GE Industrial Solutions 400- 500 Installation Guide

GE Digital Energy

Power Quality

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GE Consumer & Industrial SA

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

www.gepowerquality.com

Installation Guide

Uninterruptible Power supply

SG Series 400 & 500

400 & 500 kVA / 480Vac UL / S2

imagination at work

g

Model:

SG Series 400 & 500 UL S2

Issued by Product Document Department – Riazzino - CH

Date of issue: 06/28/2011

File name: OPM_SGT_ISG_M40_M50_2US_V021

Revision: 2.1

Identification No.: 1024191

Up-dating

Revision Concerns Date

2.0

2.1

ECN1548 - Safety Rules 02/25/2011

ECN1586 – Power connection

06/28/2011

COPYRIGHT © 2011 by GE Consumer & Industrial SA

All rights reserved.

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

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

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

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

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

Dear Customer,

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

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

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

START-UP AND COMMISSIONING

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

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

[e-mail] .

g

GE Consumer & Industrial SA

General Electric Company

CH – 6595 Riazzino (Locarno)

Switzerland

www.gepowerquality.com

Distributed in the USA by:

g

GE Digital Energy

Power Quality

2501 Pecan Street

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

E: [e-mail]

http://www.gedigitalenergy.com/ups

Your service contact:

g

GE Digital Energy

Power Quality

830 West 40th Street

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

F: 866-765-3595

E: [e-mail]

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

Preface

Congratulations on your choice of a SG Series Uninterruptible Power Supply (UPS).
It will help eliminate load disturbances due to unexpected power problem.

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

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

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

WARNING!

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

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

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

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

Safety instructions

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

Pay attention to the rectangular boxes included in the text:
They contain important information and warning concerning electrical connections and
personnel safety.

Parallel version secured with RPA

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

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Table of contents Page

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

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

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

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

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

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

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

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

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

3.3.2 Storage of battery ........................................................................................................................................................................... 11

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

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

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

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

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

3.7 ELECTRICAL WIRING...................................................................................................................................................................... 18

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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1 IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

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

- 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.

- 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).

- 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 ONLY.
INSTALLATION PERSONNEL MUST READ THIS ENTIRE SECTION BEFORE HANDLING
THE UPS AND BATTERY.

DANGER!

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

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

The qualified service person must take these precautions:

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

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

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

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

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

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

4 Align the cables on the battery terminals so that the cable lug will not contact any part of

the cabinet or rack, even if the battery is moved.

Keep the cable away from any sharp metal edges.
5 Install the battery cables in such a way that the UPS or battery cabinet doors cannot pinch them.
6 Do not connect the battery terminal to Ground.

If any battery terminal is inadvertently grounded, remove the source of the ground.

Contacting any part of a grounded battery can cause a risk of electric shock.
7 To reduce the risk of fire or electric shock, install the battery in a temperature and humidity

controlled indoor area, free of contaminants.
8 Battery system chassis ground (earth) must be connected to the UPS chassis ground (earth).

If you use conduits, this ground conductor must be routed in the same conduit as the

battery conductors.
9 Where conductors may be exposed to physical damage, protect the conductors in

accordance with all applicable codes.
10 If you are replacing the battery or repairing battery connections, shut OFF the UPS and

remove the battery fuses.

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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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2 LAYOUT

2.1 LAYOUT SG SERIES 400 & 500

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

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

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

removed protection panels

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1 Opening for top cable entry (*)

2 Opening for bottom cable

entry

(*)

3 Bus bars for Utility input and

Load output

4 Bus bars for external Battery

connection

CR Connectivity Rack

Q1 UPS output switch

Q2 Manual Bypass switch (option)

XA Terminals for 24Vdc Auxiliary

Power Supply connection

XB Terminals for EPO connection

*) Remove this panel or provide

means to capture metal filings
from cutting conduit entry holes

￭) Dual mains customer

connection bars are optional

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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.

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Fig. 3.1.1-1 UPS cabinet dimensions

UPS rating

kVA

SG Series 400 & 500

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

Dimensions SG Series 400 & 500

H

(W x D x H)

80.71 x 33.47 x 76.78 inches

2,050 x 850 x 1,950 mm

Weight SG Series 400 & 500

Weight

lbs / kg

Floor loading

lbs/sq.ft - kg/m

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

2

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3.2 DELIVERY

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

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

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

NOTE !

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

3.3 STORAGE

3.3.1 Storage of the UPS

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

It is advisable to store the UPS in its original package in a dry, dust-free room, away from chemical
substances, and with a temperature range not exceeding -13°F (-25°C) to 131°F (55°C).
In case the battery is included please refer to Section 3.3.2.

Some important functions of the UPS, such as the customized functions, are defined by parameters
stored in a RAM memory.
A small backup battery located on the Control Unit board supplies the RAM.
If the storage time of the UPS exceeds 1 year, these functions should be verified by an authorized
Service Center before putting the UPS into operation.

3.3.2 Storage of battery

When the delivery includes a maintenance free battery, keep in mind that they are subject to self­discharge and therefore you must recharge the battery.

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

The optimal temperature for Battery storage is 68°F (20°C) to 77°F (25°C) and shall never exceed the
range -4°F (-20°C) to 104°F (40°C).

Recharge stored maintenance free battery every:

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

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

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

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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. 104°F / 40°C).
Refer to Section 3.5.

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

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

NOTE !

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

The SG Series 400 & 500 UPS can radiate radio frequency energy.
Although some RFI filtering is inherent to the UPS there is no guarantee that the UPS will not influence
sensitive devices such as cameras and monitors that are positioned close by.
If interference is expected, the UPS should be moved away from the sensitive equipment.

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

Positioning of the UPS SG Series 400 & 500

Min.

20" / 500mm

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

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

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

Recommended minimum clearance between
ceiling and top of the UPS should be 20” (500 mm)
for proper cooling air exhaust.

In case of additional cabinets (external Batteries or
input, output transformers) these can be placed on

Fig. 3.4.1-1 SG Series 400 & 500 clearances

either side of the cabinet.

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Openings for input and output cable connections

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

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

Utility input
Output Load
Battery

SG Series 400 & 500
openings are provided
on the top (*) and the

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bottom (*) of the UPS
for the connection of
input and output
cables.

Pay attention to the
position of these

Utility input
Output Load
Battery

openings, when
choosing the
placement of the UPS.

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These openings are
covered with a
protective plate.

*) Please remove
the plate before drilling
any holes.

Fixing of the UPS cabinet on the floor

The UPS cabinet is free standing and normally does not require to be bolted to the floor.
The UPS cabinet can be fixed however to the floor by bolting it with the supporting blocks to the
floor. See Fig. 3.4.1-4.

1.378"
35mm

22.028"

559.5mm

Ø 0.47305"

Ø 12mm

22.658"

575.5mm

==

62.205"

1580mm

30.040"

763mm

1.378"

35mm

33.268"

845mm

2.363"

28.740"

60mm

730mm

SGSU_400-500_S2_UPS view bottom_02US

2.363"

60mm

Front side

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

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UPS

3 - 4 - 5 - 6

UPS 2

UPS 1

Fig. 3.4.1-5 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.

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 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).

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.

NOTE !

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

Read all safety instructions before proceeding with the installation.

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3.5 VENTILATION AND COOLING

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

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

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

UPS produces maximum heat dissipation while operating in Double Conversion Mode, design ventilation
or cooling system to meet heat dissipation for this operating mode. Install suitable ventilation or cooling
system to extract the heat from the UPS room.

NOTE !

Do not put anything on the top of the cabinet.

Air filtration systems could be required when the UPS operates in a dirty environment.
Contact your 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 = 0.9 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).

Losses Cooling air flow

UPS rating with options

BTU / hr kW CFM m3 / h

SG Series 400 with 5th filter

SG Series 400 with 5th & 11th filter

SG Series 400 in eBoost™ Operation Mode

SG Series 500 with 5th filter

78,499 23.0 3,949 6,709

79,864 23.4 4,018 6,825

13,652 4.0 687 1,167

99,659 29.2 5,013 8,517

SG Series 500 with 5th & 11th filter

SG Series 500 in eBoost™ Operation Mode

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101,366 29.7 5,099 8,663

17,065 5.0 859 1,459

3.6 UNPACKING

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

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

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

White color
Red color

Fig. 3.6-1 ShockWatch device

= without any anomaly

= anomaly evidence

The package of the SG Series 400 & 500 is
equipped with ShockWatch (indicator for shock),
and TiltWatch (indicator for overthrow) on the
outside.

These devices indicate an eventual shock or
overthrow during transport.

Whenever these devices show a possible
anomaly, the UPS shall not be commissioned
before consulting a “Service Center”.

Fig. 3.6-2 TiltWatch device

NOTE !

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

A damaged UPS must never be installed or connected to Utility 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.

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Transport fastening to remove

2

S

_

0

0

5

-

0

0

4

_

U

S

G

S

1

0

_

g

n

i

n

e

t

s

a

f

t

r

o

p

s

n

a

r

t

S

P

U

_

Rear side

Fig. 3.6-3 Transport fastening to remove

The chokes fitted in the UPS cabinet are supported both at the chassis.

These supports must be removed before placing the cabinet in the final location.

These supports are yellow and are indicated with an appropriate symbol on the assembly layout
drawing (see Fig. 3.6-1).

For parallel systems, the delivery also includes the bus control cables for inter­connecting the UPS modules.

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.

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3.7 ELECTRICAL WIRING

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.

3.7.1 Utility input connection

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.

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

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. 3.8.3-3.

Dual Input Configuration Rectifier & Bypass (option)

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.

Always verify that the received UPS is as per the configuration ordered.
While installing UPS dual source, shorting jumpers BR1, BR2 and BR3 should not be
present. See Fig. 3.8.3-3.

Common Input Rectifier & Bypass Dual Input Configuration Rectifier & Bypass (option)

Fig. 3.7.1-1 Common Input Rectifier & Bypass

Fig. 3.7.1-2 Dual Input Configuration Rectifier & Bypass (option)

1 = Rectifier
2 = Inverter

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3 = Automatic Bypass
4 = Manual Bypass Q2 (option)

6 = Load
5 = Utility input

7 = Battery

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.

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.

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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3.7.3 Battery over current protection and wire sizing

NOTE !

• 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.

• The remote rack mounted batteries are to be used then DC over current
protection must be provided by others.

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

• Minimum battery cable requirement is based on the current data below.

• The maximum available fault current from the battery supply is: 20kA.

• The minimum breaker voltage rating is 540V

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

SG Series 400

SG Series 500

AC Input Rectifier AC Input Bypass

F1 F3

F2

Max.

512 A 615 A 481 A 512 A 615 A 702 A

617 A 708 A 600 A 617 A 708 A 960 A

AC Input DC Input

F4

Nom. Nom. Max.

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

SG Series 400

SG Series 500

AC Input Rectifier AC Input Bypass AC Input DC Input

F1 F2 F3 F4

800 A 700 A 800 A 1,000 A

1,000 A 800 A 1,000 A 1,200 A

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

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

Maximum recommended cable size

UPS rating Rectifier Input Bypass Input DC Input AC Output GND

SG Series 400
SG Series 500

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4x500 kcmil 4x500 kcmil 4x600 kcmil 4x500 kcmil 3x500 kcmil

NEC SECTION 210-20 (A)

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

Temperature Rating of Conductor (See table 310-13)

Size

AWG

or

kcmil

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

Types

TW, UF

18
16
14
12
10

8
6
4
3
2

1
1/0
2/0
3/0
4/0
250
300
350
400
500
600
700
750
800
900

1000
1250
1500
1750
2000

Ambient

Temperature

70 – 77°F (21 – 25°C)
79 – 86°F (26 - 30°C)
88 – 95°F (31 - 35°C)

97 – 104°F (36 - 40°C)
106 – 113°F (41 - 45°C)
115 – 122°F (46 - 50°C)
124 – 131°F (51 - 55°C)

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

--- --- 18 --- --- --­20 20 25 --- --- --­25 25 30 20 20 25
30 35 40 25 30 35
40 50 55 30 40 45
55 65 75 40 50 60
70 85 95 55 65 75
85 100 110 65 75 85

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

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

CORRECTION FACTORS

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

1.08 1.05 1.04 1.08 1.05 1.04

1.00 1.00 1.00 1.00 1.00 1.00

0.91 0.94 0.96 0.91 0.94 0.96

0.82 0.88 0.91 0.82 0.88 0.91

0.71 0.82 0.87 0.71 0.82 0.87

0.58 0.75 0.82 0.58 0.75 0.82

0.41 0.67 0.76 0.41 0.67 0.76

appropriate factor below

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3.8 WIRING CONNECTION

WARNING!

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

3.8.1 Power connections

Input/output and DC connections are provided with 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.

• If the UPS is installed in such a way that the accessibility to the right side panel is reduced, field
wiring connections can be made from the front side by removing the front right side panel
protection cover/panel ( E ) as indicated in Fig. 3.8.1-1 be advised that installation performed from
the front position will give the installer reduced visibility to the terminal lugs.

• The input/output cables must be connected in clockwise phase rotation for both Bypass and
Rectifier Input Terminals if separate, taking care to avoid risk of short circuit between different poles.

• The grounding and neutral connection of the electrical system must be in accordance with local
regulations.

• In case of additional cabinets containing batteries, input/ output transformers, etc, their ground
terminals must be connected to the UPS main ground terminal.

• Once the power cables have been connected, re-install the internal safety shields and close the
cabinets by re-installing all external panels.

Torque Specifications

Lugs bolted to Buss Blades

Input / Output / Neutral / Battery and GND

UPS rating

BOLT Size

(inches)

BOLT Torque

(Lb-in)

BOLT Torque

(N-m)

SG Series 400 & 500

1/2 428 48

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CAUTION !

Panel “A, B, C and D” should never be removed or replaced with power applied to the
UPS.

This panel is in close proximity to 480V live buss bars.
Always disconnect the rectifier, bypass, load and battery sources from the UPS

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

Access to power wiring terminals for the cable connections.

S

GS

U

_

4

0

0

-

5

0

0

_

S

2

_

U

P

S

c

o

n

n

e

c

t

i

o

n

_

0

1

US

B

Top entry cables

!

Please remove the plate

before drilling any holes

C

A

) Manual Bypass switch is optional

*

) Dual mains customer connection bars are optional

Detail of the power wiring terminal for the AC input/output

Ø 0.55" / 14mm

1.75"

44.5mm

2

"

5

1

m

2

m

"

5

1

m

2

m

"

5

1

m

m

1

.

0

2

"

2

6

m

m

"

7

5

.

m

0

m

.5

4

1

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

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

• Remove the protection panel “A, B and C”.

• Remove the UPS side panel “D”.

"

7

5

.

0

m

5

.

4

1

"

.5

1

3

m

m

0

8

0

O

F

F

I ON

Q1

0

O

F

F

I ON

Q2

*

Detail of the power wiring terminal for external battery connection

m

Ø 0.55" / 14mm

Bottom entry cables

Please remove the plate

!

before drilling any holes

0.98"

25mm

1.97"

50mm

0.98"

25mm

"

9

7

.

0

"

5

7

.

1

m

m

5

.

4

m

m

0

2

D

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3.8.2 Power connection with common input utility

S

GS

U

_

4

0

0

-

5

0

0

_

S

2

_

U

P

S

co

n

n

e

ct

i

o

n

co

m

m

o

n

_

GE

_

0

1

US

PE Input Utility

PE Load

PE

PE

-

Load Neutral

Utility Neutral

L1-1

L2-1

L3-1

PE

L1

L2

+

Position of the PE bolt in case the

cable input is from the bottom of the UPS

L3

Fig. 3.8.2-1 Power connection with Common Input Utility

Use 1/2” bolts for the cable connections on INPUT / OUTPUT power wiring Bus Bars.

Load

Typical installation using

common NEMA two hole lugs

1 - INPUT UTILITY
RECTIFIER & BYPASS

Typical installation using

common NEMA two hole lugs

Cable terminations are to the Rectifier Input / Output Bus Bars as shown above.

Connect wire to the Bus Bars using appropriate tools and appropriate torque.

Torque specification for two hole lugs on Bus Bars: see Section 3.8.1.

Common Input Rectifier / Bypass

L1-1

L2-1

L3-1

N

Rectifier + Bypass Phase A

Rectifier + Bypass Phase B

Rectifier + Bypass Phase C

Utility Neutral

PE Input Utility

The interconnection bus bars BR1, BR2 and BR3 MUST REMAIN CONNECTED

3.8.3-3).

Output Load

L1

N

Load Phase A

Load Neutral

L2

PE Load

Load Phase B

Load Ground

Ground

L3

Load Phase C

(see Fig.

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

NOTE !

This UPS is only designed to operate in a wye-configured electrical system with a
solidly grounded neutral.
The UPS cannot be operated from a mid-point or end-point grounded delta supply
source.

If the Load requires a Neutral, a Bypass Source Neutral MUST BE PROVIDED.
If no Neutral Connection is available with the Bypass Input (3-wire input + ground) and the Load does
not require a Neutral, solidly connect the Output Neutral of the UPS to ground with a ground
bonding jumper.
For single module applications install the ground bonding jumper directly at the UPS output.
Cable size for this connection shall be per National Electric Code and applicable local regulations,
but not less than AWG 3/0.

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

Absolutely no Load Connection permitted to the Neutral of the output transformer.
DO NOT install both a source Neutral and a bonding jumper!

In a RPA Parallel System configuration it is most
important to connect the Neutrals of the UPS
outputs together.
The output distribution cabinet must contain a
Neutral Bus (see Fig .3.8.2-2).
If no Neutral Connection is available with the
Bypass Input (3-wire input + ground) and the Load
does not require a Neutral, solidly connect the

Output Neutral of the UPS to ground in the Output
Distribution Cabinet.
Wire Neutral Conductors from the UPS to the

output distribution cabinet (common point of
connection) and solidly connect to ground with a
ground bonding jumper.

Fig. 3.8.2-2 RPA Parallel System

Cable size for the ground bonding jumper shall be per National Electric Code and applicable local
regulations, but not less than AWG 3/0.

Attention: DO NOT INSTALL both a source Neutral and a bonding jumper.

If the UPS is equipped with an Input Bypass Transformer, the Secondary of the transformer must be
wye-configured with Neutral Solidly Grounded.
The Neutral of the Output Transformer must be connected to the wye secondary winding of the
Bypass Transformer.

eBoost™ Operation Mode

For installations intended to be operated in eBoost™ Operation Mode, the Input Neutral Conductor
must be connected from the source of supply.
An Input Neutral Conductor MUST be pulled into the UPS.
Neutral to ground bonding jumper shall NOT be installed in UPS installations intended to be
operated in eBoost™ Operation Mode.

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

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3.8.3 Power connection with dual input utility (option)

S

G

S

U

_

4

0

0

-

5

0

0

_

S2

_UP

S

c

o

n

n

e

c

ti

o

n

s

e

p

a

ra

t

e_

G

E_

0

1

U

S

PE Input Utility

PE Load

PE

PE

+

-

Load Neutral

Utility Neutral

L2-2

L2

L3-2

L1

Load

PE

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

L3

Fig. 3.8.3-1 Power connection with Dual Input Utility (option)

Use 1/2” bolts for the cable connections on INPUT / OUTPUT power wiring Bus Bars.
Cable terminations are to the Rectifier Input / Output Bus Bars as shown above.
Connect wire to the Bus Bars using appropriate tools and appropriate torque.
Torque specification for two hole lugs on Bus Bars: see Section 3.8.1.

Typical installation using

common NEMA two hole lugs

L1-1

1 - INPUT UTILITY

L2-1

RECTIFIER

L3-1

L1-2

I

T

U

T

U

S

A

NP

P

I

Y

-

B

2

Typical installation using

)

Y

n

T

common NEMA two hole lugs

I

o

L

i

t

p

o

(

S

Dual Input Configuration Rectifier / Bypass (option)

L1-1

L2-1

L3-1

Rectifier Phase A

Rectifier Phase B

Rectifier Phase C

PE Input Utility

Ground

N - Bypass

L1-2

L2-2

L3-2

Bypass Phase A

Bypass Phase B

Bypass Phase C

Bypass Neutral

For dual input configurations, a neutral conductor is required from the bypass source
only.
Always verify that the received UPS is as per the configuration ordered.
While installing UPS dual source, shorting jumpers BR1, BR2 and BR3 should not be
present. See Fig. 3.8.3-3.

Output Load

L1

N

Load Phase A

Load Neutral

L2

PE Load

Load Phase B

Load Ground

L3

Load Phase C

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

NOTE !

This UPS is only designed to operate in a wye-configured electrical system with a
solidly grounded neutral.
The UPS cannot be operated from a mid-point or end-point grounded delta supply
source.

If the Load requires a Neutral, a Bypass Source Neutral MUST BE PROVIDED.
If no Neutral Connection is available with the Bypass Input (3-wire input + ground) and the Load does
not require a Neutral, solidly connect the Output Neutral of the UPS to ground with a ground
bonding jumper.
For single module applications install the ground bonding jumper directly at the UPS output.
Cable size for this connection shall be per National Electric Code and applicable local regulations,
but not less than AWG 3/0.

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

Absolutely no Load Connection permitted to the Neutral of the output transformer.
DO NOT install both a source Neutral and a bonding jumper!

In a RPA Parallel System configuration it is most
important to connect the Neutrals of the UPS
outputs together.
The output distribution cabinet must contain a
Neutral Bus (see Fig .3.8.3-2).
If no Neutral Connection is available with the
Bypass Input (3-wire input + ground) and the Load
does not require a Neutral, solidly connect the

Output Neutral of the UPS to ground in the Output
Distribution Cabinet.
Wire Neutral Conductors from the UPS to the

output distribution cabinet (common point of
connection) and solidly connect to ground with a
ground bonding jumper.

Fig. 3.8.3-2 RPA Parallel System

Cable size for the ground bonding jumper shall be per National Electric Code and applicable local
regulations, but not less than AWG 3/0.

Attention: DO NOT INSTALL both a source Neutral and a bonding jumper.

If the UPS is equipped with an Input Bypass Transformer, the Secondary of the transformer must be
wye-configured with Neutral Solidly Grounded.
The Neutral of the Output Transformer must be connected to the wye secondary winding of the
Bypass Transformer.

eBoost™ Operation Mode

For installations intended to be operated in eBoost™ Operation Mode, the Input Neutral Conductor
must be connected from the source of supply.
An Input Neutral Conductor MUST be pulled into the UPS.
Neutral to ground bonding jumper shall NOT be installed in UPS installations intended to be
operated in eBoost™ Operation Mode.

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

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

Notices for installation

S

G

S

U_

4

0

0

-

5

0

0

_

S

2

_

UP

S

B

R

1

-

2

-

3

_

GE

_

0

1

L1-1

PE

L3-1

L2-1

BR1

L1-1

BR2

BR3

BR1, BR2 and BR3
MUST BE REMOVED

!

in case of dua l input utility

BR2

BR3

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

For separate Bypass and Rectifier input configuration (option), the AC Bus Bars BR1, BR2 and BR3
MUST BE REMOVED

.

BR1

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

3.8.4 Battery and External Battery Breaker connection

S

G

S

U

_

4

0

0

-

5

0

0

_

S

2

_

U

P

S

c

o

n

n

e

c

t

i

o

n

b

a

t

t

e

r

y

_

G

E

_

0

1

U

S

PE

Typical installation using

common NEMA two hole lugs

+

-

Fig. 3.8.4-1 Power connections Battery

Use 1/2” bolts for the cable connections on BATTERY power wiring Bus Bars.
Battery Cable Terminations are to the Positive and Negative Terminals as shown above.

Connect wire to the Bus Bars using appropriate tools and appropriate torque.
Torque specification for two hole lugs on Bus Bars: see Section 3.8.1.

Battery connection

+

-

PE

Positive pole of the battery

Negative pole of the battery

Battery ground

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 (steel) conduit!

External Battery Breaker Release

For connection or disconnection of the
Battery an external breaker CB with UVR
is required.

The UVR of the external breaker must be
connected to terminal XA (see Fig. 4.1.7-1).

The release signal will allow, after the
Rectifier soft-start, the manual closure of

Fig. 3.8.4-2 External battery breaker connection

the breaker.

In either case, fuses or breaker, an auxiliary contact must signalize the closure of breaker or fuse
holder to Input channel 1 of the P4 - Customer Interface (see Section 4.1). When multiple strings /
cabinets are used, the auxiliary contacts from the breakers are to be connected in series.
Contact must be open with Battery disconnected (Normally Open).

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

3.8.5 Interface to External Bypass for single unit

If the UPS system is equipped with an External Maintenance Bypass Switch, connect the NO (normally
open) voltage free auxiliary contact from the External Bypass Switch to X4 - 1, 2 of P27 – IM0108 -

Interface for External Bypass inserted in the Connectivity Rack.

When this NO (Normally Open) contact closes, the Inverter Output Contactor K7 opens and the Load
transfer to Inverter will be inhibited.

SG Series 400 & 500 has to be
interfaced to the External Bypass
Auxiliary Contacts (NO) for safety
reasons.
This will prevent contactor K7
from closing when the external
bypass breaker is on.

The connections shown in the
diagram are mandatory.

Fig. 3.8.5-1 Interface to External Bypass for single unit

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

In a parallel system, this connection must be made between each UPS to a
separate AUX contact of the External Maintenance Bypass Switch.

Fig. 3.8.6-1 Connections to External Bypass switch in case of RPA Parallel System

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

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

NOTE !

For systems intended to be operated in eBoost™ Operation Mode, the
installation shall be protected with suitable surge protection devices (SPDs) on
the AC bus feeding the UPSs.

Please contact your Service Center for more information.

NOTE !

If an emergency generator set supplies the UPS in case of Mains Failure, and the
system is intended to be operated in eBoost™ Operation Mode, eBoost
operation shall be prevented during generator operation.

This can be accomplished by either installing a “Generator ON” signal (refer to

Section 4.1.4) or an “eBoost/IEMi control” signal (refer to Section 4.1.6).

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

3.9 RPA PARALLEL SYSTEM CONNECTION

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.

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 (9) is equal for each unit (a+b
= c+d = e+f = g+h = i+l = m+n). Tolerance: +/- 10%.

The RPA Cable Saver option introduces a Bypass Inductor in every UPS module, reducing the influence of
external conductor length on bypass current sharing.
The RPA Cable Saver option may extends the cable length tolerance to +/-25% for runs not exceeding
160 feet (49m).
For details of the RPA Cable Saver option and further recommendations on power wiring and system
connections, please contact your Service Center, which will help you find cost effective solutions.

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

NOTE !

It is strongly recommended that no transformers, automatic circuit breakers or
fuses be inserted between the unit’s output and the Load common bus bars.

However, it is recommended that a disconnection or isolation switch be installed in
order to totally isolate a unit if needed.

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

1

Rectifier

=

2

Inverter

=

3

Automatic Bypass

=

4

Manual Bypass (option)

=

5

Input Utility Distribution

=

6

Unit Output Load

=

7

External Battery fuse or MCB

=

8

External Battery

=

Common bus bar and Output

9

=

Load Distribution

= UPS Number 1

c

= UPS Number 2

2

= UPS Number 3

3

= UPS Number 4

4

Fig. 3.9.1-1 Power wiring of RPA Parallel System

= UPS Number 5

5

=

6

UPS Number 6

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

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.

NOTE !

Under no circumstance should the control bus cable connecting JA (1/2/3/4/5) and

JB (1/2/3/4/5) be connected or disconnected after the system has been powered On.

JP3

JP3

JP4

JP1

JA

JP2

IM 0048

JP2 JP1

UPS 3

JP4

JB2

JA2

JA3

JB3

Next parallel

UPS 1 UPS 2

JP3

JP4

JP3

JP4

JP1

JA

JP2

IM 0048

JB

JP1

JP2

SGSU_400-500_S2_RPA-IM0048_01US

JB1

JA1

JP3

JP4

JB1

JA1

JA2

JB2

JB

JP3

JP4

JP1

JA

JP2

IM 0048

JB

JP1JP2

unit 4, 5, 6

JA3 + JB3JA2 + JB2JA1 + JB1

Fig. 3.9.2-1 RPA System - Control bus connection

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

JB

JA

JP2

JP3

JP3

JP4

JP1

JP2

JP4

JA1

IM 0048

JB1

JP1

SGSU_400-500_S2_RPA-IM0048_02

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

.

JB

JA

JP2

JP3

JP3

JP4

JP1

JP2

IM 0048

JP4

JP1

JA1

JA2

JB2

JB1

SGSU_400-500_S2_RPA-IM0048_03

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).

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

3.9.3 Control bus cable location

t

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.

0

O

F

F

I ON

Q1

0

O

F

F

I ON

Q2

S

G

S

_

4

0

0

-

5

0

0

_

S

2

_

R

P

A

c

o

n

t

r

o

l

b

u

s

c

a

b

l

e

_

0

1

U

S

Access to the control bus
connection.

The control bus connection
between parallel units must be
made on the electronic module
(P34 – Bus Interface) situated at
the inside of the UPS door.

2

5
6

7
8

13112
14

9

22

21

164315
17

18
19
20

10
11

N

ext

P

a

r

a

l

l

e

l

U

n

i

Fig. 3.9.3-1 View electronic module on intermediate unit

Control bus cables connection.

• Plug the cables JA

S

U

2

0

_

e

l

b

ca

s

u

b

l

o

r

JA

A

JA1
JA2

t

n

o

c

A

P

R

_

2

S

_

0

0

5

-

0

0

4

_

U

S

G

S

(1/2/3/4/5) and JB
(1/2/3/4/5) 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).

JA1

• Fix both cables JA

JA2

JB

B

Next parallel unit

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

(1/2/3/4/5) and JB
(1/2/3/4/5) to parallel bus

socket connecting the cable
shield to ground by means
the cable clamps “A“.

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

S

G

S

U

_

4

0

0

-

5

0

0

_

S

2

_

R

P

A

c

o

n

t

r

o

l

b

u

s

c

a

b

l

e

_

0

3

U

S

JA

JA1

JB1

JB

2131
3

4

5
12
14

15

16

U

P

S

1

0

O

F

F

I ON

Q1

JA

JA1
JA2

0

O

F

F

I ON

Q2

6
7
8

9
21

22
17
18

2019

10

11

JB2

JB1

JB

JB1

JA1

0

O

F

F

I ON

Q1

0

O

F

F

I ON

Q2

1
2
3
4

5
7186

8

12
14

9

13

21

15

22

16
17
19

20
10
11

JB2

N

e

x

t

P

ar

U

P

S

2

JA2

U

nit

al

3

,

4

,

5

,

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 and JB-1/2/3/4/5 inside the UPS cabinets in the position
illustrated in the drawing.

NOTE !

le

l

6

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 and JB-1/2/3/4/5 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.

Modifications reserved Page 36/41

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

4 CUSTOMER INTERFACE

r

4.1 CUSTOMER INTERFACE

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

Suitable for JUMP protocol

Pin 2: TX (out)

12 13

14

15

16

17

18

19

20

21

22

21

1

2

3

4

5

6

7

8

9
10

11

JP3

J5

X1

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

J2/1, 2, 3
J2/4, 5, 6
J2/7, 8, 9
J2/14, 15, 16
J2/17, 18, 19
J2/20, 21, 22

Signals on terminals X1 and on connector J2 are in parallel and
therefore not separated galvanically from each other.

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

NO, C, NC Utility Failure
NO, C, NC Load on Inverter
NO, C, NC Stop Operation
NO, C, NC Load on Utility
NO, C, NC General Alarm
NO, C, NC Acoustic Alarm

XB - Terminals for EPO connection (see Section Section 4.1.8)

J2

14

1

9

J3

1

J4

Fig. 4.1-1 Customer interface

XB/1, 4 or J2/12, 25
Note: to enable this function, remove cable short-circuiting XB / 2 – 3 (see

Section 4.1.8) and the Jumper JP3 on P4 – Customer Interface.

X1 – Output signals on voltage free contacts - terminals

X1/1, 2, 3
X1/4, 5, 6
X1/7, 8, 9
X1/12, 13, 14
X1/15, 16, 17
X1/18, 19, 20

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

NO = Normally Open

NC EPO (Emergency Power Off) See Section 4.1.8

NO, C, NC Utility Failure
NO, C, NC Load on Inverter
NO, C, NC Stop Operation
NO, C, NC Load on Utility
NO, C, NC General Alarm
NO, C, NC Acoustic Alarm

The connectors J4 and J5 can be used for additional 3-ph SNMP/WEB plug-in adapter or an additional Custome
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 27
signals can be selected from the display, entering with

the appropriate password.

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- Inve.rter-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

EPO (Emergency Power Off)

26­27- eBoost/IEMi mode

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”

8 – eBoost/IEMi control

Voltage free contacts: Max. DC / AC: 24V / 1.25A

Pin 3: RX (in) Pin 5: GND

(default Parameter RL=1)
(default Parameter RL=3)
(default Parameter RL=5)
(default Parameter RL=2)
(default Parameter RL=4)
(default Parameter RL=6)

(default Parameter RL=1)
(default Parameter RL=3)
(default Parameter RL=5)
(default Parameter RL=2)
(default Parameter RL=4)
(default Parameter RL=6)

Input contacts

Programmable (default = RL1)
Programmable / Generator ON (NO) (def. = RL2)

C = Common NC = Normally Closed

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

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

4.1.1 Serial Port J3

S

G

S

_

4

0

0

-

5

0

0

_

C

u

st

o

m

e

r

i

n

t

e

r

f

a

c

e

J3

_

0

1

J3

Fig. 4.1.1-1 Serial port J3

The serial port J3 - RS232 is enabled
on all the units of the parallel system.

4.1.2 Output free potential contacts

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 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:

X1 / 1, 2, 3

X1 / 4, 5, 6

X1 / 7, 8, 9

X1 / 12, 13, 14

X1 / 15, 16, 17

X1 / 18, 19, 20

or

or

or

or

or

or

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

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

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

J2 / 14, 15, 16 (NO, C, NC) Load on Utility

J2 / 17, 18, 19 (NO, C, NC) General Alarm

J2 / 20, 21, 22 (NO, C, NC) Acoustic Alarm

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.

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”.

Modifications reserved Page 38/41

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

4.1.3 Programmable input free contacts

Some programmable UPS functions (indicated in Section 8.1), can be activated by closing an external contact, if
connected, on:

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

Additionally, when the “Generator ON” input contact is closed, the UPS will inhibit eBoost™ Operation Mode and
revert to double-conversion operation.

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

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.

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.

4.1.6 eBoost/IEMi control signal

The UPS operation in either eBoost or IEMi operating modes can be controlled via an NO (Normally Open) contact by
installing the “eBoost/IEMi control” signal, routed to the programmable function contacts (see Fig. 4.1-1 / X1 and J2).
The Parameter for the activation of such function is password protected. Call the nearest Service Center for its
activation.
When this contact closes, eBoost or IEMi operation is inhibited.
This function is particularly useful for controlling eBoost or IEMi operation following critical conditions on either the
load side or the input utility, including generator operation when the “Generator ON” signal has not been installed.

When using the “eBoost/IEMi control” function on the programmable user relays of the
customer interface X1/J2 terminals in a parallel system, a separate NO (Normally Open)
contact must be connected to each individual unit.

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

Terminals XA

1

0

_

A

X

s

l

a

n

i

m

r

e

T

_

0

0

5

-

0

0

4

_

S

G

SGS_400-500_UPS_XA-XB_01

S

XA-1 24Vdc
XA-2 GND

XA-3 Positive (+)

1

2

3

4

1

2

3

4

1

2

3

4

XA

XB

XA-4 Negative (-)

Fig. 4.1.7-1 Terminals XA for connection 24Vdc and Battery Breaker Release

Modifications reserved Page 39/41

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

Battery Breaker Release Voltage

Battery Breaker Release Voltage

4.1.8 EPO (Emergency Power Off) Input contact

BE AWARE:

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

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 - Interface Customer.

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.

1

2

3

4

1

2

3

4

XA

XB

Terminals XB

_0

XB

s

l

a

n

i

m

er

_T

500

S_400-

G

S

SGS_400-500_UPS_XA-XB_01

When opened, this contact causes the immediate opening of the

Bypass Contactors K6 and K7, Rectifier input contactor, K4,
External Battery Breaker (if present) as well as the shut-down of
the Rectifier and the Inverter and the Static-Switch.

1

S

G

S

_

4

0

0

-

5

0

0

_

C

u

s

t

o

m

e

r

i

n

t

e

r

f

a

c

e

E

P

O

_

0

1

1

2

3

4

Fig. 4.1.8-1 Terminals XB for connection EPO

Fig. 4.1.8-2 Customer interface

JP3

J2

NOTE ! This procedure could imply a Load shut-down.

NOTE !

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

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.

When the EPO has been activated, the system must be restored as follows:

• Press the push-button EPO (contact on X7 / 1, 2 is closed again).

• Press the key “O” (inverter off – see Section 5.2 – Operating Manual) on the control panel.

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

Modifications reserved Page 40/41

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

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.

Date Description Done by

Modifications reserved Page 41/41

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