GE Industrial Solutions 10 – 20 – 30 – 40 kVA Installation Guide

GE Digital Energy
Power Quality
SGT5000_030-040_UPS_GE_0 1
Manufactured by:
GE Consumer & Industrial SA General Electric Company CH – 6595 Riazzino (Locarno) Switzerland T +41 (0)91 / 850 51 51 F +41 (0)91 / 850 51 44
www.gedigitalenergy.com
Installation Guide
Uninterruptible Power supply
Digital Energy™
10 – 20 – 30 – 40 kVA
480 VAC UL / Series 0
GE imagination at work
Model:
SG Series 10, 20, 30 & 40 kVA / Series 0
Issue by Product Document Department – Riazzino - CH
Date of issue: 11/12/2008
File name: OPM_SGS_ISG_10K_40K_0US_V040
Revision: 4.0
Identification No.:
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
COPYRIGHT © 2008 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.
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OPM_SGS_ISG_10K_40K_0US_V040.doc Installation Guide SG Series 10 –20 – 30 - 40 kVA
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 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 use 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 pqservices@ge.com
g
GE Consumer & Industrial SA
General Electric Company
CH – 6595 Riazzino (Locarno)
Switzerland
www.gedigitalenergy.com
Distributed in the USA by:
g
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
Your service contact:
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OPM_SGS_ISG_10K_40K_0US_V040.doc Installation Guide SG Series 10 –20 – 30 - 40 kVA
Preface
Congratulations on your choice of a SG Series 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 kVA 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.
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Table of contents Page
1
SAFETY RULES ................................................................................................................................................. 6
2 LAYOUT ............................................................................................................................................................ 9
2.1 LAYOUT SG Series 10 & 20 kVA .......................................................................................................................................................9
2.2 LAYOUT SG Series 30 & 40 kVA .................................................................................................................................................... 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 kVA......................................................................... 27
3.8.3 Power connection with common input utility of SG Series 30 & 40 kVA......................................................................... 28
3.8.4 Power connection dual input utility of SG Series 10 & 20 kVA............................................................................................. 29
3.8.5 Power connection dual input utility of SG Series 30 & 40 kVA............................................................................................. 31
3.8.6 Battery connection of SG Series 10 & 20 kVA ............................................................................................................................. 33
3.8.7 Battery connection of SG Series 30 & 40 kVA ............................................................................................................................. 34
3.8.8 Setup for SG Series 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 Signalling (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) input contact................................................................................................................................... 44
5 NOTES............................................................................................................................................................. 45
5.1 NOTES FORM........................................................................................................................................................................................ 45
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1 SAFETY RULES

SAVE THESE INSTRUCTIONS
This manual contains important instructions for models SG Series 10 – 20 –30 – 40 kVA that should be followed during installation and maintenance of the UPS and battery.
- Move the UPS in an upright position in its original package to the final destination room. To lift the cabinets, use a forklift or lifting belts with spreader bars.
- Check for sufficient floor and elevator loading capacity.
- Check the integrity of the UPS equipment carefully. If you notice visible damage, do not install or start the UPS. Contact the nearest Service Center immediately.
- WARNING! RISK OF ELECTRICAL SHOCK: Do not remove covers, there are no user serviceable parts inside.
- 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.
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 95°F (35°C).
- Optimal battery life is obtained if the ambient temperature does not exceed 77°F (25°C).
- It is important that air can move freely around and through the unit. Do not block the air vents.
- Avoid locations in direct sunlight or near heat sources.
- Store the UPS in a dry location; storage temperature must be within -13°F (-25°C) to 131°F (+55°C).
- If the unit is stored for a period exceeding 3 months, the battery must be recharged periodically (time depending on storage temperature).
- 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.
GENERAL
STORAGE
BATTERY
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Safety instructions when working with battery
EXTERNAL BATTERY MUST BE INSTALLED AND CONNECTED TO THE UPS BY QUALIFIED SERVICE PERSONNEL. INSTALLATION PERSONNEL MUST READ THIS ENTIRE SECTION 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 unauthorised 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.
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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.
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OPM_SGS_ISG_10K_40K_0US_V040.doc Installation Guide SG Series 10 –20 – 30 - 40 kVA

2 LAYOUT

2.1 LAYOUT SG Series 10 & 20 kVA

Fig. 2.1-1 SG Series general view
SGT5000_010-020_UPS_GE_02
SGT5000_010-020_UPS_GE_03
Fig. 2.1-2 SG Series general view with open doors
1 4
1 Opening for top cable entry
SGT5000_010-020_UPS_GE_04
2 Opening for bottom cable entry
3 Terminals for Utility input and
load output
3
4 Terminals for external Battery
connection
5
5 Battery Shelf
CR Connectivity Rack
XA Terminals for 24VDC Auxiliary
CRXA XB
Fig. 2.1-3 SG Series general view with optional 5
and removed protection panels
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2
th
harmonic filter
Power Supply connection
XB Terminals for EPO connection

2.2 LAYOUT SG Series 30 & 40 kVA

Fig. 2.2-1 SG Series general view
SGT5000_030-040_UPS_GE_02
Q1
Q2
ON
ON
OFF
OFF
SGT5000_030-040_UPS_GE_03
Fig. 2.2-2 SG Series general view with open doors
1 4
SGT5000_030-040_UPS_GE_04
ON
ON
OFF
OFF
3
2XBXA CR
Fig. 2.2-3 SG Series 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
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3 INSTALLATION

3.1 TRANSPORT

Forklift
Crane
Fig. 3.1-1 UPS cabinets moving

3.1.1 Dimensions and weight

Transport UPS only in upright position!
The UPS is packaged on a pallet suitable for handling with a forklift.
Pay attention to the center of gravity.
The UPS must be moved in upright position. Do not tilt cabinets more than +/- 10° during handling.
Move the UPS in it’s original package to the final destination site.
Do not stack other packages on top: This could damage
the UPS.
If the UPS must be lifted by crane, use suitable lifting straps and spreader bars. Note of the center of gravity marked on the package.
Take all necessary precautions to avoid damage to the cabinet while hoisting the UPS.
NOTE !
Check for sufficient floor and elevator loading capacity.
SGT5000_030-040_UPS dimensi o ns_GE_01US
H
Dimensions SG Series 10 - 20 - 30 - 40 kVA
(W x D x H)
26.78 x 31.50 x 70.90 inches
680 x 800 x 1,800 mm
D
Fig. 3.1.1-1 UPS cabinet dimensions
W
Weight SG Series 10 - 20 - 30 - 40 kVA
UPS without battery UPS with battery
UPS rating
Weight
lbs / kg
SG Series 10 kVA SG Series 20 kVA SG Series 30 kVA SG Series 40 kVA
P.S.: Weights including the 5th harmonic filter.
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OPM_SGS_ISG_10K_40K_0US_V040.doc Installation Guide SG Series 10 –20 – 30 - 40 kVA
735 / 333 126 / 613 1,121 / 508 192 / 934 763 / 346 131 / 637 1,169 / 530 200 / 975 970 / 440 166 / 809
1,147 / 520
Floor loading
lbs/sq.ft - kg/m
196 / 956
2
Weight
lbs / kg
– –
Floor loading
lbs/sq.ft - kg/m2

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).
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).
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)
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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. 95°F / 35°C). Refer to Section 3.5.
Check for sufficient floor load capacity before installing the UPS and the battery. Refer to Section 3.1.1.
For battery installation follow the local codes and the recommendation of the battery supplier.
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 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 (120 VAC) should be provided near the UPS for connection of power tools, test equipment or connectivity devices. This outlet must be grounded.
Positioning of the UPS SG Series
Min.
16" / 400mm
SGT5000_030-040_UPS disposition_GE_01
Fig. 3.4.1-1 SG Series 10 – 20 - 30 - 40 kVA 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.
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Openings for input and output cable connections
Utility input Output Load
S
U
01
_
op
t
w
e
i
v
S
P
U
0_
2
0
0-
01
0_
00
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S
2
.
7
6
2
6
.
7
8
"
6
8
0
m
m
"
7
0
m
m
1
4
0
Battery
"
"
6
0
0
.
5
.
9
m
1
3
m
m
0
m
3
0
2
0
"
6
m
0
.
m
9
0
3
.
5
8
"
m
m
2
8
Battery
Utility input Output Load
S
U
1
0
_
p
o
t
w
e
i
v
S
P
U
0_
4
0
-
0
3
0
_
0
00
5
T
G
S
"
8
.7
3
1
m
50
2
.
7
6
2
6
.
7
8
"
6
8
0
m
m
"
7
0
m
m
1
.
5
8
.3
"
4
4
0
0
m
m
1
1
3
3"
m
m
"
0
5
.
1
3
m
m
m
0
0
8
Fig. 3.4.1-2 Opening on top of the cabinet for input and
cables of SG Series 10 & 20 kVA
Utility input Output Load
S
U
1
0
_
m
o
t
t
o
b
w
e
i
v
S
P
U
_
0
4
0
-
0
3
0
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0
0
0
5
T
G
S
2
.
7
6
2
6
.
7
8
6
8
0
m
m
"
7
"
0
m
1
.
m
9
7
"
5
0
m
m
"
9
0
.
7
m
m
0
8
1
"
8
8
.
7
m
m
0
0
2
Fig. 3.4.1-4 Opening on the bottom of the cabinet for input and
output cables SG Series 10 - 20 - 30 - 40 kVA
Positioning of the UPS cabinet
SG Series 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.
The UPS cabinet is free standing and normally does not require to be bolted to the floor. The UPS cabinet can be fixed
SGT5000_010-020_UPS fixing_01
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. 3.4.1-3 Opening on top of the cabinet for input and
cables of
SG Series 30 & 40 kVA
SG Series openings are provided on the top and the bottom of the UPS for the connection of input and output cables.
"
0
5
.
1
3
m
m
0
0
8
Pay attention to the position of these openings, when choosing the placement of the UPS. These openings are covered with a protective plate.
Fig. 3.4.1-4 Bolts for the regulation of the cabinet
0 - 360°
Fig. 3.4.1-5 Fixing of the UPS cabinet on the floor
To lift
To lower
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