectifier & Bypass (recommended) Common input Rectifier & Bypass

Fig. 3.7.1-1 Separate input Rectifier & Bypass Fig. 3.7.1-2 Common input Rectifier & Bypass

1 = Rectifier 2 = Inverter

is to be used for both Bypass Supply and Rectifier Input (input

3 = Automatic Bypass 4 = Manual Bypass

6 = Load 5 = Utility input

7 = Battery

OPM_SGS_ISG_M22_M30_0US_V011.doc 17/38 Installation Guide

SG Series

225 & 300 kVA

3.7.2 Input/output over current protection and wire sizing

The cabling of the UPS system has to be sized according to the UPS power rating. Sizing of circuit breakers, fuses and cables for Input Utility, Output Load and Battery must meet the requirements of local and national electrical codes.

Before connecting the UPS, verify that the Utility Voltage and Frequency, the Output Load Voltage and Frequency and Battery Data (cells number, floating voltage, autonomy) are according to the required specifications.

Output Load configuration may be such that one phase may carry a Load current at 100% of that phases maximum current rating while the other two phases run at 0% or any combination in between. Ensure that the Load does not consist of any equipment that may require high starting currents such as electric motors, laser printers, etc. This may cause the UPS to occasionally go into Bypass due to overload conditions

To choose the correct input fuses or circuit breaker, consider the available short-circuit

current

Choose the correct fuse or breaker using current data shown in the chart and the appropriate NEC code.

The ratings indicated in the following chart do not consider any line voltage drop.

In case of optional input transformer the input protective devices should be sized to allow the transformer magnetization inrush current.

Caution when using four-pole circuit breakers as protection. A potential problem exists for situations with Non-linear Loads:

The neutral current could be greater than the phase currents.

The three-phase Utility power supply must be symmetrical with respect to ground, due to the existence of voltage surge protection devices inside the UPS.

To ensure coordination when the UPS is configured for separate Bypass and Rectifier Inputs, special care must be taken in choosing the fuse or circuit breaker ratings installed in the output distribution circuits. Protective devices on the output of the UPS should be coordinated with the Bypass Input circuit protection. Due to the relatively low short circuit capability of the UPS inverter, a short circuit in the Load will cause an immediate transfer to Bypass.

The largest fuse or circuit breaker in the output distribution should be rated at no more than 60% of the rating of the protective device supplying the Bypass line.

If circuit selectivity is required while the Load is fed from the inverter (Bypass Utility not available), the largest fuse or circuit breaker should be rated at no more than 20% of the UPS output current rating.

of the system up-stream.

If you use

ELCB breaker (Earth Limiting Circuit Breaker)

to protect the input connections, consider the high leakage current generated by the noise suppression capacitors.

If these ELCB breakers are strictly necessary, we suggest using the largest type suitable for non-linear current and for delayed operations.

OPM_SGS_ISG_M22_M30_0US_V011.doc 18/38 Installation Guide

SG Series

225 & 300 kVA

3.7.3 Battery over current protection and wire sizing

• Please read the safety precautions at the front of this guide carefully, and thoroughly

review the Battery manufacturers installation and maintenance manual before connecting the batteries to the UPS.

• If the UPS system has been purchased with an accompanying Battery Cabinet, that

cabinet should have an integral If the UPS has been purchased without a Battery Cabinet or remote rack mounted batteries are to be used then DC over current protection must be provided by others.

• Choose an appropriate DC fuse or circuit breaker using the current data in the chart

below.

• Minimum Battery Cable requirement is based on the current data below.

The AC values below are current ratings per phase.

These maximum and nominal ratings should be considered when choosing the

appropriate AC over current protection device.

NEC (National Electric Code) Section 210-20 a rules must be applied.

DC current rating is the maximum battery discharge current which the UPS allows.

AC Input

SG Series 225 kVA SG Series 300 kVA

Size of Branch Circuit Over current Protection - All Models: - "CAUTION - To reduce

the risk of fire, only connect UPS to a circuit provided with (See below) maximum

amperes branch circuit over current protection in accordance

with the NEC (National Electric Code), NSI / NFPA 70

SG Series 225 kVA SG Series 300 kVA 600 A 500 A 600 A 700 A

Maximum cable diameter that compression lugs can accept. Refer to torque specifications table for torque requirements.

Rectifier Input Bypass Input DC Input AC Output GND

SG Series 225 kVA SG Series 300 kVA

Rectifier

Nom. Max.

301 A 360 A 271 A 301 A 360 A 401 A 401 A 480 A 361 A 401 A 480 A 535 A

AC Input Rectifier

F1 F2 F3 F4

450 A

WIRING Wire sizing according to NEC Section 210-20 (a) Table 310-16 Use 75°C (167°C) copper wire

Wiring requirements: AC INPUT RECTIFIER: 3-Phase, 3 wire plus Ground AC INPUT BYPASS: 3-Phase, 4 wire plus Ground AC OUTPUT: DC INPUT: 2 wire (positive and negative) plus Ground

2 x 500 kcmil 2 x 500 kcmil 2 x 750 kcmil 2 x 500 kcmil 350 kcmil 2 x 750 kcmil 2 x 500 kcmil 2 x 750 kcmil 2 x 500 kcmil 350 kcmil

Battery Circuit Breaker

(See Fig. 3.7.1-1 and 3.7.1.2)

AC Input

Bypass

F1 F3

350 A 450 A 600 A

AC Input

Bypass

3-Phase, 4 wire plus Ground

AC Input DC Input

Nom. Max.

AC Input DC Input

OPM_SGS_ISG_M22_M30_0US_V011.doc 19/38 Installation Guide

SG Series

225 & 300 kVA

NEC SECTION 210-20 (a)

Table 310-16. Allowable Ampacities of Insulated Conductors Rated O Through 2000 Volts, 60°C Trough 90°C (140°F Trough 194°F) Not More than Three Current-Carrying Conductors in Raceway, Cable, or Earth (Directly Buried), Based on Ambient Temperature of 30°C (86°F).

Size Temperature Rating of Conductor (See table 310-13)

AWG

kcmil

18 16 14 12 10

1/0 2/0 3/0

4/0 250 300 350 400 500 600 700 750 800 900

1000 1250 1500 1750 2000

Ambient

Temp. (°C)

21 - 25 26 - 30 31 - 35 36 - 40 41 - 45 46 - 50 51 - 55

60°C (140°F) 75°C (167°F) 90°C (194°F) 60°C (140°F) 75°C (167°F) 90°C (194°F)

Types

TW, UF

--- --- 14 --- --- ---

--- --- 18 --- --- --20 20 25 --- --- --25 25 30 20 20 25 30 35 40 25 30 35

8 6 4 3 2 1

40 50 55 30 40 45 55 65 75 40 50 60 70 85 95 55 65 75 85 100 110 65 75 85

95 115 130 75 90 100 110 130 150 85 100 115 125 150 170 100 120 135 145 175 195 115 135 150 165 200 225 130 155 175 195 230 260 150 180 205 215 255 290 170 205 230 240 285 320 190 230 255 260 310 350 210 250 280 280 335 380 225 270 305 320 380 430 260 310 350 355 420 475 285 340 385 385 460 520 310 375 420 400 475 535 320 385 435 410 490 555 330 395 450 435 520 585 355 425 480 455 545 615 375 445 500 495 590 665 405 485 545 520 625 705 435 520 585 545 650 735 455 545 615 560 665 750 470 560 630

For ambient temperatures other than 30°C (86°F), multiply the allowable ampacities shown above by the

1.08 1.05 1.04 1.08 1.05 1.04

1.00 1.00 1.00 1.00 1.00 1.00

0.91 0.94 0.96 0.91 0.94 0.96

0.82 0.88 0.91 0.82 0.88 0.91

0.71 0.82 0.87 0.71 0.82 0.87

0.58 0.75 0.82 0.58 0.75 0.82

0.41 0.67 0.76 0.41 0.67 0.76

Types

FEPW, RH,

RHW, THHW,

THW, THWN, XHHW, USE,

Types

TBS, SA, SIS,

FEP, FEPB, MI,

RHH, RHW-2,

THHN, THHW,

THW-2,

THWN-2, USE-2,

XHH, XHHW,

XHHW-2,ZW-2

Types

TW, UF

Types

RH, RHW,

THHW,

THW, THWN,

XHHW, USE

COPPER ALUMINUM or COPPER-CLAD ALUMINUM

CORRECTION FACTORS

appropriate factor below

Types

TBS, SA, SIS,

THHN, THHW,

THW-2, THWN-2, RHH, RHW-2, USE-2,

XHH, XHHW,

XHHW-2,

ZW-2

OPM_SGS_ISG_M22_M30_0US_V011.doc 20/38 Installation Guide

SG Series

225 & 300 kVA

3.8 WIRING CONNECTION

WARNING! UPS installation and connection must be performed by qualified service personnel only.

3.8.1 Power connections

Input/output and DC connections are provided with compression lugs. Please refer to chart for torque specifications.

Carefully read the following recommendations before proceeding:

• Ensure that the AC and DC external isolators are OFF and locked to prevent their

inadvertent operation.

• Do not close any external isolators prior the commissioning of the equipment.

The preferred power cable entry location for installation purposes is from the right side of

•

the UPS, either top or bottom. To facilitate the terminations remove the right side panel in order to access the input/output terminal lugs. In case of cable entry from the top of the cabinet, remove the cover plate fitted on the roof and provide for a suitable isolated protection cover. In case of cable entry from the bottom remove cover plate and perform the same procedure.

• If the UPS is installed in such a way that the accessibility to the right side panel is reduced,

field wiring connections can be made from the front side by removing the front right side panel protection cover/panel ( D ) as indicated in Fig. 3.8.1-1 be advised that installation performed from the front position will give the installer reduced visibility to the terminal lugs.

• The input/output cables must be connected in clockwise phase rotation for both

Bypass and Rectifier Input Terminals if separate, taking care to avoid risk of short circuit between different poles.

The grounding and neutral connection of the electrical system must be in accordance with

•

local regulations.

• In case of additional cabinets containing batteries, input/ output transformers, etc, their

ground terminals must be connected to the UPS main ground terminal.

• Once the power cables have been connected, re-install the internal safety shields and close

the cabinets by re-installing all external panels.

Torque Specifications

Mechanical Compression Lugs

Input / Output / Battery and GND

WIRE SIZE RANGE

AWG / kcmil

6 – 4

Lb - in

110 12.4

WIRE SIZE RANGE

AWG / kcmil

3/0 – 200

Lb - in

250 28.2

3 – 1

1/0 – 2/0

OPM_SGS_ISG_M22_M30_0US_V011.doc 21/38 Installation Guide

150 19.6

180 20.3

250 – 350

500 – 750

325 36.7

375 42.4

SG Series

225 & 300 kVA

CAUTION ! Panel “E” should never be removed or replaced with power applied to the UPS. This panel is in close proximity to 480V live buss bars. Always disconnect the rectifier, bypass, load and battery sources from the

UPS before removing or replacing this panel. If not serious injury or death could occur!

How to access the compression lugs for the cable connections.

Top entry cables

SGS_225-300_UPS connection_01US

Fig. 3.8.1-1 Access to the input / output connections

To access input, output and Battery Connections proceed as follows:

Bottom entry cables

• Unscrew bolts “B” to open the electronics “A”.

• Remove protection panel “C”.

• Remove protection panel “D”.

• Remove protection panel “E”.

Remove UPS side panel “F”.

•

OPM_SGS_ISG_M22_M30_0US_V011.doc 22/38 Installation Guide

SG Series

225 & 300 kVA

3.8.2 Power connection with common input utility

SGS_225-300_UPS connection common_GE_01US

PE Load

Position of the PE compression lugs in case the cable input is from the bottom of the UPS

PE Load

Input rectifier

L3-1

L1-1

L2-1

Fig. 3.8.2-1 Power connections Common Input Utility

Common Input Rectifier / Bypass

L1-1 Rectifier + Bypass Phase A L2-1 Rectifier + Bypass Phase B L3-1

Rectifier + Bypass Phase C

N Neutral (Bypass) PE Ground

Output Load

Load Phase A

Load Phase B

Load Phase C

N Neutral PE Ground

Bus bars BR1, BR2 and BR3 must remain connected.

Cable terminations are to the Rectifier Input Lugs and Output Lugs as shown above. Connect wire to the Lugs using appropriate tools and appropriate torque. Torque specification for input/output and DC power connections on Bus Bars: Section 3.8.1.

OPM_SGS_ISG_M22_M30_0US_V011.doc 23/38 Installation Guide

SG Series

225 & 300 kVA

This UPS is only designed to operate in a wye-configured electrical system with a solidly grounded neutral.

In case of 3-wire utility input the following solutions are possible:

1- Connection of a “3-wire kit” between Utility Input and Neutral of the

output transformer.

Attention: With this configuration, load can only be connected

phase-phase. Absolutely no load connection permitted to the Neutral of the output transformer.

In a RPA configuration with 3-wire kit, it’s most important to connect the Neutrals of the UPS outputs together (see Fig .3.8.2-2).

Cable section for this connection shall be not less then AWG 1.

2- Bypass transformer.

In this case the Neutral of wye secondary winding must be connected to the Neutral of the output transformer.

Fig. 3.8.2-2 3-wire kit for RPA Parallel System

Contact your Service Centre, which will help you to find valuable solutions.

OPM_SGS_ISG_M22_M30_0US_V011.doc 24/38 Installation Guide

SG Series

225 & 300 kVA

3.8.3 Power connection separate input utility

SGS_225-300_UPS co nnection separate_GE_01US

PE Load

Position of the PE compression lugs in case the cable input is from the bottom of the UPS

PE Load

Input rectifier

L3-1

L1-1

L2-1

L3-2

L2-2

L1-2

2 - INPUT BYPASS

Fig. 3.8.3-1 Power connections Separate Input Utility

Separate Input Rectifier / Bypass

L1-1 Rectifier Phase A L1-2 Bypass Phase A L2-1 Rectifier Phase B L2-2 Bypass Phase B L3-1 Rectifier Phase C L3-2 Bypass Phase C N Neutral (Bypass) PE Ground

The interconnection links BR1, BR2 and BR3 must be removed (see Fig. 3.8.3-2).

Output Load

Load Phase A

Load Phase B

Load Phase C

N Neutral PE Ground

Bus bars BR1, BR2 and BR3 must be removed.

Cable terminations are to the Rectifier/Bypass Input Lugs and Load Output Lugs as shown above. Connect wire to the Lugs using appropriate tools and appropriate torque. Torque specification for Input/Output and DC power connections on Bus Bars: Section 3.8.1.

OPM_SGS_ISG_M22_M30_0US_V011.doc 25/38 Installation Guide

SG Series

225 & 300 kVA

This UPS is only designed to operate in a wye-configured electrical system with a solidly grounded neutral.

In case of 3-wire utility input the following solutions are possible: 1- Connection of a “3-wire kit” between Utility Input and Neutral of the

output transformer.

Attention: With this configuration, load can only be connected phase-

phase. Absolutely no load connection permitted to the Neutral of the output transformer.

In a RPA configuration with 3-wire kit, it’s most important to connect the Neutrals of the UPS outputs together (see Fig .3.8.3-2).

Cable section for this connection shall be not less then AWG 1.

Fig. 3.8.3-2 3-wire kit for RPA Parallel System

2- Bypass transformer.

In this case the Neutral of wye secondary winding must be connected to the Neutral of the output transformer.

Contact your Service Centre, which will help you to find valuable solutions.

Notices for installation

SGS_225-300_UPS BR1-2-3_01

BR1 BR2

BR3

Fig. 3.8.3-3 AC bus bars BR1, BR2 and BR3

For separate Bypass and Rectifier input configuration AC bus bars BR1, BR2 and BR3 must be removed

OPM_SGS_ISG_M22_M30_0US_V011.doc 26/38 Installation Guide

SG Series

225 & 300 kVA

SGS

225

300

UPS

01US

3.8.4 Battery connection

ery_ a

connec

BATTERY

Fig. 3.8.4-1 Power connections Battery

Battery

+ Positive pole of the Battery – Negative pole of the Battery

Do not insert the Battery Fuses before the commissioning.

Battery Cable Terminations are to the Positive and Negative Terminals as shown above.

Connect wire to the Lugs using appropriate tools and appropriate torque.

Torque specification for Input/Output and DC power connections on Bus Bars: See section 3.8.1.

OPM_SGS_ISG_M22_M30_0US_V011.doc 27/38 Installation Guide

SG Series

225 & 300 kVA

3.8.5 Setup for SG Series when functioning as frequency converter

When the SG Series is utilized for different output frequency compared to the input frequency

Load cannot be transferred to Utility in case of overload, short circuit, or inverter failure.

In situations where the UPS needs to be powered down for maintenance purposes, the critical

Manual Bypass, serious damage to the Load could result.

, the Automatic Bypass and Manual Bypass functions are disabled, therefore the

Load

must also be powered down during this time, the UPS cannot be transferred to

Circuit breaker Q2 - Manual Bypass must be blocked in the open position, to avoid any accidental closure, by means of a padlock or a similar device, when the UPS is used as a frequency converter.

As an added measure of safety the bus bar connections BR1, BR2 and BR3 should also be removed.

See Fig. 3.8.3-2.

NOTE !

The standard output frequency conversion.

It is recommended that the static switch bypass be electronically blocked if the UPS is to operated as a frequency converter in order to prevent damage to the load.

Check with a Global Services Field Service Engineer to facilitate the parameter change.

CAUTION !

SG Series

SGS_225-300_Switches Q2_01

Fig. 3.8.5-1 Switch Q2 – Manual Bypass

UPS may be operated at 50Hz input with 60Hz

The output transformer of the UPS is designed for 60Hz only. Operation at 50Hz, 480V output may overheat the transformer. The optional 5th harmonic filter is designed for 60Hz operation. If the UPS is purchased with this internal filter it may not be operated

at 50Hz input or damage to the filter could result.

OPM_SGS_ISG_M22_M30_0US_V011.doc 28/38 Installation Guide

SG Series

225 & 300 kVA

3.9 POWER WIRING OF PARALLEL UNITS

To guarantee good Load sharing between the units of a parallel system, we recommend it is recommended that the cable length from the input distribution board (5) to the output distribution board (10) are the same length for each unit (a+b = c+d = e+f = g+h = i+l = m+n = o+p = q+r). Tolerance: +/-10%.

The AC input power of the Bypass must be the same for all units of the parallel system - no phase shift allowed between units.

It is strongly recommended that no transformers, automatic circuit breakers or fuses should be inserted between the unit’s output and the Load common bus bars. However, it is recommended that a disconnect or isolation switch be inserted

Verify that power wiring and control wiring are run in separate conduits or cable trays. UPS input cables must be run in separate conduits from the output cables.

in order to totally isolate a unit if needed

Fig. 3.9-1 RPA Parallel System

= Rectifier

1 2 = Inverter

= Electronic Bypass

3 4 = Manual Bypass

= Input Utility Distribution

5 6 = Unit Output Load 7 = External Battery MCB 8 = External Battery fuse 9 = External Battery

10 = Common Busbar and Output Load Distribution

In a RPA configuration with 3-wire kit, it’s most important to connect the Neutrals of the UPS outputs together (see Fig .3.8.2-2 and 3.8.3-2). Cable section for this connection shall be not less then AWG 1

OPM_SGS_ISG_M22_M30_0US_V011.doc 29/38 Installation Guide

= Unit Number 1

= Unit Number 2

= Unit Number 3

= Unit Number 4

= Unit Number 5

= Unit Number 6

= Unit Number 7

= Unit Number 8

SG Series

225 & 300 kVA

3.10 PARALLEL CONTROL BUS CONNECTION

In cases of parallel operation, the communication between the units takes place through the control bus cables.

Each parallel unit is equipped with an additional board “P13 – RPA Board IM0006“ where the connectors J52 (A) and J62 (B) are located. A short control cable provided with a ferrite ring core links the parallel board “P13 – RPA

Board IM0048” with the parallel bus socket on which must be connected the control bus cables JA and JB on PCB “P34 – Bus Interface IM0048”.

All the parallel units are connected to the same control bus.

This connection allows:

• The microprocessors of each unit to communicate with each other.

• The oscillators of each unit to be locked together.

• The regulation loops to compare the output current of each unit in order to equally share

the Load current.

For increased reliability, this connection is made with redundant cables. In this way, communication is maintained between units in case one of the control cables should fail or be accidentally damaged or disconnected.

The standard length of the control bus cable between two parallel unit is 40 ft / 12 m. Maximal overall length of bus connection, between the first and the last unit, should not be longer than 276 ft / 84 m. Verify that control wiring is run in individual separate steel conduit.

Under no circumstance should the control bus cable connecting JA (1/2/3/4/5/6/7) and JB (1/2/3/4/5/6/7) be connected or disconnected after the

system has been powered On.

UPS 1 UPS 2 UPS 3

JB1

JA1

The shield of the control bus cable, connected on JA and JB must be connected to ground with the appropriate cable clamps fitted on parallel bus socket.

It is important to place the units in sequence of their assigned number. A unit number from 1 to 8, is defined by the setting of parameters and displayed on the panel. This number is also marked inside and outside the packaging.

OPM_SGS_ISG_M22_M30_0US_V011.doc 30/38 Installation Guide

JP1 JP2

IM 0048

JP2

JP1

JP4

JP3

JP4 JP3

JA1 + JB1 JA2 + JB2 JA3 + JB3

JB1

JB2

JA1

JA2

JP4 JP3

JP2JP1

IM 0048

JP2

JP1

JP4

JP3

Fig. 3.10-1 RPA System - Control bus connection

JB3

JA2

JA3

SG Series

JP1 JP2JB2

JP4 JP3

Next parallel unit 4,5,6,7,8

225 & 300 kVA

IM 0048

JP2

JP1

JP4

JP3

SGT5000_100-150_RPA-IM0048_01

SGT5000_100-150_RPA-IM0048_02

JB1

JA1

JP1 JP2

IM 0048

JP4

JP2

JP1

JP4

JP3

Terminal units On the parallel bus PCB “P34 – Bus Interface IM0048”, of the first and last units (terminal) of the parallel system the Jumpers JP1, JP2, JP3 and JP4 must be inserted

SGT5000_100-150_RPA-IM0048_03

Fig. 3.10-2 Bus connection on terminal units

JB1

JB2

JA1

JA2

Intermediate units On the parallel bus PCB “

parallel system the Jumpers JP1, JP2, JP3 and JP4 must be removed

In a parallel system composed of 2 or more units, only the first and last units (having 1 input JA and JB free) have the Jumper JP1, JP2, JP3 and JP4 inserted on parallel bus PCB “P34 – Bus Interface IM0048” (see Fig. 3.10-2).

Fig. 3.10-3 Bus connection on intermediate units

P34 – Bus Interface IM0048”

JP4 JP3

of the

IM 0048

intermediate units

JP2JP1

JP2

JP1

JP4

JP3

of the

OPM_SGS_ISG_M22_M30_0US_V011.doc 31/38 Installation Guide

SG Series

225 & 300 kVA

3.11 CONTROL BUS CABLE LOCATION

Warning! This installation must be verified by trained personnel before the initial start-up

(ensure that the UPS installation is completely powered down).

SGS_225-300_RPA control bus cable_01

Access to the control bus connection.

The control bus connection between parallel units must be made on the front of the

electronic module fitted behind the front doors.

To properly route the control bus cables the safety screen “A” must be removed.

Fig. 3.11-1 View electronic module on intermediate unit

JB1

JB2

JA1

JA2

Next parallel unit

Fig. 3.11-2 Front view electronic module on intermediate unit

Control bus cables connection.

Plug the cables

•

(1/2/3/4/5/6/7)

and JB (1/2/3/4/5/6/7) onto the RJ connectors JA and JB located on parallel bus PCB “P34 – Bus

Interface IM0048” (going to “P13 – RPA Board IM0006” J52(A) and

SGT5000_100-150_RPA control bus cable_02US

J62(B)).

• Fix both cables JA (1/2/3/4/5/6/7)

and JB (1/2/3/4/5/6/7) to parallel bus socket connecting the cable shield to ground by means the cable clamps “A“.

OPM_SGS_ISG_M22_M30_0US_V011.doc 32/38 Installation Guide

SG Series

225 & 300 kVA

JB1

JA1

SGS_225-300_RPA control bus cable_02US

JB1

JA1

Fig. 3.11-3 Control Bus cable routing and connection

Control bus cables routing

Place and fix the cables

JA-1/2/3/4/5/6/7

position illustrated in the drawing.

Pay attention when cabling and routing the bus cables JA and JB inside the UPS cabinet.

In case one unit should be removed from the parallel system, the bus cables JA and JB must be removed from the cabinet without disconnecting them from the metal plate where the sockets JA and JB are located.

For reliability reasons the cables

JA-1/2/3/4/5/6/7

should be run in separated protected conduits (as indicated in fig. 3.11-3) separated from the power cables.

It is important that the cable JA must be the same length as cable JB.

JB1 JB2

JA1 JA2

and

JB-1/2/3/4/5/6/7

and

JB-1/2/3/4/5/6/7

JB2

JA2

inside the UPS cabinets in the

connecting the units

The connection of the control bus cable in a UPS system already powered requires a special reset operation, which can be made by only a trained operator.

OPM_SGS_ISG_M22_M30_0US_V011.doc 33/38 Installation Guide

SG Series

225 & 300 kVA

4 CUSTOMER INTERFACE

4.1 CUSTOMER INTERFACE

Serial port J3 - RS 232 (sub D - female 9 pin)

1234

Pin 2: TX (out) Pin 3: RX (in) Pin 5: GND

J2 (subD-female 25p) – Output signals on voltage free contacts

12 13

1 2

JP3

1234

Fig. 4.1-1 Customer interface

J2/1, 2, 3 J2/4, 5, 6 - NO, C, NC - Load on Inverter (def. Param. RL=3) J2/7, 8, 9 - NO, C, NC - Stop Operation (def. Param. RL=5) J2/14, 15, 16 - NO, C, NC - Load on Utility (def. Param. RL=2) J2/17, 18, 19 - NO, C, NC - General Alarm (def. Param. RL=4) J2/20, 21, 22

Signals on terminals X1 and on connector J2 are in parallel

and therefore not separated galvanically from each other. The programmable signals on X1 and J2 will be disabled with Q1 open, with the exception of the signals for “16 - Manual Bypass ON” and “26 - EPO”.

X2 / 1, 2 or J2 / 12, 25 Note: to enable this function, remove cable short-circuiting XB / 2 – 3 and

the Jumper JP3 on P4 – Customer Interface.

X1 – Output signals on voltage free contacts - terminals

X1/1, 2, 3 - NO, C, NC - Utility Failure (def. Param. RL=1) X1/4, 5, 6 - NO, C, NC - Load on Inverter (def. Param. RL=3) X1/7, 8, 9 X1/12, 13, 14 X1/15, 16, 17 - NO, C, NC - General Alarm (def. Param. RL=4) X1/18, 19, 20 - NO, C, NC - Acoustic Alarm (def. Param. RL=6)

SGS_225-300_Customer interface_01

X1/10, 21 or J2/10, 23 X1/11, 22 or J2/11, 24 Programmable / Generator ON (NO) (def. = RL2)

NO = normally open C = common NC = normally closed

The connectors J4 and J5 can be used for additional SNMP Card, Environmental Card (not available yet) or an additional

: terminals for 24VDC Auxiliary Power Supply connection. XB: terminals for EPO connection.

Customer Interface

(installation only when the UPS is switched Off).

Programmable user relays Programmable functions on contacts (X1 - J2)

On terminals X1 or J2 connector, six of the following 26

can be selected from the display, entering with the

signals

appropriate 0- No Information

1- Buzzer 2- General Alarm 3- Load on Utility 4- Stop Operation 5- Load on Inverter 6- Utility Failure 7- DC Over Voltage 8- Low Battery 9- Overload 10- Over Temperature 11- Inverter-Utility not syncr. 12- Bypass Locked 13- Bypass Utility Failure

password.

14- Rectifier Utility Failure 15- Battery Discharge 16- Manual Bypass ON 17- Rectifier ON 18- Inverter ON 19- Boost Charge 20- Battery Earth Fault 21- Battery Fault 22- Relay Input 1 23- Relay Input 2 24- Relay Output ON 25- Relay Output OFF 26- EPO (Emergency

Power Off)

Suitable for JUMP protocol

- NO, C, NC - Utility Failure

- NO, C, NC - Acoustic Alarm (def. Param. RL=6)

(def. Param. RL=1)

XB - Terminals for EPO connection

- NO, C, NC - Stop Operation (def. Param. RL=5)

- NO, C, NC - Load on Utility (def. Param. RL=2)

EPO (Emergency Power Off)

Input contacts

Programmable (default = RL1)

Some UPS functions can be activated with parameters when an external Normally Open contact is closed on:

X1-10, 21 / J2-10, 23 or X1-11, 22 / J2- 11, 24

Selectable functions by changing parameters (password required) are:

0 - No function 1 - Inverter ON 2 - Inverter OFF 3 - Print All 4 - Status Relay 5 - Generator ON 6 - External Bypass ON 7 - External Battery Fuses, or External K3.

See Alarm 4104 - “Battery Fuses”.

Voltage free contacts:

Max. DC / AC: 24V / 1.25A

IEC 950 (SELV circuit) Min. Signal Level: 5VDC/50mA

OPM_SGS_ISG_M22_M30_0US_V011.doc 34/38 Installation Guide

SG Series

225 & 300 kVA

4.1.1 Serial Port J3

Serial port J3 - RS-232 (sub D, female 9 pin) that allows:

• Total remote management of the system using new generation software JUMP (Java

Universal Management Platform) for system protection and management of systems using GE Industrial Systems UPS’s. JUMP system is written in JAVA and supports virtually all platforms having JAVA runtime environment version 1.1 or higher.

The serial port J3 - RS-232 is enabled on all the units of the parallel system.

Serial port J3 connection to PC

Fig. 4.1.1-1 Serial port J3 connection to PC

4.1.2 Output potential free contacts

The interface board provide 6 voltage free relay contacts giving some UPS critical alarms and operation mode.

These signals are available either on connector blocks X1.

J2- (sub D, female 25 pin)

The meaning of the alarms on the free contacts in standard configuration (default) is the following:

X1 / 1, 2, 3 or J2 / 1, 2, 3 (NO, C, NC) Utility Failure

X1 / 4, 5, 6 or J2 / 4, 5, 6 (NO, C, NC) Load on Inverter

X1 / 7, 8, 9 or J2 / 7, 8, 9 (NO, C, NC) Stop Operations

X1 / 12, 13, 14 or J2 / 14, 15, 16 (NO, C, NC) Load on Utility

X1 / 15, 16, 17 or J2 / 17, 18, 19 (NO, C, NC) General Alarm

X1 / 18, 19, 20 or J2 / 20, 21, 22 (NO, C, NC) Acoustic Alarm

(def. Par. RL=1)

(def. Par. RL=3)

(def. Par. RL=5)

(def. Par. RL=2)

(def. Par. RL=4)

(def. Par. RL=6)

In case different alarms or operating status are required, they can be configured on the same terminals via software from the control panel.

The configuration can be changed in parameters mode by a trained operator using the appropriate password.

The programmable signals on X1 and J2 will be disabled with Q1 open, with the exception of the signals for “16 - Manual Bypass ON” and “26 - EPO”.

or terminal

OPM_SGS_ISG_M22_M30_0US_V011.doc 35/38 Installation Guide

SG Series

225 & 300 kVA

4.1.3 Programmable input free contacts

Some programmable UPS functions (indicated in section 4.1), can be activated by closing an external contact, if connected, on:

X1 / 10, 21 or J2 / 10, 23 User Input 1 (default = Not used) (RL1) X1 / 11, 22 or J2 / 11, 24 User Input 2 (default = Emergency GEN ON) (RL2)

4.1.4 Gen Set Signaling (GEN ON)

If an emergency generator set supplies the UPS in case of Utility Failure and the generator is particularly unstable in frequency, it should be suitable to install the signal on X1/11, 22 or J2/11, 24 (this input is programmed as default for this function).

When this contact closes, it causes the change of certain functions (programmable) such as:

• Enabling or disabling of synchronization and consequently the Load transfer to generator.

• Reduction or elimination or delay of Battery recharging during the generator operation.

In a parallel system a separate NO (Normally Open) contact must be connected individually to each unit.

4.1.5 AUX external Maintenance Bypass

“Generator ON”

If the UPS system is equipped with an external Maintenance Bypass Switch, it is possible to connect a NO (normally open) voltage free aux. contact from the External Bypass Switch to the programmable input switch Q2 has closed.

This function can be activated by changing a dedicated parameter (password required).

X1/10-21

J2/10-23

, making the UPS operate as if the internal

When this NO (Normally Open) contact closes, the output Inverter Contactor K7 it is automatically opened and the Load transfer back to Inverter will be inhibited.

In a parallel system, the input on customer interface of each unit must be connected to a separate AUX contact of the External Maintenance Bypass Switch.

4.1.6 Auxiliary Power Supply (APS) 24 VDC / 1A

XA - 1 24 VDC

XA - 2

GND

XA - 3 24 VDC

XA - 4 GND

Fig. 4.1.6-1 Terminals for connection 24 VDC

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SG Series

225 & 300 kVA

4.1.7 EPO (Emergency Power Off) Input contact

n external Emergency switch

(Normally Closed voltage-free

JP3

Fig. 4.1.7-1 Terminals for connection EPO

To enable this function, remove cable short-circuiting XB / 2 - 3 on the Terminal XB and the Jumper JP3 on P4 – Customer Interface, when the cables have been already connected on XB or J2.

In a parallel system a separate NC (Normally Closed) contact must be connected individually to each unit.

When opened, this contact causes the immediate opening of the Contactors K3, K4, K6, K7 and K8, as well as the shutdown of Rectifier, Inverter and Static-Switch.

contact) can be connected on terminals XB / 1 - 4 or connector

J2 / 12 - 25 of the P4 - Interface Customer.

Remove the cable shortcircuiting terminals XB 2 - 3) when using this external switch.

Be aware: The reliability of the system depends on this contact!

After closure of the Emergency contact, a reset is necessary to enable the restart of the UPS, by pressing the key “O” (inverter off) on the control panel.

In case of a parallel system press the key “O” (inverter off) on the control panel of each unit connected on parallel bus and having it’s output switch Q1 closed.

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SG Series

225 & 300 kVA

5 NOTES

5.1 NOTES FORM

It is recommended to note in this section Notes, with date and short description all the operations performed on the UPS, as: Maintenance, components replacement, anormal situations, etc.

Date Description Done by

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SG Series

225 & 300 kVA

GE 225, 300 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual