GE Industrial Solutions SG Series UL LISTED BATTERY CABINETS User Manual
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
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
COPYRIGHT © 2008 by GE Enterprise Solutions
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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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:
g
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
g
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
g
GE Digital Energy
Power Quality
F 866 765 3595
option # 7
Table of contents Page
BATTERY SAFETY PRECAUTIONS.............................................................................................................................. 6
1
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
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 rather than discarded.
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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