GE SG 400 Series, SG Series 500 Installation Manual

GE Digital Energy

Power Quality

S

G

S

_

4

0

0

-

5

0

0

_

S

2

_

U

P

S

_

G

E

_

0

1

Installation Guide

Uninterruptible Power supply

SG Series 400 & 500

400 & 500 kVA / 480Vac UL / S2

GE Consumer & Industrial SA

General Electric Company
CH – 6595 Riazzino (Locarno)
Switzerland
T +41 (0)91 / 850 51 51
F +41 (0)91 / 850 52 52

www.gepowerquality.com

g

imagination at work

Model:

SG Series 400 & 500 UL S2

Issued by Product Document Department – Riazzino - CH

Date of issue: 06/28/2011

File name: OPM_SGT_ISG_M40_M50_2US_V021

Revision: 2.1

Identification No.: 1024191

Up-dating

Revision Concerns Date

2.0

ECN1548 - Safety Rules 02/25/2011

2.1

ECN1586 – Power connection

06/28/2011

COPYRIGHT © 2011 by GE Consumer & Industrial SA

All rights reserved.

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.

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.

Modifications reserved Page 2/41

OPM_SGS_ISG_M40_M50_2US_V021.doc User Manual SG Series 400 & 500 UL S2

Dear Customer,

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

We trust that the use of the SG Series 400 & 500
Uninterruptible Power Supply system, developed and
produced to the highest standards of quality, will give
you complete satisfaction.

Please read carefully the Installation Guide, which
contains all the necessary information and describes all
you need to know about the installation of the UPS.
Thank you for choosing GE !

START-UP AND COMMISSIONING

A GE GLOBAL SERVICES FIELD ENGINEER must perform start-up and
commissioning of the UPS.

Please Contact GE. GLOBAL SERVICES at least two weeks prior to schedule
start-up and commissioning at 1-800-637-1738, or by E-mail at

[e-mail] .

Distributed in the USA by:

Your service contact:

g

GE Consumer & Industrial SA

General Electric Company

CH – 6595 Riazzino (Locarno)

Switzerland

www.gepowerquality.com

g

GE Digital Energy

Power Quality

2501 Pecan Street

Bonham, TX 75418
T: [phone]
F: [phone]

E: [e-mail]

http://www.gedigitalenergy.com/ups

g

GE Digital Energy

Power Quality

830 West 40th Street

Chicago, IL 60609
24/7 T: 800-637-1738
24/7 T: 773-299-6600

F: 866-765-3595

E: [e-mail]

Modifications reserved Page 3/41

OPM_SGS_ISG_M40_M50_2US_V021.doc User Manual SG Series 400 & 500 UL S2

Preface

Congratulations on your choice of a SG Series Uninterruptible Power Supply (UPS).
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 assumes no responsibility or liability for any losses or damages resulting from the use
of the information contained in this document.

WARNING!

SG Series 400 & 500 is a product that needs to be installed by a licensed and
knowledgeable contractor.

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.

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.

Modifications reserved Page 4/41

OPM_SGS_ISG_M40_M50_2US_V021.doc User Manual SG Series 400 & 500 UL S2

Table of contents Page

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

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

2.1 LAYOUT SG Series 400 & 500 .......................................................................................................................................................9

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

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...................................................................................................................................................................... 18

3.7.1 Utility input connection ................................................................................................................................................................. 18

3.7.2 Input/output over current protection and wire sizing..................................................................................................... 19

3.7.3 Battery over current protection and wire sizing................................................................................................................ 20

3.8 WIRING CONNECTION .................................................................................................................................................................. 22

3.8.1 Power connections.......................................................................................................................................................................... 22

3.8.2 Power connection with common input utility ..................................................................................................................... 24

3.8.3 Power connection with dual input utility (option).............................................................................................................. 26

3.8.4 Battery and External Battery Breaker connection ........................................................................................................... 29

3.8.5 Interface to External Bypass for single unit......................................................................................................................... 30

3.8.6 Connections to External Bypass switch in case of RPA Parallel System ................................................................ 30

3.8.7 Set-up for SG Series 400 & 500 intended to be operated in eBoost™ Operation Mode .................................. 31

3.9 RPA PARALLEL SYSTEM CONNECTION .................................................................................................................................. 32

3.9.1 Power wiring of parallel units ..................................................................................................................................................... 32

3.9.2 Parallel control bus connection................................................................................................................................................. 33

3.9.3 Control bus cable location ........................................................................................................................................................... 35

4 CUSTOMER INTERFACE ............................................................................................................................. 37

4.1 CUSTOMER INTERFACE................................................................................................................................................................ 37

4.1.1 Serial Port J3 ...................................................................................................................................................................................... 38

4.1.2 Output free potential contacts .................................................................................................................................................. 38

4.1.3 Programmable input free contacts ......................................................................................................................................... 39

4.1.4 Gen Set Signaling (GEN ON)......................................................................................................................................................... 39

4.1.5 AUX external Maintenance Bypass......................................................................................................................................... 39

4.1.6 eBoost/IEMi control signal ........................................................................................................................................................... 39

4.1.7 Auxiliary Power Supply (APS) 24Vdc and Battery Breaker Release........................................................................... 39

4.1.8 EPO (Emergency Power Off) Input contact........................................................................................................................... 40

5 NOTES .......................................................................................................................................................... 41

5.1 NOTES FORM ....................................................................................................................................................................................41

Modifications reserved Page 5/41

OPM_SGS_ISG_M40_M50_2US_V021.doc User Manual SG Series 400 & 500 UL S2

1 IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

This manual contains important instructions for models SG Series 400 & 500 that should be followed
during installation and maintenance of the UPS and battery.

GENERAL

- 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.

- After switching off takes 5 minutes for the DC capacitors to discharge because a lethally high voltage
remains at the terminals of the electrolytic capacitors.

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

- The field-wiring outlets 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.

- End user must follow applicable regional occupational safety codes/regulations during installation,
operation and equipment maintenance. This may require additional field marking or labeling defining
appropriate level of PPE (Personal Protection Equipment) to reduce the risk of Arc-flash related injuries.
Contact our Technical Support for product specific information.

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.

- WARNING! HIGH EARTH LEAKAGE CURRENT:
Earth 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.

STORAGE

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

- The optimal temperature for Battery storage is 68°F (20°C) to 77°F (25°C) and shall never exceed the range -

4°F (-20°C) to 104°F (40°C).

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

BATTERY

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

- When replacing the battery, use the same cells number, voltage (V), capacity (Ah).
All the battery used, shall be of the same manufacturer and date of production.

- 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 the batteries.
When working with batteries, remove watches, rings or other metal objects, and only use insulated tools.

- In case of air shipment, the cables +/- going to the battery fuses/terminals shall be disconnected and isolated.

Modifications reserved Page 6/41

OPM_SGS_ISG_M40_M50_2US_V021.doc User Manual SG Series 400 & 500 UL S2

Safety instructions when working with battery

EXTERNAL BATTERY MUST BE INSTALLED AND CONNECTED TO THE UPS BY
QUALIFIED SERVICE PERSONNEL ONLY.
INSTALLATION PERSONNEL MUST READ THIS ENTIRE SECTION BEFORE HANDLING
THE UPS AND BATTERY.

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.
If the terminals are shorted together or to ground they may cause severe injury.
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 uninsulated battery terminals.

A qualified service person, who 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 the 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 battery, 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 in such a way that 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 conduits, 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 the battery or repairing battery connections, shut OFF the UPS and

remove the battery fuses.

Modifications reserved Page 7/41

OPM_SGS_ISG_M40_M50_2US_V021.doc User Manual SG Series 400 & 500 UL S2

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.

Modifications reserved Page 8/41

OPM_SGS_ISG_M40_M50_2US_V021.doc User Manual SG Series 400 & 500 UL S2

2 LAYOUT

2.1 LAYOUT SG SERIES 400 & 500

S

G

S

_

4

0

0

-

5

0

0

_

S

2

_

U

P

S

_

G

E

_

0

2

Fig. 2.1-1 SG Series 400 & 500 general view

Q1

0

O

F

F

I ON

Q2

0

O

F

F

I ON

S

G

S

U

_

4

0

0

-

5

0

0

_

S

2

_

U

P

S

_

0

3

11
22

10
21

2

1

18

12
13

16

1415

17

7

1
2

34

6

5

1920

8
9

4

3

2

1

15

14

131298

20

19

56

7

171618

21

10

22

11

Fig. 2.1-2 SG Series 400 & 500 general view with open doors

Q1

0

O

F

F

I ON

Q2

0

O

F

F

I ON

S

G

S

U

_

4

0

0

-

5

0

0

_

S

2

_

U

P

S

_

0

4

1

4

3

XA/XB

CR

2

Q1

Q2

Fig. 2.1-3 SG Series 400 & 500 general view with optional 5th harmonic filter and

removed protection panels

1 Opening for top cable entry (*)

2 Opening for bottom cable

entry

(*)

3 Bus bars for Utility input and

Load output

4 Bus bars for external Battery

connection

CR Connectivity Rack

Q1 UPS output switch

Q2 Manual Bypass switch (option)

XA Terminals for 24Vdc Auxiliary

Power Supply connection

XB Terminals for EPO connection

*) Remove this panel or provide

means to capture metal filings
from cutting conduit entry holes

￭) Dual mains customer

connection bars are optional

Modifications reserved Page 9/41

OPM_SGS_ISG_M40_M50_2US_V021.doc User Manual SG Series 400 & 500 UL S2

3 INSTALLATION

3.1 TRANSPORT

Forklift

Crane

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.

Take all necessary precautions to avoid damage to the
cabinet while hoisting the UPS.

NOTE !

Check for sufficient floor and elevator
loading capacity.

Fig. 3.1-1 UPS cabinets moving

3.1.1 Dimensions and weight

Dimensions SG Series 400 & 500

(W x D x H)

80.71 x 33.47 x 76.78 inches

2,050 x 850 x 1,950 mm

S

G

S

U

_

4

0

0

-

5

0

0

_

S

2

_

U

P

S

d

i

m

e

n

s

i

o

n

s

_

G

E

_

0

1

U

S

D

H

W

Fig. 3.1.1-1 UPS cabinet dimensions

Weight SG Series 400 & 500

UPS rating

kVA

Weight

lbs / kg

Floor loading

lbs/sq.ft - kg/m

2

SG Series 400 & 500

5,226 / 2,370 279 / 1,359

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

Modifications reserved Page 10/41

OPM_SGS_ISG_M40_M50_2US_V021.doc User Manual SG Series 400 & 500 UL S2

3.2 DELIVERY

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

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

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

NOTE !

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

3.3 STORAGE

3.3.1 Storage of the UPS

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).
In case the battery is included please refer to Section 3.3.2.

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 1 year, these functions should be verified by an 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 self­discharge 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) and shall never exceed the
range -4°F (-20°C) to 104°F (40°C).

Recharge stored maintenance free battery every:

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)

Modifications reserved Page 11/41

OPM_SGS_ISG_M40_M50_2US_V021.doc User Manual SG Series 400 & 500 UL S2

3.4 PLACE OF INSTALLATION

3.4.1 UPS location

WARNING !

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. 104°F / 40°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.

NOTE !

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

The SG Series 400 & 500 UPS can radiate radio frequency energy.
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 (120Vac) 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 SG Series 400 & 500

S

G

S

U

_

4

0

0

-

5

0

0

_

S

2

_

U

P

S

d

i

s

p

o

s

i

t

i

o

n

_

0

1

Min.

20" / 500mm

Fig. 3.4.1-1 SG Series 400 & 500 clearances

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 20” (500 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.

Modifications reserved Page 12/41

OPM_SGS_ISG_M40_M50_2US_V021.doc User Manual SG Series 400 & 500 UL S2

Openings for input and output cable connections

2

,

0

5

0

m

m

8

0

.

7

1

"

2

0

0

m

m

7

.

8

8

"

1

.

9

7

"

4

0

m

m

1

.

5

8

"

5

0

m

m

3

3

.

4

7

"

2

9

.

5

3

"

7

5

0

m

m

8

5

0

m

m

S

G

S

U

_

4

0

0

-

5

0

0

_

S

2

_

U

P

S

vi

e

w t

o

p

_

0

1

U

S

Utility input
Output Load
Battery

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

SG Series 400 & 500
openings are provided
on the top (*) and the
bottom (*) of the UPS
for the connection of
input and output
cables.

Pay attention to the
position of these
openings, when
choosing the
placement of the UPS.
These openings are
covered with a
protective plate.

Utility input
Output Load
Battery

7

.

8

8

"

2

0

0

m

m

1

.

1

9

"

7

0

0

m

m

2

7

.

5

6

"

8

5

0

m

m

3

3

.

4

7

"

0

m

m

3

.

1

5

"

2

,

0

5

0

m

m

8

0

.

7

1

"

3

0

m

m

S

G

S

U

_

4

0

0

-

5

0

0

_

S

2

_

U

P

S

v

i

e

w

b

o

t

t

o

m

_

0

1

U

S

*) Please remove
the plate before drilling
any holes.

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.

Ø 0.47305"

Ø 12mm

Front side

35mm

1.378"
1580mm

62.205"
35mm

1.378"

2.363"

60mm

28.740"

730mm

2.363"

60mm

==

30.040"

763mm

575.5mm

22.658"

559.5mm

22.028"

33.268"

845mm

SGSU_400-500_S2_UPS view bottom_02US

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

Modifications reserved Page 13/41

OPM_SGS_ISG_M40_M50_2US_V021.doc User Manual SG Series 400 & 500 UL S2