GE SG Series Installation Manual

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SGT5000_030-040_UPS_GE_01a

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.gecriticalpower.com

Installation Guide

Uninterruptible Power Supply

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GE_UPS_OPM_SGS_ISG_10K_40K_0US_V070.docx

Installation Guide SG Series 10-20-30-40 UL S

Model:

SG Series 10 - 20 - 30 - 40 UL S0

Issued by

Product Document Department – Riazzino - CH

Approved by:

R & D Department – Riazzino - CH

Date of issue:

11/20/2013

File name:

GE_UPS_OPM_SGS_ISG_10K_40K_0US_V070

Revision:

7.0

Identification No.:

1024195

Up-dating

Revision

Concerns

Date

2.0

Modified Section 3.8.4 & 5 – Power connection dual input utility

08/25/2004

3.0

House-style GE Consumer & Industrial

01/30/2006

4.0

ECN 1251: GE Digital Energy – Power Quality / Table DC current rating

11/12/2008

5.0

ECN 1348 – Soft 3.30 & DSP 10.0

12/15/2009

6.0

ECN1548 - Safety Rules

02/25/2011

7.0

ECN 2079 (EPO for RPA Parallel System) Customer Interface Board / SNMP card & GE Critical Power template

11/20/2014

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.

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Installation Guide SG Series 10-20-30-40 UL S

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 10-20-30-40 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

pqservice@ge.com .

Distributed in the USA by:

Your service contact:

GE Consumer & Industrial SA

General Electric Company

CH – 6595 Riazzino (Locarno)

Switzerland

www.gepowerquality.com

GE Digital Energy

Power Quality

2501 Pecan Street

Bonham, TX 75418 T: +1 800-637-1738 F: +1 903-640-0533

E: GEPQSales@ge.com

http://www.gedigitalenergy.com/ups

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: pqservice@ge.com

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Installation Guide SG Series 10-20-30-40 UL S

Congratulations on your choice of a SG Series 10-20-30-40 Uninterruptible Power Supply (UPS). It will help eliminate Load disturbances due to unexpected power problems.

This Manual 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.

Please refer to the accompanying Installations Guide, which describes how to prepare the installation site, and it provides weight, dimensions and procedures for moving, installing and connecting the UPS.

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.

NOTE!

SG Series 10-20-30-40 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.

Preface

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Installation Guide SG Series 10-20-30-40 UL S

Table of contents Page

1 SAFETY RULES ................................................................................................................................................. 6

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

2.1 LAYOUT SG SERIES 10 & 20 ................................................................................................................................................................... 9

2.2 LAYOUT SG SERIES 30 & 40 .................................................................................................................................................................10

3 INSTALLATION............................................................................................................................................... 11

3.1 TRANSPORT .................................................................................................................................................................................................11

3.1.1 Dimensions and weight ........................................................................................................................................................................ 11

3.2 DELIVERY ......................................................................................................................................................................................................12

3.3 STORAGE .......................................................................................................................................................................................................12

3.3.1 Storage of the UPS .................................................................................................................................................................................. 12

3.3.2 Storage of battery ................................................................................................................................................................................... 12

3.4 PLACE OF INSTALLATION ......................................................................................................................................................................13

3.4.1 UPS location ............................................................................................................................................................................................... 13

3.4.2 Battery location ........................................................................................................................................................................................ 15

3.5 VENTILATION AND COOLING ..............................................................................................................................................................16

3.6 UNPACKING.................................................................................................................................................................................................17

3.7 ELECTRICAL WIRING ...............................................................................................................................................................................19

3.7.1 Utility input connection ......................................................................................................................................................................... 19

3.7.2 Input/output over current protection and wire sizing ............................................................................................................. 20

3.7.3 Battery over current protection and wire sizing ........................................................................................................................ 21

3.8 WIRING CONNECTION ...........................................................................................................................................................................24

3.8.1 Power connections .................................................................................................................................................................................. 24

3.8.2 Power connection with common input utility of SG Series 10 & 20 .................................................................................. 27

3.8.3 Power connection with common input utility of SG Series 30 & 40 .................................................................................. 28

3.8.4 Power connection dual input utility of SG Series 10 & 20 ...................................................................................................... 29

3.8.5 Power connection dual input utility of SG Series 30 & 40 ...................................................................................................... 31

3.8.6 Battery connection of SG Series 10 & 20 ....................................................................................................................................... 33

3.8.7 Battery connection of SG Series 30 & 40 ....................................................................................................................................... 34

3.8.8 Set-up for SG Series 10-20-30-40 when functioning as frequency converter ............................................................. 35

3.9 RPA PARALLEL SYSTEM CONNECTION ...........................................................................................................................................36

3.9.1 Power wiring of parallel units ............................................................................................................................................................. 36

3.9.2 Parallel control bus connection ......................................................................................................................................................... 37

3.9.3 Control bus cable location ................................................................................................................................................................... 39

4 CUSTOMER INTERFACE ................................................................................................................................ 41

4.1 CUSTOMER INTERFACE ..........................................................................................................................................................................41

4.1.1 Serial Port J3 .............................................................................................................................................................................................. 42

4.1.2 Output free potential contacts .......................................................................................................................................................... 42

4.1.3 Programmable input free contacts ................................................................................................................................................. 43

4.1.4 Gen Set Signaling (GEN ON) ................................................................................................................................................................. 43

4.1.5 AUX external Maintenance Bypass .................................................................................................................................................. 43

4.1.6 Auxiliary Power Supply (APS) 24 Vdc ............................................................................................................................................... 43

4.1.7 “EPO - Emergency Power Off” command connection ............................................................................................................. 44

5 NOTES ............................................................................................................................................................. 46

5.1 NOTES FORM ..............................................................................................................................................................................................46

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Installation Guide SG Series 10-20-30-40 UL S

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.

1 SAFETY RULES

SAVE THESE INSTRUCTIONS

This manual contains important instructions for models SG Series 10-20-30-40 that should be followed during installation and maintenance of the UPS and battery.

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Installation Guide SG Series 10-20-30-40 UL S

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

Safety instructions when working with battery

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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.

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:

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Installation Guide SG Series 10-20-30-40 UL S

Fig. 2.1-1 SG Series 10 & 20 general view

Fig. 2.1-2 SG Series 10 & 20 general view with open doors

Fig. 2.1-3 SG Series 10 & 20 general view with optional 5th harmonic filter

and removed protection panels

1 Opening for top cable entry

2 Opening for bottom cable entry

3 Terminals for Utility input and load

output

4 Terminals for external Battery

connection

5 Battery Shelf

CR Connectivity Rack

XA Terminals for 24Vdc Auxiliary

Power Supply connection

XB Terminals for EPO connection

SGT5000_030-040_UPS_GE_02a

SGT5000_010-020_UPS_GE_03

SGT5000_010-020_UPS_GE_04

CRXA XB

2 LAYOUT

2.1 LAYOUT SG Series 10 & 20

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Installation Guide SG Series 10-20-30-40 UL S

Fig. 2.2-1 SG Series 30 & 40 general view

Fig. 2.2-2 SG Series 30 & 40 general view with open doors

Fig. 2.2-3 SG Series 30 & 40 general view with optional 5th harmonic filter

and removed protection panels

1 Opening for top cable entry

2 Opening for bottom cable entry

3 Terminals for Utility input and load

output

4 Terminals for external Battery

connection

CR Connectivity Rack

XA Terminals for 24Vdc Auxiliary

Power Supply connection

XB Terminals for EPO connection

SGT5000_030-040_UPS_GE_02a

SGT5000_030-040_UPS_GE_03

OFF

SGT5000_030-040_UPS_GE_04

2XBXA CR

OFF

2.2 LAYOUT SG Series 30 & 40

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Installation Guide SG Series 10-20-30-40 UL S

Forklift

Crane

Fig. 3.1-1 UPS cabinets moving

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. 3.1.1-1 UPS cabinet dimensions

Dimensions SG Series 10-20-30-40

(W x D x H)

26.78 x 31.50 x 70.90 inches

680 x 800 x 1,800 mm

Weight SG Series 10-20-30-40

UPS rating

kVA

UPS without battery

UPS with battery

Weight

lbs / kg

Floor loading

lbs/sq.ft - kg/m2

Weight

lbs / kg

Floor loading

lbs/sq.ft - kg/m2

SG Series 10

735 / 333

126 / 613

1,121 / 508

192 / 934

SG Series 20

763 / 346

131 / 637

1,169 / 530

200 / 975

SG Series 30

970 / 440

166 / 809

–

SG Series 40

1,147 / 520

196 / 956

–

SGSU_030-040_UPS dimensions_GE_01aUS

3 INSTALLATION

3.1 TRANSPORT

3.1.1 Dimensions and weight

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

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Installation Guide SG Series 10-20-30-40 UL S

NOTE !

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

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)

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.

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 room 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).

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Installation Guide SG Series 10-20-30-40 UL S

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.

NOTE !

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

Positioning of the UPS SG Series 10-20-30-40

Fig. 3.4.1-1 SG Series 10-20-30-40 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 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.

SGSU_030-040_UPS disposition_GE_01a

16" / 400mm

Min.

3.4 PLACE OF INSTALLATION

3.4.1 UPS location

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.

The SG Series 10-20-30-40 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.

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Installation Guide SG Series 10-20-30-40 UL S

Openings for input and output cable connections

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

cables of SG Series 10 & 20

Fig. 3.4.1-3 Opening on top of the cabinet for input and

cables of SG Series 30 & 40

Fig. 3.4.1-4 Opening on the bottom of the cabinet for input and

output cables SG Series 10-20-30-40

SG Series 10-20-30-40 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.

Positioning of the UPS cabinet

SG Series 10-20-30-40 is equipped with wheels for easy placement of the UPS.

To make the UPS movable on wheels, the bolts on each leg of the cabinet have to be turned counter-clockwise, until they are free from the floor and thus the cabinet supported on wheels.

After having positioned the UPS at its final location, the cabinet has to be secured by rotating the bolts on each leg clockwise, but the wheels must still touch the floor.

Fig. 3.4.1-4 Bolts for the regulation of the cabinet

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. The supporting blocks can be used in different positions (0°

- 360°)

These supporting blocks are

part of the shipping package.

See Fig. 3.4.1-5.

Fig. 3.4.1-5 Fixing of the UPS cabinet on the floor

SGT5000_010-020_UPS view top_01US

31.50" 800mm

9.06"

1.58"

40mm

230mm

9.06"

70mm

2.76"

26.78"

680mm

230mm

Utility input Output Load Battery

SGT5000_030-040_UPS view top_01US

31.50" 800mm

13.78"

1.58"

40mm

110mm

4.33"

70mm

2.76"

26.78"

680mm

350mm

Utility input Output Load

Battery

SGT5000_030-040_UPS view bottom_01US

26.78"

680mm

7.09" 180mm

70mm

2.76" 50mm

1.97"

7.88" 200mm

31.50" 800mm

Utility input Output Load

To lower

To lift

SGSU_050-080_UPS wheels_01aUS

SGSU_010-020_UPS fixing_01a

0 - 360°

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Installation Guide SG Series 10-20-30-40 UL S

Fig. 3.4.1-6 RPA system disposition

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 “side by side”,

the side panels must be mounted on all units.

NOTE !

Battery installation and connection must be performed by QUALIFIED PERSONNEL ONLY.

Read all safety instructions before proceeding with the installation.

SGSU_050-080_RPA disposition_GE_01aUS

UPS 1

UPS

3 - 4 - 5 - 6 - 7 - 8

UPS 2

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 Battery location 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).

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.

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Installation Guide SG Series 10-20-30-40 UL S

Fig. 3.5-1 Installation on plain floor

Fig. 3.5-2 Installation on raised floor

NOTE !

Do not put anything on the top of the cabinet.

UPS rating

kVA

Losses

Cooling air flow

BTU / hr

CFM

m3 / h

SG Series 10

3,036

0.89

135

230

SG Series 20

6,751

1.98

301

512

SG Series 30

8,104

2.37

361

614

SG Series 40

10,808

3.17

482

819

3.5 VENTILATION AND COOLING

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.

Air filtration systems could be required when the UPS operates in a dirty environment. Contact your Dealer or the nearest Service Center for appropriate solutions.

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

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NOTE !

Check for sufficient floor and elevator loading capacity. Take care not to damage the UPS when moving by forklift. Remove the cabinet from the pallet with care because of the heavy weight of the

equipment.

1 2

 Make sure to have sufficient space around

the UPS before you start unpacking.

 Cut the three straps “A” fixing the carton box.

 Remove package “B” and “C”.  Remove the protection “D” outside the cabinet

and the accessories bag.

 Remove the wooden support “E”, which must be

used to hoist the UPS.

 Unscrew anchoring bolt “F” from plate on all

four legs.

3 4

 Position the fork lift “G” with an opening

between the forks of 33.50” (850mm).

 Insert the wooden support “E” underneath

the UPS, paying attention that the 2 guides “E1” are positioned with the UPS in the center.

 Lift the UPS cabinet.  Remove the wooden pallet “H”.  Loosen the 4 screws “I” and remove then the 4

anchoring plates “L”.

 Put the UPS down on the floor.  Remove finally the wooden support “E”.

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.

To unpack the cabinet packaged in Carton Box follow the instructions below:

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1 2

 Make sure to have sufficient space

around the UPS before you start unpacking.

 Remove the wooden sides “A” and “B” loosening the

appropriate screws.

 Remove the protection “C” outside the cabinet and the

accessories bag.

 Remove the wooden support “D”, which must be used

to hoist the UPS.

 Unscrew anchoring bolt “E” from plate on all four legs.

3 4

 Position the fork lift “F” with an opening

between the forks of 33.50” (850mm).

 Insert the wooden support “D”

underneath the UPS, paying attention that the 2 guides “D1” are positioned with the UPS in the center.

 Lift the UPS cabinet.  Remove the wooden pallet “G”.  Loosen the 4 screws “H” and remove then the 4

anchoring plates “I”.

 Put the UPS down on the floor.  Remove finally the wooden support “D”.

NOTE !

A damaged UPS must never be installed or connected to mains or battery! In case of any damage sustained during the transport, immediately inform the shipping agent! A detailed report of the damage is necessary for any indemnity claim.

Packing material recycling

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

To unpack the cabinet packaged in Wooden Crate follow the instructions below:

Included in the delivery you can find the following parts:

 An accessories bag  Control Bus cables (only for RPA parallel system)

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WARNING !

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.

NOTE !

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.

Dual Input Configuration 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. 3.8.4-2 for SG Series 10 & 20 and Fig. 3.8.5-2 for SG Series 30 & 40.

Common input Rectifier & Bypass

The same power source is to be used for both Bypass Supply and Rectifier Input (input 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. 3.8.4-2 for SG Series 10 & 20 and Fig. 3.8.5-2 for SG Series 30 & 40.

Dual Input Configuration Rectifier & Bypass

Common input Rectifier & Bypass

Fig. 3.7.1-1 Dual Input Configuration Rectifier & Bypass

Fig. 3.7.1-2 Common Input Rectifier & Bypass

1 = Rectifier 2 = Inverter

3 = Automatic Bypass 4 = Manual Bypass

6 = Load 5 = Utility input

7 = Battery

3.7 ELECTRICAL WIRING

3.7.1 Utility input connection

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

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NOTE !

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.

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 of the system up-stream. 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.

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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 nominal battery discharge current which the UPS allows.

(See Fig. 3.7.1-1 and 3.7.1.2)

UPS rating

AC Input Rectifier

AC Input

Bypass

AC Input

DC Input

Nom.

Max.

Nom.

Max.

SG Series 10

17.2 A

20.2 A

12 A

17.2 A

20.2 A

19.6 A

SG Series 20

27.3 A

36.6 A

24.1 A

27.3 A

36.6 A

36 A

SG Series 30

40.4 A

53.1 A

36.1 A

40.4 A

53.1 A

55.2 A

SG Series 40

53.9 A

63.2 A

48.2 A

53.9 A

63.2 A

76 A

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

UPS rating

AC Input Rectifier

AC Input Bypass

AC Input

DC Input

SG Series 10

30 A

15 A

30 A

25 A

SG Series 20

50 A

35 A

50 A

SG Series 30

70 A

50 A

70 A

SG Series 40

80 A

70 A

80 A

100 A

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 battery circuit breaker. 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.

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WIRING

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

Wiring requirements:

AC INPUT RECTIFIER: 3-Phase, 3 wire plus Ground

AC INPUT BYPASS: 3-Phase, 4 wire plus Ground

AC OUTPUT: 3-Phase, 4 wire plus Ground

DC INPUT: 2 wire (positive and negative) plus Ground

Maximum cable diameter that terminals can accept

Refer to torque specifications table for torque requirements

UPS rating

Rectifier Input

Bypass Input

DC Input

AC Output

GND

SG Series 10

3 AWG

SG Series 20

3 AWG

SG Series 30

1 AWG

SG Series 40

1 AWG

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Temperature Rating of Conductor (See table 310-13)

Size

60°C (140°F)

75°C (167°F)

90°C (194°F)

60°C (140°F)

75°C (167°F)

90°C (194°F)

AWG

kcmil

Types

TW, UF

Types

FEPW, RH, RHW,

THHW, THW,

THWN, XHHW,

USE, ZW

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

Types

TBS, SA, SIS,

THHN, THHW,

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

XHH, XHHW,

XHHW-2,

ZW-2

COPPER

ALUMINIUM or COPPER-CLAD ALUMINIUM

---

60 4 70

100

110

115

130

100

110

130

150

100

115

1/0

125

150

170

100

120

135

2/0

145

175

195

115

135

150

3/0

165

200

225

130

155

175

4/0

195

230

260

150

180

205

250

215

255

290

170

205

230

300

240

285

320

190

230

255

350

260

310

350

210

250

280

400

280

335

380

225

270

305

500

320

380

430

260

310

350

600

355

420

475

285

340

385

700

385

460

520

310

375

420

750

400

475

535

320

385

435

800

410

490

555

330

395

450

900

435

520

585

355

425

480

1000

455

545

615

375

445

500

1250

495

590

665

405

485

545

1500

520

625

705

435

520

585

1750

545

650

735

455

545

615

2000

560

665

750

470

560

630

CORRECTION FACTORS

Ambient

Temp. (°C)

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

below

21 - 25

1.08

1.05

1.04

1.08

1.05

1.04

26 - 30

1.00

31 - 35

0.91

0.94

0.96

0.91

0.94

0.96

36 - 40

0.82

0.88

0.91

0.82

0.88

0.91

41 - 45

0.71

0.82

0.87

0.71

0.82

0.87

46 - 50

0.58

0.75

0.82

0.58

0.75

0.82

51 - 55

0.41

0.67

0.76

0.41

0.67

0.76

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).

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WARNING!

UPS installation and connection must be performed by QUALIFIED SERVICE PERSONNEL ONLY.

Torque Specifications

Mechanical Terminals

Input / Output / Battery and GND

UPS rating

WIRE SIZE RANGE

Lb - in

SG Series 10 & 20

20 AWG to 3 AWG

SG Series 30 & 40

16 AWG to 1 AWG

2.5

3.8 WIRING CONNECTION

3.8.1 Power connections

Input/output and DC connections are provided with terminal blocks. 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. 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.

 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.

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SG Series 10 & 20

How to access the terminals for the cable connections.

Fig. 3.8.1-1 Access to the input / output connections of SG Series 10 & 20

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

 Remove protection panel “A”.  Remove protection panel “B”.  Remove UPS side panel “C”.  Only for Dual Input Utility:

Remove with appropriate tool the metallic window “D” from the metal screen “C”.

Bottom entry cables

Top entry cables

SGUL_010-020_UPS connection_01US

Please remove the plate "E & F" before drilling any wholes.

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Installation Guide SG Series 10-20-30-40 UL S

SG Series 30 & 40 How to access the terminals for the cable connections.

Fig. 3.8.1-2 Access to the input / output connections of SG Series 30 & 40

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

 Remove protection panel “A”.  Remove protection panel “B”.  Remove UPS side panel “C”.  Only for Dual Input Utility:

Remove with appropriate tool the metallic window “D” from the metal screen “C”.

Bottom entry cables

Top entry cables

before drilling any wholes.

Please remove the plate "E & F"

SGUL_030-040_UPS connection_01US

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Installation Guide SG Series 10-20-30-40 UL S

Fig. 3.8.2-1 Power connections Common Input Utility of SG Series 10 & 20

Common Input Rectifier / Bypass

L1-1

Rectifier + Bypass Phase A

L2-1

Rectifier + Bypass Phase B

L3-1

Rectifier + Bypass Phase C

N Neutral

Ground

Output Load

Load Phase A

Load Phase B

Load Phase C

Load Neutral

Load Ground

NOTE !

This UPS is only designed to operate in a wye-configured electrical system with a solidly grounded neutral. If the UPS is equipped with an input transformer, the secondary of the transformer must be wye-configured with neutral solidly grounded.

SGT5000_010-020_UPS connection common_01US

L1-1

1 - INPUT LOAD

L3-1 L2-1

L2 L1

RECTIFIER

BYPASS

3.8.2 Power connection with common input utility of SG Series 10 & 20

SG Series 10 & 20 Max. rating X1 terminals: 3 AWG (25mm2)

The interconnection links BR1, BR2 and BR3 MUST REMAIN CONNECTED. Cable terminations are to the Rectifier Input Terminals and Output Terminals as shown above. Connect wire to the Terminals using appropriate tools and appropriate torque. Torque specification for Input / Output and DC power connections on Terminals: see Section 3.8.1.

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Fig. 3.8.3-1 Power connections Common Input Utility of SG Series 30 & 40

Common Input Rectifier / Bypass

L1-1

Rectifier + Bypass Phase A

L2-1

Rectifier + Bypass Phase B

L3-1

Rectifier + Bypass Phase C

N Neutral

Ground

Output Load

Load Phase A

Load Phase B

Load Phase C

Load Neutral

Load Ground

NOTE !

L1-1

RECTIFIER

1 -

INPUT

LOAD

SGT5000_030-040_UPS connection common_01US

L2-1

L3-1

OFF

& BYPASS

3.8.3 Power connection with common input utility of SG Series 30 & 40

SG Series 30 & 40 Max. rating X1 terminals: 1 AWG (50mm2)

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Installation Guide SG Series 10-20-30-40 UL S

Fig. 3.8.4-1 Power connections Dual Input Utility of SG Series 10 & 20

Dual Input Configuration 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

Ground

N - Bypass

Bypass Neutral

For dual input configurations, a neutral conductor is required from the bypass source only.

The interconnection links BR1, BR2 and BR3 MUST BE REMOVED (see Fig. 3.8.4-2).

Output Load

Load Phase A

Load Phase B

Load Phase C

Load Neutral

Load Ground

NOTE !

SGT5000_010-020_UPS connection separate_01US

2- INPUT BYPASS

L1-2

L2-2

L3-2

L1-1

1 - INPUT LOAD

L3-1 L2-1

N - Bypass

L2 L1

RECTIFIER

3.8.4 Power connection dual input utility of SG Series 10 & 20

SG Series 10 & 20: Max. rating X1 and X2 terminals: 3 AWG (25mm2)

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

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Notices for installation

Fig. 3.8.4-2 Interconnection links BR1, BR2 and BR3 of SG Series 10 & 20

For separate Bypass and Rectifier Input configuration, the interconnection links BR1, BR2 and BR3 MUST BE REMOVED.

SGT5000_010-020_UPS BR1-2-3_01

BR2BR1

BR3

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Fig. 3.8.5-1 Power connections Dual Input Utility of SG Series 30 & 40

Dual Input Configuration 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

Ground

N - Bypass

Bypass Neutral

For dual input configurations, a neutral conductor is required from the bypass source only.

The interconnection links BR1, BR2 and BR3 MUST BE REMOVED (see Fig. 3.8.5-2).

Output Load

Load Phase A

Load Phase B

Load Phase C

Load Neutral

Load Ground

NOTE !

L1-1

SGT5000_030-040_UPS connection separate_01US

L2-1

L3-1

N - Bypass

OFF

2- INPUT BYPASS

L1-2

L2-2

L3-2

RECTIFIER

1 - INPUT LOAD

3.8.5 Power connection dual input utility of SG Series 30 & 40

SG Series 30 & 40 Max. rating X1 and X2 terminals: 1 AWG (50mm2)

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Installation Guide SG Series 10-20-30-40 UL S

Notices for installation

Fig. 3.8.5-2 Interconnection links BR1, BR2 and BR3 of SG Series 30 & 40

For separate Bypass and Rectifier Input configuration, the interconnection links BR1, BR2 and BR3 MUST BE REMOVED.

SGT5000_030-040_UPS BR1-2-3_01

OFF

BR1 BR2

BR3

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Installation Guide SG Series 10-20-30-40 UL S

Fig. 3.8.6-1 Power connections of internal / external battery for SG Series 10 & 20

Battery

Positive pole of the Battery

–

Negative pole of the Battery

Do not insert the Battery Fuses before the commissioning.

NOTE !

To meet standards concerning electromagnetic compliance, the connection between the UPS and external battery must be done by using a shielded cable or suitable shielded (metal) conduit! This UPS is only designed to operate in a wye-configured electrical system with a solidly grounded neutral. If the UPS is equipped with an input transformer for, the secondary of the transformer must be wye-configured with neutral solidly grounded.

NOTE !

When an additional battery cabinet is connected, no batteries must be installed inside the UPS cabinet.

SGT5000_010-020_UPS connection battery_01

When the unit is equipped with internal battery, for safety reasons it is

The battery plug "BC" must be connected to the battery connector fitted on

External battery connection

Internal battery connection

delivered with the battery fuses already inserted, but with the battery plug "BC" disconnected.

battery enclosure just before the commissioning.

3.8.6 Battery connection of SG Series 10 & 20

Max. rating Battery terminals: 3 AWG (25mm2)

Battery cable terminations are to the Positive and Negative Terminals as shown above. Connect wire to the Terminals using appropriate tools and appropriate torque. Torque specification for Input / Output and DC power connections on Terminals: See section 3.8.1.

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Fig. 3.8.7-1 Power connections battery of SG Series 30 & 40

Battery

Positive pole of the Battery

–

Negative pole of the Battery

Do not insert the Battery Fuses before the commissioning.

NOTE !

To meet standards concerning electromagnetic compliance, the connection between the UPS and external battery must be done by using a shielded cable or suitable shielded (metal) conduit!

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

If the UPS is equipped with an input transformer for, the secondary of the transformer must be wye-configured with neutral solidly grounded.

SGT5000_030-040_UPS connection battery_01US

BATTERY

3.8.7 Battery connection of SG Series 30 & 40

Max. rating Battery terminals: 1 AWG (50mm2)

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NOTE !

The set-up for SG Series 10-20-30-40 when functioning as frequency converter requires a particular installation and adequate setting of some parameters, (accessible only through password), and can therefore only be done by a QUALIFIED SERVICE ENGINEER GE.

The handle of the switch Q2 - Manual Bypass should be removed to avoid attempts to transfer to Manual Bypass when the UPS is being used as a frequency converter.

As an added measure of safety the interconnection links BR1, BR2 and BR3 should also be removed.

See Fig. 3.8.4-2 (SG Series 10 & 20) or

Fig. 3.8.5-2 (SG Series 30 & 40).

Fig. 3.8.8-1 Switch Q2 – Manual Bypass

NOTE !

The standard SG Series 10-20-30-40 UPS may be operated at 50Hz input with 60Hz 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 !

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.

3.8.8 Set-up for SG Series 10-20-30-40 when functioning as frequency converter

When the SG Series 10-20-30-40 is utilized for different output frequency compared to the input frequency, the Automatic Bypass and Manual Bypass functions are disabled, therefore the 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 load must also be powered down during this time, the UPS cannot be transferred to Manual Bypass, serious

damage to the load could result.

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WARNING !

This operation must be performed by QUALIFIED SERVICE PERSONNEL ONLY before the initial start-up.

ENSURE THAT THE UPS INSTALLATION IS COMPLETELY POWERED DOWN.

NOTE !

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 disconnection or isolation switch is installed in order to totally isolate a unit if needed.

Fig. 3.9.1-1 Power wiring of RPA Parallel System

Rectifier

Inverter

Automatic Bypass

Manual Bypass

Input Utility Distribution

Unit Output Load

External Battery fuse or MCB

External Battery

Common bus-bar and Output Load Distribution



UPS Number 1



UPS Number 2



UPS Number 3



UPS Number 4



UPS Number 5



UPS Number 6



UPS Number 7



UPS Number 8

3.9 RPA PARALLEL SYSTEM CONNECTION

3.9.1 Power wiring of parallel units

To guarantee good Load sharing between the units of a parallel system, we recommend that the cable length from the input distribution board (5) to the output distribution board (10) is equal 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.

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NOTE !

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.

Fig. 3.9.2-1 RPA System - Control bus connection

SGT5000_100-150_RPA-IM0048_01

JP3

JP1

JP4

IM 0048

JP2

JP1 JP2

JP4 JP3

JB1

JA1

JB1

JA1

JP2JP1

JP3

JP4

JP3

JP2

JP1

JP4

IM 0048

JB2

JA2

JP1 JP2JB2

JA2 JA3

JB3

JP4 JP3

JP3

JP2

JP1

JP4

IM 0048

JA1 + JB1 JA2 + JB2 JA3 + JB3

UPS 1 UPS 2 UPS 3

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

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

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.

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Fig. 3.9.2-2 Bus connection on terminal units

Terminal units On the parallel bus PCB “P34 – Bus Interface”, of the first and last units (terminal) of the parallel system the Jumpers JP1, JP2, JP3 and JP4 MUST BE INSERTED.

Fig. 3.9.2-3 Bus connection on intermediate units

Intermediate units On the parallel bus PCB “P34 – Bus Interface” of the intermediate units of the parallel system the

Jumpers JP1, JP2, JP3 and JP4 MUST BE REMOVED.

NOTE !

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” (see Fig. 3.9.2-2).

SGT5000_100-150_RPA-IM0048_02

JP3

JP1

JP4

IM 0048

JP2

JP1 JP2

JP4 JP3

JB1

JA1

JB1

JA1

JP2JP1

JP3

JP4

JP3

JP2

JP1

JP4

IM 0048

JB2

JA2

SGT5000_100-150_RPA-IM0048_03

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WARNING !

This operation must be performed by QUALIFIED SERVICE PERSONNEL ONLY before the initial start-up.

ENSURE THAT THE UPS INSTALLATION IS COMPLETELY POWERED DOWN.

Fig. 3.9.3-1 View electronic module on intermediate unit

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.

Fig. 3.9.3-2 Front view electronic module on intermediate unit

Control bus cables connection.

 Plug the cables JA (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” (going to “P13 – RPA Board” J52(A) and 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“.

SGT5000_030-040_RPA control bus cable_01

OFF

SGT5000_100-150_RPA control bus cable_02US

Next parallel unit

JB2

JB1

JA2

JA1

3.9.3 Control bus cable location

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Fig. 3.9.3-3 Control Bus cable routing and connection

Control bus cables routing

Place and fix the cables JA-1/2/3/4/5/6/7 and JB-1/2/3/4/5/6/7 with the appropriate clamps inside the UPS cabinets in the position shown in the drawing Fig 3.9.3-1. Pay attention to the fact, that routing of cables shall allow the removal of the protection covers “A”.

NOTE !

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 and JB-1/2/3/4/5/6/7 connecting the units should be run in separated protected conduits (as indicated in Fig. 3.9.3-3) separated from the power cables.

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

WARNING !

Connection and commissioning of an additional UPS to an existing parallel system, must be performed by a GE SERVICE ENGINEER from of your Service Center.

SGT5000_030-040_RPA control bus cable_02US

Next parallel

unit 3, 4, 5, 6, 7, 8

JB2

JA2

UPS 1

JA1

JB1

JA1

JB1

JB1 JB2

JA2

JA1

JA2

UPS 2

OFF

JB2

OFF

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Fig. 4.1-1 Customer interface

Serial port J3 - RS 232 (sub D - female 9 pin) (see Section 4.1.1)

Suitable for JUMP protocol

Pin 2: TX (out)

Pin 3: RX (in)

Pin 5: GND

J2 (subD-female 25p) – Output signals on voltage free contacts(see Section 4.1.2)

J2/1, 2, 3

NO, C, NC

Utility Failure

(default Parameter RL=1)

J2/4, 5, 6

NO, C, NC

Load on Inverter

(default Parameter RL=3)

J2/7, 8, 9

NO, C, NC

Stop Operation

(default Parameter RL=5)

J2/14, 15, 16

NO, C, NC

Load on Utility

(default Parameter RL=2)

J2/17, 18, 19

NO, C, NC

General Alarm

(default Parameter RL=4)

J2/20, 21, 22

NO, C, NC

Acoustic Alarm

(default Parameter RL=6)

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”.

XB - Terminals for EPO connection(see Section 4.1.7)

XB/1, 4 or J2/12, 25

EPO (Emergency Power Off)

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 (see Section 4.1.2)

X1/1, 2, 3

NO, C, NC

Utility Failure

(default Parameter RL=1)

X1/4, 5, 6

NO, C, NC

Load on Inverter

(default Parameter RL=3)

X1/7, 8, 9

NO, C, NC

Stop Operation

(default Parameter RL=5)

X1/12, 13, 14

NO, C, NC

Load on Utility

(default Parameter RL=2)

X1/15, 16, 17

NO, C, NC

General Alarm

(default Parameter RL=4)

X1/18, 19, 20

NO, C, NC

Acoustic Alarm

(default Parameter RL=6)

Input contacts (see Section 4.1.3)

X1/10, 21 or J2/10, 23

Programmable (default = RL1)

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 3-ph SNMP/WEB plug-in adapter or an additional Customer Interface (installation only when the UPS is switched Off).

XA: terminals for 24Vdc Auxiliary Power Supply connection. XB: terminals for EPO connection.

Programmable user relays

Programmable functions on contacts (X1 - J2)

On terminals X1 or J2 connector, six of the following 26 signals can be selected from the display, entering with

the appropriate password.

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 60950 (SELV circuit) Min. Signal Level: 5Vdc/5mA

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

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)

12 13

SGSU_100-150_Customer interface_01

JP3

4 CUSTOMER INTERFACE

4.1 CUSTOMER INTERFACE

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Fig. 4.1.1-1 Serial port J3

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

Total remote management of the system using software GE Power Diagnostics, GE Data Protection or GE Service Software for system protection

and management of the UPS systems.

Fig. 4.1.1-2 Serial port J3 connection to PC with RS232 1:1 cable DB9m – DB9f

The serial port J3 - RS232 is enabled

on all the units of the parallel system.

X1 / 1, 2, 3

J2 / 1, 2, 3

(NO, C, NC)

Utility Failure

X1 / 4, 5, 6

J2 / 4, 5, 6

(NO, C, NC)

Load on Inverter

X1 / 7, 8, 9

J2 / 7, 8, 9

(NO, C, NC)

Stop Operations

X1 / 12, 13, 14

J2 / 14, 15, 16

(NO, C, NC)

Load on Utility

X1 / 15, 16, 17

J2 / 17, 18, 19

(NO, C, NC)

General Alarm

X1 / 18, 19, 20

J2 / 20, 21, 22

(NO, C, NC)

Acoustic Alarm

NOTE !

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”.

SGT5000_100-150_Customer interface J3_01

4.1.1 Serial Port J3

4.1.2 Output free potential contacts

The interface board provides 6 voltage free relay contacts giving some UPS critical alarms and operation mode. These signals are available either on connector J2- (sub D, female 25 pin) or terminal blocks X1.

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

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.

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X1 / 10, 21 or J2 / 10, 23 User Input 1 (default = Not used)

X1 / 11, 22 or J2 / 11, 24 User Input 2 (default = Emergency GEN ON)

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

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

Fig. 4.1.6-1 Terminals for connection 24Vdc

XA - 1 24Vdc

XA - 2 GND

XA - 3 24Vdc

XA - 4 GND

SGT5000_100-150_Customer interface 24VDC_01

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:

4.1.4 Gen Set Signaling (GEN ON)

If an emergency generator set supplies the UPS in case of Mains Failure and the generator is considerably unstable in frequency, it should be suitable to install the signal “Generator ON” on X1 / 11, 22 or J2 / 11, 24). See Fig. 4.1-1 / X1 and J2.

Since the Parameter for of the reading of the Generator function is password protected, call the nearest Service Center for it's activation.

When this contact closes, it changes certain (programmable) functions 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.

4.1.5 AUX external Maintenance Bypass

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 X1 / 10, 21 or J2 / 10, 23, making the UPS operate as if the internal switch Q2 has closed.

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

4.1.6 Auxiliary Power Supply (APS) 24 Vdc

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Be aware:

The reliability of the system depends on this contact NC (Normally Closed)!

Fig. 4.1.7-1 Terminals for connection EPO

An external Emergency switch (Normally Closed voltage-free contact) can be connected on terminals XB / 1 - 4 or connector

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

NOTE !

To enable this function, remove cable shortcircuiting 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.

When opened, this contact causes the immediate opening of the

Contactors K3, K4, K6, K7 and K8, as well as the shut-down of Rectifier, Inverter and Static-Switch.

NOTE !

This procedure could imply a load shut-down.

NOTE !

In case of parallel Customer Interface the EPO contact must be connected to one “P4

- Customer Interface” only, but the bridge on X2 and jumper JP3 on the “P4 Customer Interface” must be removed on all other boards.

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

Fig. 4.1.7-2 XB “EPO - Emergency Power Off” – RPA Parallel System connection schematics

SGT5000_100-150_Customer interface EPO_01

JP3

EPO

XB 2-3

SGSU_010-040_UPS_EPO-RPA connection schematic_GE_01

4.1.7 “EPO - Emergency Power Off” command connection

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When the “EPO - Emergency Power Off” has been activated, the system must be restored as follows:

 Realize the push-button “EPO - Emergency Power Off” (contact on XB / 1, 4 is closed again).

 Press the key “O” (Inverter OFF - Shut-down) on the Control Panel.

(see User Manual to Section 5.2).

In case of a Parallel System press the key “O” (Inverter OFF) on the Control Panel of each unit connected on the Parallel Bus and having its output switch Q1 closed.

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Date

Description

Done by

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, abnormal situations, etc.