GE Industrial Solutions SG Series UL LISTED BATTERY CABINETS User Manual

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GE Digital Energy

Power Quality

Installation – Operation – Maintenance Guide

UL LISTED BATTERY CABINETS

Manufactured by:

GE Digital Energy

Power Quality 2501 Pecan Street Bonham, Texas 75418 USA T 903 640 7900

www.gedigitalenergy.com/ups

Uninterruptible Power supply

Digital Energy™

SG Series

imagination at work

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Model:

SG Series / Series 1

Date of issue: 05/05/2008

File name: OPM_SGS_XXU_ISG_BAT_XUS_V020

Revision: 2.0

Identification No.:

Up-dating

Revision Item(s) Date

2.0 Figures 1-4 updated June 26, 2008

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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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-Operating- Maintenance Manual, which contains all the necessary information and describes all you need to know about the use of the UPS. Thank you for choosing GE!

Manufactured by:

Distributed in the USA by:

Your service contact:

GE Digital Energy

Power Quality

2501 Pecan Street

Bonham, Texas 75418 USA

T 903 640 7900

www.gedigitalenergy.com/ups

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Bonham, Texas 75418 USA

www.gedigitalenergy.com/ups

GE Digital Energy

Power Quality

2501 Pecan Street

T 903 640 7900

F 903 640-0533

2500 Discovery Blvd.

Rockwall, Texas 75032 USA

T 1-800-637-1738 - option #3

Emergency 1 800 637 1738 –

www.gedigitalenergy.com/ups

GE Digital Energy

Power Quality

F 866 765 3595

option # 7

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Table of contents Page

BATTERY SAFETY PRECAUTIONS.............................................................................................................................. 6

2 PREPARING THE SITE ................................................................................................................................................. 8

2.1 ENVIRONMENT CONSIDERATIONS...............................................................................................................................................................8

2.2 INSPECTING AND UNPACKING THE BATTERY CABINET ......................................................................................................................8

2.3 PREPARING FOR WIRING THE BATTERY SYSTEM....................................................................................................................................8

3 BATTERY CABINETS.................................................................................................................................................... 9

3.1 BATTERY STORAGE..............................................................................................................................................................................................9

3.2 INSTALLATION.......................................................................................................................................................................................................9

3.3 REINSTALLATION..................................................................................................................................................................................................9

3.4 ENVIRONMENT......................................................................................................................................................................................................9

3.5 SERVICE CLEARANCE..........................................................................................................................................................................................9

3.6 CABLES.....................................................................................................................................................................................................................9

3.7 GROUNDING....................................................................................................................................................................................................... 10

3.8 REMOTE BATTERY CABINETS/RACKS........................................................................................................................................................ 10

3.9 BATTERY WIRING ..............................................................................................................................................................................................10

4 COMPLETING THE INSTALLATION CHECKLIST ....................................................................................................11

5 OPERATION & MAINTENANCE................................................................................................................................ 12

5.1 BATTERY CABINETS.......................................................................................................................................................................................... 13

5.2 VOLTAGE RECORDS .........................................................................................................................................................................................13

5.3 BATTERY CELL TERMINALS............................................................................................................................................................................ 13

5.4 BATTERY OPERATION ...................................................................................................................................................................................... 14

5.5 PROTECTION EQUIPMENT CONNECTIONS............................................................................................................................................. 14

5.6 WARRANTY.......................................................................................................................................................................................................... 15

6 APPENDIX .................................................................................................................................................................. 16

7 TABLES .......................................................................................................................................................................17

8 FIGURES .....................................................................................................................................................................19

9 INSTALLATION CHECKLIST ..................................................................................................................................... 31

ADDRESS ________________________________________________................................................................................................... 32

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1 BATTERY SAFETY PRECAUTIONS

This battery cabinet contains its own energy source. The internal wiring and output terminals may carry live voltage even when the UPS is not connected to an AC source.

- To reduce the risk of fire or electric shock, install the battery cabinet(s) in a temperature and humidity controlled, indoor environment, free of conductive contaminants. Ambient temperature must not exceed 40°C (104°F). Do not operate near water or excessive humidity (95% max non-condensing). The system is not intended for outdoor use.

- Ensure all DC power is disconnected from the UPS before performing installation or service.

- Keep the battery cabinet(s) door(s) closed to ensure proper cooling, airflow and to protect personnel from

dangerous levels of voltages inside the unit.

- Do not install the battery cabinet(s) close to gas or electric heat sources.

- The operating environment should be maintained within the parameters stated in this manual.

- Keep surroundings uncluttered, clean, and free from excess moisture.

- Observe all DANGER, CAUTION, and WARNING notices affixed to the inside and outside of the equipment.

Installation of batteries should be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.

Be sure to observe the grounding recommendations when installing batteries. When replacing batteries, use the same number and type of batteries from the same manufacturer unless all batteries are being replaced at the same time.

! CAUTION

Lead-acid batteries contain hazardous materials. Batteries must be handled, transported and recycled in accordance with federal, state and local regulations. Because lead is a toxic substance, lead-acid batteries must be recycled.

Do not open or mutilate the batteries. Released electrolyte is harmful to the skin and eyes, and may be toxic.

Do not dispose of batteries in a fire. The battery may explode.

Do not install any batteries that are cracked, leaking or show other signs of damage. Contact GE Service at 1800-637-1738 (option #3)

Batteries can present a risk of electrical shock and high short circuit current. The following precautions should be observed when working on batteries:

• Remove watches, rings and other metal objects.

• Use tools with insulated handles.

• Wear rubber gloves and boots.

• Do not lay tools or metal parts on top of batteries.

• Disconnect charging source prior to connecting or disconnecting battery terminals.

• Determine if battery is inadvertently grounded. If inadvertently grounded, remove source of ground. Contact

with any part of a grounded battery can result in electrical shock. The likelihood of such shock will be reduced if such grounds are removed during installation and maintenance.

Lead-acid batteries can present a risk of fire because they generate hydrogen gas. The following procedures should be followed:

• DO NOT SMOKE when near batteries.

• DO NOT cause flame or spark in battery area.

• Discharge static electricity from body before touching batteries by first touching a grounded metal surface.

• After replacing batteries in the cabinet, replace the retaining straps that hold them in place on the shelves.

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This will limit accidental movement of the batteries and connectors should the cabinet ever need to be repositioned or relocated. Regular maintenance of the batteries is an absolute necessity. Battery voltage and connection resistance should be periodically inspected. Strictly follow the procedures outlined in the battery manufacturer’s manual, available on the manufacturer’s Web site.

NOTE

Do not use cleaners on the batteries. Solvents can make the battery cases brittle. Use only a dry cloth or a cloth moistened in water.

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2 PREPARING THE SITE

For the battery system to operate at peak efficiency, the installation site should meet the environmental parameters outlined in this manual. If the battery system is to be operated at an altitude higher than 1500m (5000 ft), contact a GE Sales Representative for important information about high altitude operation.

The GE SG Series battery cabinets use convection cooling to regulate internal component temperature. Air inlets are on the front and the back of the cabinet and the outlets are on the top. Clearance must be allowed in front (36” minimum), and top (18” minimum) each cabinet for proper air circulation.

2.1 ENVIRONMENT CONSIDERATIONS

The life of the battery system is adversely affected if the system is not;

- Installed on a level floor suitable for computer or electronic equipment.

- Installed in a temperature and humidity controlled indoor area free of conductive contaminants.

Failure to follow guidelines may void your warranty.

2.2 INSPECTING AND UNPACKING THE BATTERY CABINET

The cabinet is shipped bolted to a pallet, see Figure 4, and protected with outer protective packaging material.

The battery cabinet is extremely heavy. If unpacking instructions are not closely followed, the cabinet may tip and cause serious injury or death.

1. Carefully inspect the outer packaging for evidence of damage during transit. Do not install a damaged

cabinet. Report any damage to the carrier and contact a GE Sales Representative immediately.

2. Use a forklift or pallet jack to move the packaged cabinet to the installation site, or as close as possible,

before unpacking. Insert the forklift or pallet jack‘s forks between the pallet supports on the bottom of the unit.

NOTE

Verify that the forklift or pallet jack is rated to handle the weight of the cabinet, (see Table 1).

Do not tilt the battery cabinet more than 10° from vertical or cabinet may tip over.

3. Set the pallet on a firm, level surface, allowing a minimum clearance of 3m (10 ft) on each side for removing

the cabinet from the pallet.

4. Remove the protective covering from the cabinet.

5. Remove the packing material, and discard or recycle them in a responsible manner.

6. After removing the protective covering, inspect the contents for any evidence of physical damage, and

compare each item with the Bill of Loading. If damage has occurred or shortages are evident, contact a GE Sales Representative immediately to determine the extent of the damage and its impact upon further installation.

NOTE

While waiting for installation, protect the unpacked cabinet from moisture, dust and other harmful contaminants. Failure to store and protect the battery cabinet properly may void your warranty.

2.3 PREPARING FOR WIRING THE BATTERY SYSTEM

The electrical contractor supplies power and control wiring for battery cabinets. Wiring requirements, for battery cabinets installed separate from the UPS cabinet, including the minimum AWG size of external wiring, can be found on Table 3.

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3 BATTERY CABINETS

Optional battery cabinets are available from GE and other qualified vendors. Consult GE Sales representative for more information.

SG series battery cabinets are either 44” (111.76cm) or 27” (68.58cm) wide and both are 31.9” (81.03cm) deep and 70.69” (179.55cm) high. See Figures 1 & 2.

The same model battery cabinet may be paralleled in multiple cabinet strings for additional capacity. Battery capacity (in minutes) at your installation will depend on the number and the model of the battery cabinets and the amount of critical load on the UPS.

3.1 BATTERY STORAGE

The batteries can be stored indoors in a temperature-controlled environment, for up to six months without any appreciable deterioration. Self-discharge rate of the batteries is approximately 3% per month when the batteries are stored in temperatures of 59°F to 77°F (15-25°C). If the battery cabinet must be stored for longer than six months, contact GE Sales Representative. The battery cabinet should never be stored outdoors or on a loading dock.

3.2 INSTALLATION

Battery cabinets must be installed as shown in the system drawings. The front access- only-design eliminates side and rear service clearance requirements. The battery shelves ship disconnected for safety and need to be reconnected before the system is put into service.

3.3 REINSTALLATION

If at any time it becomes necessary to move the battery cabinet to another location, contact GE Service Representative to inspect the internal battery at 1-800-637-1738 option 3

3.4 ENVIRONMENT

Locate the battery cabinet in a clean, dry environment. Recommended temperature range for optimum performance and lifetime is 68°F to 77°F (20-25°C).

3.5 SERVICE CLEARANCE

Allow front access to the battery cabinet at all times for maintenance and servicing. Electrical codes require that the battery cabinet be installed with no less than 3 ft. (1m) of clearance at the front of the cabinet when operating. Side and rear panels do not require service clearance.

3.6 CABLES

Multiple battery cabinets wired in a “home-run” configuration. Cables for this setup may be run between parallel battery cabinets through the wire-ways in the top of the cabinets, eliminating the need for external conduit runs. See Figures 5 & 6 for wire routing and for connection of the system. Route cables before moving cabinets into their final position. Low voltage control wiring must be kept separate from the power wiring. Remove top panels for access. No top or bottom entry cables are required, except for remotely located cabinets, which require conduits. Refer to your submittal drawings for instructions on wiring cabinets in parallel.

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3.7 GROUNDING

The battery cabinets have ground studs. Use an equipment-grounding conductor to connect the lugs of the cabinets together and to connect the cabinets to the ground bus bar in the UPS module. See Figure 5.

3.8 REMOTE BATTERY CABINETS/RACKS

When batteries cabinets/racks other than GE’s are used, a remote battery disconnect switch with over-current protection is required to be installed per the National Electrical Code. Over-current protection is needed also if the battery cabinets are separated from the UPS. See the over-current protection ratings of the battery cabinets to calculate the applicable circuit breaker size. Contact your GE Sales Representative for more information.

1. Verify battery area has adequate ventilation and operating temperature complies with manufacturer’s

specification. If installed, vented lead-acid batteries MUST have adequate ventilation to remove explosive gases per local and national codes. Contact Consulting Engineer for more information.

2. Low voltage control wiring must be kept separate from power wiring and run in separate conduits.

3. Ensure that battery cabinets are properly grounded according to local code requirements. If there are any

questions concerning batteries, battery racks or accessories, contact your GE Sales Representative.

! CAUTION

Cables between batteries and the UPS should be run in matched pairs, positive-with-negative, within each conduit or cable run. Grouping like-polarity cables together (i.e., positive-with-positive and negative-withnegative) will cause stress or damage to the cables, conduit or bus-work.

3.9 BATTERY WIRING

Power wiring to the battery cabinet connects positive and negative cables along with ground wire from the battery cabinet to the associated UPS. Connection of the UPS to the battery cabinet serves to both charge and discharge the batteries (when needed). The battery disconnect (circuit breaker) requires a control cable. GE battery cabinets include power and control cables to join multiple cabinets together into a system. See Figure

8. Additional (field-supplied) power or control wiring might be necessary to connect the battery cabinet system

to the UPS.

! WARNING

Battery connections on each tier of the GE battery cabinet are disconnected for safety during shipment. If a local electrical contractor completes these connections as part of start-up, a GE Field Service Engineer will verify the connections. Otherwise the GE Field Service Engineer will complete and verify the connections. Polarity must be correct when wiring the battery cabinet to the connected equipment (positive to positive; negative to negative). An improperly installation can result in personal injury or damage to equipment.

NOTE

A GE Specialist can perform a detailed inspection of the entire battery system to ensure it meets current IEEE standards. This inspection service is recommended because batteries are a very critical part of the UPS system.

NOTE

DC power and battery circuit breaker control cables are provided with GE battery cabinets for use between multiple cabinets. Power cables are sized for interconnecting battery cabinets. Field supplied cabling must be provided to connect stand-alone battery cabinets to the UPS module. Connections from the final battery cabinet to the UPS are provided in the field.

NOTE

The lengths of wires between each battery cabinet and the transition cabinet are to be the same (within 10% tolerance) to keep the wire resistances of the battery system equal.

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4 COMPLETING THE INSTALLATION CHECKLIST

The final step in installing your battery cabinet is to complete the Installation Checklist. This checklist ensures that you have installed all hardware, cables, and other equipment. Completing all items on the checklist will ensure a smooth installation. Make a copy of the Installation Checklist before filling it out, and retain the original. After completing your installation, a GE Service Representative will be able to verify the operation of your battery cabinet, and commission it to support your critical load. The service representative cannot perform any installation tasks other than verifying that the battery cabinet has been correctly installed. Service personnel may request a copy of the completed Installation Checklist to be sure you have completed all applicable equipment installation requirements.

NOTE

The Installation Checklist MUST be completed prior to starting the UPS system for the first time.

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5 OPERATION & MAINTENANCE

! WARNINGS

Servicing of batteries should be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries. When replacing batteries, use the same number and type of batteries.

DC fuses operate at the rated battery voltage at all times. A blown DC bus fuse indicates a serious problem. Serious injury or damage to the equipment can result if the fuse is replaced without knowing why it failed.

Do not open or mutilate the batteries.

Do not dispose of battery or batteries in a fire. The battery may explode.

A battery can present a risk of electrical shock and high short circuit current. The following precautions should be observed when working on batteries:

• Remove watches, rings and other metal objects.

• Use tools with insulated handles.

• Wear rubber gloves and boots.

• Do not lay tools or metal parts on top of batteries.

• Disconnect charging source prior to connecting or disconnecting battery terminals.

• Determine if battery is inadvertently grounded. If inadvertently grounded, remove source of ground.

Contact with any part of a grounded battery can result in electrical shock. The likelihood of such shock will be reduced if such grounds are removed during installation and maintenance.

Lead-acid batteries can present a risk of fire because they generate hydrogen gas. In addition, the electrical connections must be protected against accidental short circuits, which can cause sparks. The following procedures should be followed:

• DO NOT SMOKE when near batteries.

• DO NOT cause flame or spark in battery area.

• Discharge static electricity from body before touching batteries by first touching a grounded metal

surface.

• After replacing battery jars in a battery cabinet, replace the retaining straps that hold the jars in place

on the shelves. This will limit accidental movement of the jars and connectors should the cabinet ever need to be repositioned or relocated.

Regular maintenance of the battery module is an absolute necessity. Periodic inspections of battery and terminal voltages, specific gravity and connection resistance should be made. Strictly follow the procedures outlined in the battery manufacturer’s manual, available on the manufacturer’s Web site.

Valve-regulated lead-acid (sealed-cell) batteries do require periodic maintenance. Although maintenance of electrolyte levels is not required, visual inspections and checks of battery voltage and connection resistance should be made.

NOTE

Do not use cleaners on the batteries. Solvents can make the battery cases brittle. Use only a dry cloth or a cloth moistened in water.

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Since individual battery characteristics are not identical and may change over time, the UPS module is equipped with circuitry to equalize battery cell voltages. This circuit increases charging voltage to maintain flooded type battery cells at full capacity.

NOTE

Do not use equalize charge on valve-regulated lead-acid (VRLA) batteries. Consult the battery manufacturer’s manual for specific information about equalize-charging.

Basic environmental requirements for operation:

• Ambient Temperature Range: 0-40°C (32-104°F)

• Recommended Operating Range: 20-25°C (68-77°F)

• Maximum Relative Humidity: 95%, non-condensing

5.1 BATTERY CABINETS

The Battery Cabinets should be given a periodic inspection and electrical check. Checks should be performed at least annually to ensure years of trouble-free service.

5.2 VOLTAGE RECORDS

-With the Battery Cabinet DC circuit breaker closed and the connected UPS operating, measure and record

battery float voltage.

-With the DC circuit breaker open, measure and record the nominal (open circuit) voltage.

(Both these measurements should be made across the final positive and negative terminal lugs.)

-Compare these values with those shown below. The recorded nominal voltage should be no less than the

value shown, while the recorded float voltage should be within the range shown. If a discrepancy is found, contact GE Service Representative at 1-800-637-1738 option 3.

Number of Cells

Battery Voltage (VDC)

Nominal Float

240 480 527-576

5.3 BATTERY CELL TERMINALS

Check for discoloration, corrosion and connection integrity. Clean and tighten if necessary. Note that when installing a new battery, the initial torque value is 5 inch lbs. more than the re-torque value. Contact battery manufacturers documentation or refer to their website for torque values.

To access battery cell terminals; disconnect the inter-tier cable and two shelf retaining screws. Once disconnected, insulate (with protective boot or electrical tape) the cables to prevent accidental shorts.

The battery shelf can now be pulled out. Tighten each terminal connection to the re-torque value. When replacing a battery, the terminal connections must be cleaned and tightened. Disconnect and insulate the cables connected to the battery. Secure each battery shelf with retaining screws when maintenance is complete.

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5.4 BATTERY OPERATION

The separate battery manufacturer’s manual, available on the battery manufacturer’s Web site, provides the necessary information for the installation, operation, charging and maintenance of the battery. Use the battery manual in conjunction with this manual.

For models with nominal 240-cell battery, the DC bus nominal float voltage range is 527 to 576 VDC. For maximum equalize voltage see battery manufacturer data sheet. Battery voltage at end of discharge is 400.8 VDC at the battery.

Every 8°C (15°F) increase in temperature reduces the battery life by 50%. Once the battery is damaged by heat its capacity cannot be improved. Every 8°C (15°F) decrease in temperature reduces the battery life by 50%.

5.5 PROTECTION EQUIPMENT CONNECTIONS

10-300kVA Each battery system is supplied with a circuit breaker in the master cabinet and fuses in the secondary battery cabinets.

400-750kVA Each battery cabinet is supplied with a circuit breaker.

The transition cabinet, for the 750KVA, is supplied with 2-2000A rated semiconductor protection fuses. These fuses are bolted to the landing plates with 3/8-16 Grade-8 hardware. The torque value for the hardware is 4044 ft. lbs.

UPS Cabinet KVA Fuse/Circuit Breaker (CB) Fuse Size CB Size

SG 27" 10 1 Fuse mod in each cab + 1 CB mod in Master 35 30 SG 27" 20 1 Fuse mod in each cab + 1 CB mod in Master 60 60 SG 27" 30 1 Fuse mod in each cab + 1 CB mod in Master 80 80 SG 27" 40 1 Fuse mod in each cab + 1 CB mod in Master 100 100 SG 27" 50 1 Fuse mod in each cab + 1 CB mod in Master 125 125 SG 27" 80 1 Fuse mod in each cab + 1 CB mod in Master 200 200 SG 27" 100 1 Fuse mod in each cab + 1 CB mod in Master 250 250 SG 27" 120 1 Fuse mod in each cab + 1 CB mod in Master 300 300 SG 27" 150 1 Fuse mod in each cab + 1 CB mod in Master 400 400 SG 27" 225 1 Fuse mod + 1 CB mod in each cab 300 300 SG 27" 300 1 Fuse mod + 1 CB mod in each cab 400 400

CB Torque Value

See circuit breaker

for the value

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UPS Cabinet KVA Fuse/Circuit Breaker (CB) Fuse Size

CB Size

SG 44" 10 1 Fuse mod in each cab + 1 CB mod in Master 35 30 SG 44" 20 1 Fuse mod in each cab + 1 CB mod in Master 60 60 SG 44" 30 1 Fuse mod in each cab + 1 CB mod in Master 80 80 SG 44" 40 1 Fuse mod in each cab + 1 CB mod in Master 100 100 SG 44" 50 1 Fuse mod in each cab + 1 CB mod in Master 125 125 SG 44" 80 1 Fuse mod in each cab + 1 CB mod in Master 200 200 SG 44" 100 1 Fuse mod in each cab + 1 CB mod in Master 250 250 SG 44" 120 1 Fuse mod in each cab + 1 CB mod in Master 300 300 SG 44" 150 1 Fuse mod in each cab + 1 CB mod in Master 400 400 SG 44" 225 1 Fuse mod in each cab + 1 CB mod in Master 300 600 SG 44" 300 1 Fuse mod in each cab + 1 CB mod in Master 400 800 SG 44" 400 1 CB mod in each cab 500 SG 44" 500 1 CB mod in each cab 600/400 SG 44" 750 1 CB mod in each cab /Fuses in Transition 2000 600

Circuit Breaker

Torque Value

See Circuit Breaker See Circuit Breaker See Circuit Breaker See Circuit Breaker See Circuit Breaker See Circuit Breaker See Circuit Breaker See Circuit Breaker See Circuit Breaker See Circuit Breaker See Circuit Breaker See Circuit Breaker See Circuit Breaker

275 in-lbs

5.6 WARRANTY

For warranty on batteries and other components of the UPS Battery Cabinets refer to GE UPS Limited Warranty Rider document.

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6 APPENDIX

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7 TABLES

Table 1. Equipment Weight

Component

Empty Packed** Installed**

Battery Cabinet – 27” 420 1600-3400 1500-3300 Battery Cabinet – 44” 550 1730-3530 1630-3430 Transition Cabinet 350 450

**Packed & Installed weight of the battery cabinet varies based on the make and model of the battery used.

Table 2. Battery Cabinet Clearances

From Top of Cabinet 18” for ventilation From Front of Cabinet 36” working space From Back of Cabinet None Required From Right Side of Cabinet None Required From Left Side of Cabinet None Required

Table 3. Maximum cable size

kVA Rectifier Input Bypass Inpu

10 20 30 40 50

80 100 120 150 225 300 400 500 750

#3 AWG #3 AWG #3 AWG #3 AWG #3 AWG #3 AWG #3 AWG #3 AWG #3 AWG #3 AWG #1 AWG #1 AWG #1 AWG #1 AWG #1 AWG

#1 AWG #1 AWG #1 AWG #1 AWG #1 AWG #4/0 AWG #4/0 AWG #4/0 AWG #4/0 AWG #4/0 AWG #4/0 AWG #4/0 AWG #4/0 AWG #4/0 AWG #4/0 AWG

500 MCM 500 MCM 500 MCM 500 MCM 350 MCM 500 MCM 500 MCM 500 MCM 500 MCM 350 MCM

500 MCM 500 MCM 500 MCM 500 MCM 350 MCM 2x500 MCM 2x500 MCM 2x750 MCM 2x500 MCM 350 MCM 2x750 MCM 2x500 MCM 2x750 MCM 2x500 MCM 350 MCM 4x500 MCM 2x500 MCM 4x600 MCM 2x500 MCM 350 MCM 4x500 MCM 2x500 MCM 4x600 MCM 2x500 MCM 350 MCM 5x500 MCM 4x500 MCM 6x600 MCM 4x500 MCM 4x500 MCM

DC Input

Weight - Lbs

Output (Load)

Ground

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Table 4. Battery Voltage Record

Date Float Voltage (VDC) Nominal Voltage (VDC) Ambient Temp (F)

Charger Output ____________________Amp Total Battery String Voltage _______________

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8 FIGURES

FIGURE 1

SG SERIES 27” BATTERY CABINET

Dimensions: 27” (68.58cm) x 31.9” (81.03cm) x 70.69” (179.56cm)

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FIGURE 2

SG SERIES 44” BATTERY CABINET

Dimensions: 44” (111.76cm) x 31.9” (81.03cm) x 70.69” (179.56cm)

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FIGURE 3

SG SERIES TRANSITION CABINET FOR 750kVA SYSTEMS

Dimensions: 18” (45.72cm) x 31.9” (81.03cm) x 70.69” (179.56cm)

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FIGURE 4 The cabinets are shipped bolted to a pallet and protected with outer protective packaging material. Follow below instructions while transporting.

Center of Gravity

PACKAGED UNIT

= == =

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FIGURE 5

BATTERY AND GROUND CONNECTION POINTS IN THE UPS (SG10-750KVA)

External battery connection

SGT5000_010-020_UPS connection battery_01

Internal battery connection

SGT5000_030-040_UPS connection battery_01US

When the unit is equipped with intern al battery, for safety reasons it is delivered with the battery fuses already inserted, but with the battery plug "BC" disconnected. The battery plug "BC" must be connect ed to the battery connector fitted on battery enclosure just before the comm issioning.

SG10-20kVA SG30-40kVA

BATTERY

SGT5000_100-150_UPS connectio n battery_01US

SGT5000_050-080_UPS connection battery_02US

BATTERY

SG50-80kVA SG100-150kVA

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BATTERY

SGS_225-300_UPS connection battery_01US

c t

i o n

t t

r y

_ 0

_ U

Typical installation using

common NEMA two hole lugs

SG225-300kVA SG400-500kVA

Typical installation using common NEMA two hole lugs

SGS_750_UPS connection battery_GE_01_US

SG750kVA

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FIGURE 6

SG 10-500kVA UPS BATTERY CABINET WIRING SCHEMES & CABLE ROUTING

Digital Energy

Battery System

Digital Energy

Battery System

Digital Energy

Battery System

Digital Energy

Battery System

Digital Energy

Battery System

Digital Energy

Battery System

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CABLE ROUTING

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FIGURE 7

SG750kVA UPS BATTERY CABINET WIRING SCHEMES AND CABLE ROUTING

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CABLE ROUTING

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9 INSTALLATION CHECKLIST

SG Series UPS Pre-Start up Checklist

It is our goal to ensure a smooth and uneventful start up of your UPS System. In an effort to minimize the impact of this essential procedure to your overall operations as well as to avoid incurring additional start up charges, we have provided a checklist of items that must be performed by the installing contractor prior to the actual start up date for the UPS. The electrical installation must be in accordance with NEC code. GE Digital Energy does not accept responsibility for electrical work.

Please read this entire document, complete the tasks in this form that are applicable to your system, and return to our office at the number provided below prior to the startup date*.

GE Digital Energy requires two-week notice and the completion of this document prior to scheduling the start up. This document should be completed and faxed to 866-765-3595. Unless otherwise purchased, all startups will be completed between 8am-5pm Monday through Friday. If two-weeks notice is not given, no scheduling guarantees can be made and additional charges may apply.

CONTRACTORS: Please note that there may be additional charges and warranty validation issues if during installation foreign matter (i.e. metal filings) are allowed to disperse throughout the UPS electronics. Care must be taken to capture all scrap metal when cutting/punching holes for conduit or other connections. A minimum 4-hours charge (no maximum) will be assessed to clean any foreign matter from within the UPS prior to commissioning. This activity may also include the replacement of fans or other damaged parts due to this foreign matter. All the above actions must be paid prior to the validation of the warranty on any unit found to contain foreign materials (i.e. metal filings).

THREE-WIRE KIT: If your UPS is supplied with a three-wire kit, it must be noted that the input transformer for the bypass must be a solidly grounded WYE source. The rectifier can be supplied by a DELTA source (Dual Input), but the bypass or single source input must always be supplied by a solidly grounded WYE source, whether using a three-wire kit or not.

Training will be performed upon startup completion**. It is the end user’s responsibility to have personnel

available to attend the operator training at the time of startup.

Thank you.

*Please take note that if the site and UPS are not ready for Startup, GE Consumer and Industrial will remove the Field Engineer from site. A flat rate of $1,120.00 USD will be charged to reschedule the site visit.

**Training is performed at the end of startup. Additional charges may apply if return trips are required for training.

Cancellation of the site visit must be done no later than two business days prior to the scheduled visit to avoid cancellation charges. Standard business days are Monday thru Friday 8:00am to 5:00pm Central Time.

THIS SECTION IS FOR GE POWER QUALITY USE ONLY

Enter review information in technical support log under the start-up work order. Date Reviewed:

Reviewed By (Print):

COMMENTS

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Startup Contact INFORMATION:

Date: ____________ Requested start up date: ____/____/____ Time: ______________

GE Zenith Sales Rep:________________________ Phone Number:___________________

Company name: ___________________________________________________________

Site Contact:_______________________________________________________________

Telephone #_______________Fax #_______________ E-mail_______________________

Facility/ End User Information:

Name ________________________________________________ Address

________________________________________________

City, State, Zip ___________________________________________

Contact ________________________________________________

Phone _____________ E-mail ____________________________

EQUIPMENT INFORMATION:

UPS Model #: ____________________________________

UPS Serial #: ____________________________________

INSTALLATION INFORMATION:

UPS / Battery

1. For 400/500 kVA UPS Only. Facing the back of the UPS, there are shipping restraints (yellow shipping brackets and bolts) connected to the top inductor on the left side of the UPS. This bracket and hardware must be removed prior to placing the UPS in its final installation location. Yes__ No__ N/A__

2. All packing materials are removed from UPS and battery cabinet and each is placed in its final installed position. ---------------------------------------------------------------------------------------Yes__ No__ N/A__

3. Adequate workspace and clearances are provided around UPS and battery cabinet per NEC code and the UPS installation manual.-----------------------------------------------------------------Yes__ No__ N/A__

4. The area around the UPS is clean (dust free) and free of conductive particles or moisture. Airborne conductive particles can cause malfunctions of the UPS and possible damage to the UPS and its connected loads. -----------------------------------------------------------------------------Yes__ No__ N/A__

5. Air conditioning is installed and operating properly. It should be sized for the maximum heat rejection from the UPS at full load operation and recharging batteries. If the UPS will operate for a long period during a power outage, then the hot air must be exhausted from the UPS room. The exhaust fan should be powered by UPS output power. Otherwise, the UPS and battery will overheat and shut off prematurely and possibly damage the UPS or battery. ----------------------------------Yes__ No__ N/A__

6. UPS internal input and output switches are open until the UPS is started (commissioned) by authorized personnel. (The exception is the internal bypass switch may be closed if load power must be established before commissioning. Input phase rotation [must be ABC Clockwise] should be checked prior to closing the internal bypass switch.)------------------------------------------------Yes__ No__ N/A__

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7. The UPS AC input must be from a WYE center grounded source with ABC Clockwise phase rotation and a neutral cable must be attached to the UPS input neutral terminal. A properly sized ground wire must be installed to the UPS ground terminal. (The ground terminal may be labeled PE or Earth.) --------------

--------------------------------------------------------------------------------------------------Yes__ No__ N/A__

8. For UPSs with a single AC input feeder, the AC input power cables are terminated on the Utility Input rectifier and bypass input terminals and the UPS ground terminal per the installations manual. The bus bar / cable jumpers must be left in place between the rectifier and bypass input terminals. Per NEC code, the input cables are sized for 125% of the nominal continuous rectifier input current at full load plus the non-continuous (up to an additional 25%) maximum battery recharge current. ------------------

--------------------------------------------------------------------------------------------------Yes__ No__ N/A__

9. For UPSs with dual or separate AC input feeders, the rectifier AC input cables are terminated on Utility Input rectifier input terminals and the UPS ground terminal per the installations manual. The bus bar / cable jumpers must be removed between the rectifier and bypass input terminals. A neutral connection is not required for the rectifier input. Per the NEC code, the rectifier input cables are sized for 125% of the nominal continuous rectifier input current at full load plus the non-continuous (up to an additional 25%) maximum battery recharge current. The bypass AC input cables are terminated on the Utility Input bypass input terminals and the UPS ground terminal. A neutral connection is required for the bypass input. Per NEC code, the bypass input cables are sized for 125% of the nominal continuous UPS output current at full load. -------------------------------------Yes__ No__ N/A__

10. The neutral provided for the AC input to the UPS is bonded and properly grounded at the power source or service entrance for the UPS input AC power. No additional neutral to ground bonds should exist in the UPS or downstream of the UPS. -----------------------------------------------Yes__ No__ N/A__

: On 100-500kVA units where the 3-wire kit will be used, the input supply feeding the bypass of the UPS

NOTE

must be fed from the wye-secondary of the transformer with a solidly grounded neutral. The load must consist of phase-phase loads ONLY, as no neutral is taken out of the unit.

11. The UPS output cables are terminated on Output Load and N (See note above.) output terminals and UPS ground terminal per the installation manual. (For 480 Vac output, the output neutral may not be required. For 208/120 Vac it is almost always required.) The UPS current limiting circuitry when the load is on UPS and by the bypass AC input feeder overcurrent device when the load is on bypass provides the overcurrent protection for the output cables. Note: For a single AC input feeder, this overcurrent device is larger than 125% of the rated output current. The output cables should be rated to match or a separate output overcurrent device should be installed. ----------------Yes__ No__ N/A__

12. If load is to be applied at start up, ensure that the load does not exceed the output kVA rating of the UPS. If the UPS is severely overloaded damage can occur. -----------------------------Yes__ No__ N/A__

13. If an external maintenance bypass panel is being installed with the UPS, ensure that the phasing of the UPS bypass input and the external bypass input match. --------------------------------Yes__ No__ N/A__

14. A battery disconnect is installed between the battery and the UPS (the disconnect may be inside a battery cabinet). This disconnect should not be closed until the UPS is started (commissioned) by authorized personnel. (External Battery cabinet). -----------------------------------------Yes__ No__ N/A__

15. Battery connections have been made between batteries and to the battery disconnects. If required, the battery temperature sensor is installed with the sensor located inside the battery cabinet. ----------

--------------------------------------------------------------------------------------------------Yes__ No__ N/A__

16. The battery input cables are terminated on the UPS battery input bus bar or terminal connections labeled + (plus or positive) and – (minus or negative). Polarity must be correct. A ground must be installed between the UPS and battery cabinet(s) or battery rack(s) whichever is used. The battery input cables should be sized for a maximum of 2% (1% is preferred) voltage drop at the battery input to the UPS at the maximum battery discharge current. (External Battery cabinet). ---Yes__ No__ N/A__

17. All conduits and cables are properly routed to the UPS, battery, and auxiliary cabinets. -------------------

-------------------------------------------------------------------------------------------------Yes__ No__ N/A__

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18. All auxiliary cabinets are grounded to the UPS cabinet ground. -------------------------Yes__ No__ N/A__

19. If applicable, the Remote Emergency Power Off (REPO) device(s) with one NC (normally closed contact) per UPS is mounted in its installed location and the associated wiring terminated inside the UPS cabinet. ----------------------------------------------------------------------------------------Yes__ No__ N/A__

20. If applicable, remote input and output wires (alarm contacts, serial ports, etc.) are terminated in the UPS at or near the customer interface board inside the UPS. ----------------------------Yes__ No__ N/A__

21. If purchased with the UPS, the Remote Signaling Box (RSB) has been installed and properly wired to the UPS per the installation manual. It is the contractors’ responsibility to run the wires between the UPS and the RSB. The FSE will verify connections during commissioning. ------------------Yes__ No__ N/A__

If any special testing is desired please immediately contact GE Consumer and Industrial to discuss and schedule this testing. Since this is outside the normal start up parameters an additional charge may be required.

Parallel Systems (RPA™)

22. Each cabinet in the parallel UPS system is placed in its final installed position. Note: Parallel UPS units must be installed close enough to each other that 2 each 25 or 50 foot high-speed communications bus cables can be installed between each cabinet in separate protected conduits separated from the power conduits. The high-speed communications bus cables are installed in serial daisy chain fashion from the first parallel UPS unit to the last parallel UPS unit. In other words, unit number one is connected with two communications cables to unit number two, etc up to eight units. -------------------

--------------------------------------------------------------------------------------------------Yes__ No__ N/A__

23. Parallel system input: For multi-module systems that are using single AC input only, the AC source must be the same for each module. For multi-module systems that are using dual AC inputs, the rectifier source must be the same for each module and the bypass source must be the same for each module. The same single module neutral requirements apply to a parallel system. --Yes__ No__ N/A__

24. Parallel system output: The output of each UPS must have three phases plus neutral connected to the parallel bus. The output neutral and ground must be connected to a common point even if they are not to be used with the load. Individual output disconnects are recommended for each module in a parallel system. -------------------------------------------------------------------------------Yes__ No__ N/A__

25. Parallel system single AC input: The combined input and output feeder cable lengths must be the same for each unit and the AC inputs for all modules in a parallel system must be from the same source -----------------------------------------------------------------------------------------Yes__ No__ N/A__

26. Parallel system dual AC input: The combined bypass input and output feeder cable lengths must be the same for each unit and the AC inputs for all modules in a parallel system must be from the same source -----------------------------------------------------------------------------------------Yes__ No__ N/A__

27. Parallel system Remote Emergency Power Off: In a parallel system, a separate isolated NC contact must be connected to each UPS unit. ------------------------------------------------------Yes__ No__ N/A__

28. Paralleled system input and output alarm contacts: In a parallel system, separate isolated input contacts must be connected to each UPS unit if input signals are used. Only one serial port should be connected in a parallel system. -------------------------------------------------------------Yes__ No__ N/A__

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Systems with SNMP Communication Requirements

Having the IP settings determined prior to the arrival of the GE Field Engineer, will allow the GE Field Engineer to test the SNMP card(s) during start up and setup the UPS unit(s) for use on your network prior to leaving the site. In the event that you are unable to have the network settings determined prior to the start up, please have them available before the completion of the start up by the GE Field Engineer.

If you are subscribing to our UPS remote monitoring service called IRIS, please completed the registration information on page 7.

29. Please place a check mark next to the type of SNMP communications product(s) you have purchased. -

---------------------------------------------------------------------------------------------Internal__ External__

30. Two UPS Protected standard 120 Volt outlets available near each of the UPS units for External SNMP power requirements. -------------------------------------------------------------------------Yes__ No__ N/A__

31. IP settings for use with the SNMP product(s) available now. -------------------------------------Yes__ No__

If you know the IP settings that will be used for the UPS connection(s) to your network, please enter those settings here by UPS Serial Number or use the document on page 7 if you are subscribing to IRIS for service monitoring.

Serial Number: ________________ Serial Number: ________________ IP Address: ___________________ IP Address: ___________________ Subnet Mask: _________________ Subnet Mask: _________________ Gateway: ____________________ Gateway: ____________________

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IRIS Registration Form

Please fill in all the required information

Customer Data:

First Name _____________________________ Last Name_________________________________________

Job Position ________________________ Company Name _____________________________________

Address ______________________________________________________________________________

ZIP_____________________________ City __________________________ Country _____________

Telephone ________________________ FAX Number ___________________________________

Mobile _____________________E- mail Address ____________________________________________

Telephone settings: (Example 1: “0” ext. Line, “3736982” local Number)

(Example 2: “0” ext. Line, “0041” country code, “3736982” local Number)

Provide the telephone number of the modem connected to the UPS _______________________________

Note:

The line must be enabled for international calls. International calling is required should your primary

IRIS server be down, two alternate servers will be contacted and they are located outside the continental U.S.

Options Available:

Specify which option should be enabled, if Email / SMS / Fax to be delivered in case of UPS failures.

1. _______________________________

2. _______________________________

3. _______________________________

4. _______________________________

E-MAIL



E-MAIL



E-MAIL



E-MAIL



FAX



FAX



FAX



FAX



SMS



SMS



SMS



SMS



UPS DATA (reserved for GE)

UPS Serial number ______________________ UPS Serial number ______________________

UPS Type:  SG _______ / S P Power Range: ______ x _________ kVA

Date: ________________________ Signature: ________________________

Thank you for your support.

Agreed & Accepted:___________________________________ Date: ___________________________________

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Date:

Print Name

Signature

Title

Company

Please keep one copy for your records and return the original to:

GE Zenith Controls

Maintenance Coordinator. 2500 Discovery Blvd. Rockwall, TX 75032 USA

Phone: (800) 637-1738, option #3

Fax: (866) 765-3595 Emergency Service: 1-800-637-1738, option # 7

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GE Industrial Solutions SG Series UL LISTED BATTERY CABINETS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual