Powerware 5075 kVA User Manual

Harsh Environment

BPIII

INSTALLATION & OPERATION MANUAL

UPS 50–75 kVA

www.powerware.com

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IMPORTANT SAFETY INSTRUCTIONS

Instructions Importantes Concernant La Sécurité

SAVE THESE INSTRUCTIONS

Conserver Ces Instructions

This manual contains important instructions for your Uninterruptible Power

Supply (UPS) system. You should follow these instructions during the

installation and maintenance of the UPS, options, accessories, and batteries.

Cette notice contient des instructions importantes

concernant la sécurité.

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at their own expense.

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Introduction 1........................................................

Using This Manual 3............................................

Conventions Used in This Manual 4..............................

Safety Considerations 5.........................................

Getting Help 5.................................................

Section I Installation 7...............................................

1 Getting Started 9.........................................

Creating an Installation Plan 9...................................

Preparing Your Site 9...........................................

Environmental Considerations 10.................................

Inspecting and Unpacking Each Cabinet 10........................

Unloading the UPS System From the Pallet 11......................

Wiring Requirements 12..........................................

2 Installing the Harsh Environment UPS System 13............

Installing the UPS Cabinet Sections 14.............................

Grounding Joined Cabinets 15....................................

Installing UPS Internal Power and Control Wiring 16.................

Installing UPS External Wiring 17..................................

Preparing the UPS for Installing Optional Accessories 17.............

Initial Startup 17.................................................

Completing the Installation Checklist 18............................

Installation Checklist 19..........................................

3 Installing a Remote E PO Control 21.........................

4 Installing a Remote Monitor Panel 23.......................

5 Installing a Relay Interface Module 29......................

6 Installing a Supervisory Contact 33.........................

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Section II Operation 37..............................................

7 Understanding UPS Operation 39...........................

Looking Inside the UPS 40.......................................

Normal Mode 41................................................

Bypass Mode 42................................................

Battery Mode 43................................................

Maintenance Bypass Mode 44....................................

Monitoring and Controlling UPS Operation 45......................

8 Controls and Features 47..................................

UPS Controls 47................................................

Monitor Panel 47.............................................

Control Panel 47.............................................

Maintenance Bypass 47......................................

UPS Standard Features 47.......................................

Communication Panel 47.....................................

Input Filter 47................................................

Emergency Power Off 48......................................

Automatic Battery Charge Current Limit 48......................

Installation Features 48.......................................

Options and Accessories 48......................................

Remote Monitor Panel 48.....................................

Relay Interface Module 48.....................................

Supervisory Contact Module 48................................

Modem 48..................................................

Customer Convenience Outlet 48..............................

Safety Considerations 49.........................................

Symbols, Controls, and Indicators 50..............................

9 Using the Monitor Panel 51.................................

Using the LCD Screen 52........................................

Using the Pushbuttons 53........................................

Adjusting the Contrast 53........................................

Reading the Status Indicators 54..................................

Using the Menu Options 55.......................................

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10 Operating the UPS 63....................................

Using the Operating Controls 64..................................

Operation 66...................................................

To Place the UPS in Normal Mode 66...........................

To Shut Down the UPS from Normal Mode 66...................

To Start the UPS in Bypass Mode 67...........................

To Transfer the Critical Load to Maintenance Bypass from

UPS Bypass.. 67.........................................

To Transfer the Critical Load to UPS Bypass from

Maintenance Bypass.. 67..................................

To Cold Start the UPS from Battery (No AC Input Power) 68.......

To Shut Down the UPS from Cold Start 69......................

To Reset the DC to DC Converter 69...........................

Using the EMERGENCY POWER OFF Pushbutton 70................

To use the EMERGENCY POWER OFF Pushbutton 70............

Resetting the UPS System after Emergency Power Off 70.........

11 Using Features and Options 71............................

Building Alarm Monitoring 71.....................................

Summary Alarm Contacts 72.....................................

Remote Monitor Panel 73........................................

Relay Interface Module 75........................................

Supervisory Contact Module 76...................................

12 Responding to System Events 77..........................

System Event Horns 77..........................................

System Event Lights 77..........................................

System Event Messages 78......................................

13 Serial Communications 85................................

Locating the Communications Panel 86............................

Connecting Equipment to a Serial Port 87..........................

Configuring the Serial Ports 89....................................

Mode 90....................................................

Rate 90.....................................................

Data/Stop 91................................................

Handshaking 91.............................................

Disabled (No Handshaking) 91................................

XON/XOFF 91...............................................

Save 91.....................................................

Default Settings 91...........................................

Ter mi na l M od e 9 2...............................................

Printing Selected Information 92...............................

Entire Log (Ctrl + P) 93.......................................

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Meters Printout (Ctrl + M) 94..................................

System Information Printout (Ctrl + A) 94.......................

Battery Test Printout (Ctrl + B) 95..............................

System Configuration 96.........................................

System Configuration Mode Main Menu 96......................

Program Building Alarms 96...................................

Enable/Disable Default Functions 97...........................

Customize Alarm Messages 98................................

Program Unit Name 98.......................................

Adjust Output Voltage 99.....................................

Change Password 99.........................................

Battery Test Setup 100.........................................

Modify Low Battery Time 101...................................

Calibration Mode 101.............................................

Computer Mode 101..............................................

Remote Monitor Mode 101........................................

14 Remote Notification 103...................................

Remote Notification Features 104..................................

Description of Operation 105......................................

Call Answer 105..............................................

Call Out 105..................................................

Housekeeping 106............................................

Hardware Requirements 107.......................................

Configuring the Modem 108.......................................

Basic Modem Configuration 108................................

Configuring the Modem to Call a Remote Computer 109...........

Configuring the Modem to Call a Numeric Pager 110..............

Configuring the Modem to Answer Incoming Calls 111.............

Final Modem Configuration 111.................................

UPS Setup Configuration 112......................................

User-Selected Events 113.........................................

15 Maintaining the UPS System 117...........................

Important Safety Instructions 117...................................

Performing Preventive Maintenance 118.............................

Maintenance Training 119.........................................

16 Product Specifications 121.................................

System Input 121................................................

System Output 122...............................................

Environmental Specifications 123..................................

Battery Specifications 123.........................................

Appendix A A---1.......................................................

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List of Figures

Figure 1. Powerware BPIII Harsh Environment UPS System 2.........

Figure 2. Cabinet as Shipped, with Outer Packaging and Pallet 10......

Figure 3. Removing Front and Rear Supports 12......................

Figure 4. UPS and Environmental Cabinets 13........................

Figure 5. Cabinet-to-Cabinet Grounding 15..........................

Figure 6. Remote EPO Control 21...................................

Figure 7. Remote Monitor Panel (RMP) 24...........................

Figure 8. Terminal Block Bracket 25.................................

Figure 9. Wiring an RMP to the UPS 26..............................

Figure 10. Relay Interface Module 29.................................

Figure 11. Terminal Block Bracket 30.................................

Figure 12. Wiring an RIM to the UPS 31...............................

Figure 13. Supervisory Contact Module 33............................

Figure 14. Terminal Block Bracket 34.................................

Figure 15. Wiring an SCM to the UPS 35..............................

Figure 16. Supervisory Contact Module TB2 36........................

Figure 17. Main Elements of the UPS System 40.......................

Figure 18. Path of Current Through the UPS in Normal Mode 41.........

Figure 19. Path of Current Through the UPS in Bypass Mode 42.........

Figure 20. Path of Current Through the UPS in Battery Mode 43.........

Figure 21. Path of Current Through the UPS in Maintenance

Bypass Mode 44.........................................

Figure 22. Location of the Monitor Panel and the Control Panel 45.......

Figure 23. UPS Monitor Panel 51....................................

Figure 24. Parts of the LCD Screen

(Typical for Powerware BPIII HE 75 480/480V Unit) 52.........

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Figure 25. System Meters Screen

(Typical for Powerware BPIII HE 75 480/480V Unit) 55.........

Figure 26. Load Amps Meters Screen 56..............................

Figure 27. Event History Log Screen 57...............................

Figure 28. Active System Events Screen 58...........................

Figure 29. Unit Statistics Screen 59..................................

Figure 30. Mimic Screen 60.........................................

Figure 31. Time Setup Screen 61....................................

Figure 32. Port Setup Screen 62.....................................

Figure 33. Location of the Operating Controls 63......................

Figure 34. UPS Control Panel 64.....................................

Figure 35. External Connections for Building Alarm Monitoring 71........

Figure 36. Summary Alarm Contacts 72..............................

Figure 37. Remote Monitor Panel 73.................................

Figure 38. Relay Interface Module 74.................................

Figure 39. Supervisory Contact Module 76............................

Figure 40. Location of Communications Ports on the Powerware

BPIII HE UPS (shown without the Environmental Cabinet) 86......

Figure 41. Port 1 Pin Assignments 87.................................

Figure 42. Port 2 Pin Assignments 88.................................

Figure 43. Setup Serial Port 1 Screen 89..............................

Figure 44. Event History Log 93.....................................

Figure 45. System Meters 94........................................

Figure 46. Battery Test Log 95.......................................

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Introduction

Powerware BPIII online power protection can be utilized to prevent loss of valuable electronic information, minimize equipment downtime, and/or minimize the adverse effect on equipment production due to unexpected power problems.

The Powerware BPIII Harsh Environment (HE) Uninterruptible Power Supply (UPS) system continually monitors incoming electrical power and removes the surges, spikes, sags, and other irregularities that are inherent in commercial utility power. Working with the electrical system, the UPS supplies clean, consistent power that sensitive electronic equipment requires for reliable operation. During brownouts, blackouts, and other power interruptions, one or more optional battery cabinets can provide emergency power to safeguard your operation.

The UPS will function automatically and requires very little attention during normal operation. However, read and understand the procedures described in this manual to ensure trouble-free operation.

This manual describes how to install and operate the Powerware BPIII HE Uninterruptible Power Supply (UPS) system. It contains instructions for installing and operating both the UPS and Environmental cabinets.

Each component of the Harsh Environment UPS system is housed in a free-standing cabinet. The system configuration consists of the UPS and the Environmental cabinets. Figure 1 shows the Powerware BPIII Harsh Environment UPS system.

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UPS CABINET

ENVIRONMENTAL

CABINET

Figure 1. Powerware BPIII Harsh E nvironment UPS System

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Using This Manual

This manual describes the Powerware BPIII HE UPS installation, operation and routine maintenance. The information in this manual is divided into the sections and chapters listed.

Introduction

The Introduction provides a brief description of the UPS system, a description of the content of each chapter, safety, text conventions used in the manual and reference information.

Section I -- Installation

• Chapter 1 -- Getting Started -- tells you how to prepare your site for the

installation of your UPS system. It discusses equipment environmental requirements, inspecting, and unpacking cabinets.

• Chapter 2 -- Installing the Harsh Environment UPS System -- describes

how to install the UPS system.

• Chapter 3 -- Installing a Remote EPO Control -- discusses installing the

optional Remote Emergency Power Off (EPO) control.

• Chapter 4 -- Installing a Remote Monitor Panel -- contains information for

installing the optional Remote Monitor Panel (RMP).

• Chapter 5 -- Installing a Relay Interface Module -- contains information for

installing the optional Relay Interface Module (RIM).

• Chapter 6 -- Installing a Supervisory Contact Module -- contains information

for installing the optional Supervisory Contact Module (SCM).

Section II -- Operation

• Chapter 7 -- Understanding UPS Operation -- provides information on

understanding the operation UPS.

• Chapter 8 -- Controls and Features -- describes the standard features and

controls of the UPS system.

• Chapter 9 -- Using the Monitor Panel -- describes the controls and indicators

found on the Monitor Panel and shows the various information screens displayed on the LCD screen.

• Chapter 10 -- Operating the UPS-- contains startup and shutdown

procedures for the UPS system.

• Chapter 11 -- Using Features and Options -- contains descriptions and

instructions for the UPS system features and options.

• Chapter 12 -- Responding to System Events -- lists all the alarm, messages

and notices that occur during operation of the UPS system.

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• Chapter 13 -- Serial Communications -- describes the serial communications

features of the UPS system.

• Chapter 14 -- Remote Notification -- contains instructions for using the

remote notification feature of the UPS system.

• Chapter 15 -- Maintaining the UPS System -- contains maintenance

instructions for the UPS system.

• Chapter 16 -- Product Specifications -- provides detailed specifications for

the UPS system.

• Appendix A --Customer Information -- contains important information on

wiring requirements and recommendations, and important diagrams of the cabinet’s mechanical details and electrical access.

Read through each procedure before you begin.

Conventions Used in This Manual

The text in this manual uses these conventions:

• Bold type highlights important concepts in discussions, key terms in

procedures, and menu options.

• Rectangular boxes containing bold type are warnings or cautions that pertain to

the UPS system or its electrical connections. This important information alerts you to possible dangers pertaining to personnel safety, UPS or equipment damage, critical load protection, or operational concerns.

• Italic type highlights notes and new terms where they are defined.

In this manual, the term UPS or UPS system refers to the UPS cabinet and its internal elements and the environmental cabinet. The rectifier and inverter are internal UPS components that are together referred to as the power processing unit (PPU) of the UPS.

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Safety Considerations

The UPS and Environmental cabinets are designed for industrial applications in harsh environments. However, the UPS system is a sophisticated power system and should be handled with appropriate care, following these guidelines:

• Keep surroundings clean and free from excess moisture.

• Do not operate the UPS system close to gas or electric heat sources.

• The system is not intended for outdoor use.

• The operating environment should be maintained within the parameters

stated in this manual.

• Keep the cabinet doors closed to ensure proper cooling airflow and to

protect personnel from dangerous voltages inside the unit.

• The system contains its own power source. Lethal volt ages are present

even when the UPS is disconnected from utility power.

WARNING: Only AUTHORIZED SERVICE PERSONNEL should perform service or maintenance on the parallel redundant system.

If service or routine maintenance is required:

• Ensure all power is disconnected before performing installation or service.

• Ensure the area around the UPS system is clean and uncluttered.

• Observe all DANGER, CAUTION, and WARNING notices affixed to the

inside and outside of the equipment.

Getting Help

If you need to schedule initial startup, need regional locations and telephone numbers, have a question about any of the information in this manual, or have a question this manual does not answer, please call Powerware at:

United States 1-800-843-9433 Canada 1-800-461-9166 Outside the U.S. Call your local representative

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Section I

Installation

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Getting Started

The Harsh Environment (HE) UPS system is shipped as two separate

cabinets (UPS Cabinet and Environmental Cabinet). Each cabinet is shipped on a wood/foam and steel pallet. Use a forklift or pallet jack to move the packaged cabinets to the installation site, or as close as possible to the site, before unloading from the pallets.

This is the basic sequence of the installation steps:

1. Create an installation plan for the UPS and Environmental cabinets.

1. PrepareyoursitefortheUPSsystem.

2. Inspect, unpack, and unload the cabinets.

3. Wire the cabinets as applicable (Chapter 2).

4. Complete the Installation Checklist (Chapter 2).

5. Have authorized service personnel perform preliminary checks and startup.

After wiring the UPS system to the facility power and critical load(s), be sure to ground the system according to local and/or national electrical wiring codes, using your own cabling and conduit.

NOTE: Startup and operational checks should be performed only by authorized

service personnel. This service is usually offered as part of the sales contract for your UPS system.

Creating an Installation Plan

Before beginning to install your UPS system, you should be sure you understand the instructions in this manual. Use the procedures and illustrations in the following sections to create a logical plan for installing the UPS system The information in this chapter and Chapter 2 will help you plan the installation.

Preparing Your Site

For your UPS system to operate at peak efficiency, your installation site should meet the environmental parameters outlined in this manual. If you intend to operate the UPS at an altitude higher than 1500 meters (5000 feet), contact your local sales or service office for important information about high altitude operation. The operating environment must meet the size and weight requirements shown in Table J of Appendix A.

The basic environmental requirements for operation of the UPS system are:

Ambient Temperature Range: 0 --- 5 0˚ C ( 3 2 --- 1 22 ˚ F)

Recommended Operating Range: 2 0 --- 2 5˚ C ( 6 8 --- 7 7˚ F)

Maximum Relative Humidity: 95%

The UPS and Environmental cabinets use forced air cooling to regulate internal component temperature. Air inlets are on the right side of the Environmental Cabinet and outlets are on the top of the UPS cabinet. You must allow clearance in front of and above each cabinet for proper air circulation.

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Environment Considerations

The UPS system must be installed o n a sealed concrete floor.

WARNING: Installation should be performed by qualified personnel.

Inspecting and Unpacking Each Cabinet

The first task in preparing for installation is inspecting and unpacking each cabinet. Cabinets arrive covered with protective packaging material as shown in Figure 2.

OUTER

PACKA GI N G

FOAM CUSHION

Figure 2. Cabinet as Shipped, with Outer Packaging and Pallet

1. Carefully inspect the outer packaging for evidence of damage during transit.

CAUTION: Do not install a damaged cabinet. Report any damage to the carrier and contact your local sales or service office immediately.

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2. Use a forklift or other material handling equipment to move the cabinets to a

convenient unpacking area. Insert the forklift jacks between the foam cushions on the bottom of the unit.

CAUTION: DO NOT tilt cabinets more than 10 degrees from vertical.

3. Set each pallet on a firm, level surface, allowing a minimum clearance of

4.6m (15 ft) on each side for removing the cabinets from the pallets.

4. Cut the steel bands around each cabinet.

5. Remove the protective cardboard covering from the cabinets, cutting where

indicated, using a knife blade no longer than 25 mm (1 in.).

NOTE: Do not discard the packaging material yet. Instructions for unloading the

cabinet from the pallet are printed on the cardboard, and you will need to refer to them.

6. Remove the plastic bag and foam packing material, and discard or recycle

them in a responsible manner .

Unloading the UPS System From the Pallet

The UPS and Environmental cabinets are each bolted to sheet metal pallets consisting of four supports secured to foam cushions. The foam cushions act as shock absorbers for the cabinet during shipment.

WARNING: UPS cabinets are extremely heavy. If unloading instructions are no t closely followed, the cabinet may tip and cause serious injury.

T urning the jacking bolts unevenly may cause the cabinet to become unbalanced. To prevent tipping, raise and lower the jacking bolts evenly. The cabinet should only be raised approximately 3 mm ( (just enough to remove foam cushions).

1/8 in.) above the floor

1. Starting with the UPS cabinet, open and remove the cabinet door. Remove the

retaining screw located inside the door at the bottom hinge pivot point, then lift the door off. Save the retaining screws for reinstallation of the door.

2. Locate the field kit (packed inside of the cabinet or communication panel).

Locate the four ½-in. jacking bolts and install them in the threaded holes in the front and rear supports. Place a floor protector underneath each jacking bolt, and screw the bolts down against them. The floor protectors will save the floor from being marred by the jacking bolts.

3. Loosen, but do not remove the hardware holding the foam cushions to the

front and rear supports (labeled “1” in Figure 3).

4. Turn each jacking bolt consecutively, two full turns, until the foam cushions

clear the floor by approximately 3 mm (

1/8 in.).

5. After the foam cushions clear the floor, remove the hardware loosened in

step 3. Pull the foam cushions out from under the cabinet, and discard or recycle them in a responsible manner.

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DOOR

FLOOR

PROTECTOR

FRONT

SUPPORT

SIDE

SUPPORT

FOAM CUSHION

JACKING

BOLT

Figure 3. Removing Front and Rear Supports

WARNING: Cabinet may fall. Do not loosen hardware attaching the side or front supports to cabinet base. Also, do not loosen supports from each other. The cabinet must be lowered using jacking bolts before supports can be removed.

6. Carefully and evenly lower the cabinet by turning each jacking bolt

consecutively two full turns (maximum) the cabinet is no longer supported by the jacking bolts.

until the supports contact the floor, and

7. After the cabinet is resting on the floor, remove the jacking bolts and discard or

recycle them in a responsible manner.

8. Removethehardwarelabeled“2”inFigure3,holdingthefront,rearandside

supports to the cabinet base. Discard or recycle the hardware and support brackets in a responsible manner.

9. Replace the door that was removed in step 1. The cabinet is now ready to be

rolled to its final location.

10. Repeat steps 1 through 9 for the Environmental cabinet.

Wiring Requirements

For external wiring requirements, including the minimum AWG size of external wiring, see Tables A and E of Appendix A. The power wiring for this equipment is rated at 90˚C.

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Installing the Harsh Environment

UPS System

After the UPS system is unpacked and moved to the final installation location, the UPS and Environmental Cabinets are ready to be joined. Once the cabinets are joined, internal and external wiring is installed. Figure 4 shows the UPS and Environmental cabinets assembled. The top view shows the cable entry plate in the Environmental cabinet.

TOP VIEW

FRONT VIEW

Figure 4. UPS and Environmental Cabinets

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WARNING: Installation should be performed by qualified personnel.

Note the following important information while installing the UPS:

• Dimensions in this manual are provided in millimeters and inches.

• Do not tilt the UPS or other cabinets more than 10˚ during installation.

• Cooling exhaust airflow is approximately 614.0 L/S (1300 CFM).

• The conduit landing plate is to be removed to add conduit landing holes as

required. Plate material is 16 gauge steel (0.06 in. thick).

• TerminalsE9throughE15andE19–E35areULandCSAratedat90˚C. A hex

key tool is required to attach wires to the terminals.

• Details about control wiring are provided in each procedure for connecting

options and features. Table L in Appendix A identifies the control wiring terminations.

Installing the UPS Cabinet Sections

1. Move the UPS and Environmental cabinets together, placing the UPS cabinet

on the left side of the Environmental Cabinet.

2. Secure the UPS and Environmental cabinets with the leveling feet provide on

each cabinet.

3. Locate the field kit and remove cabinet joining brackets and hardware from the

kit.

4. Install the brackets to the front and rear of each cabinet base, using the

threaded holes provided. Brackets should be mounted so that the tabs at end of the brackets meet between the two cabinets.

5. Install bolts through the tabs at front and back and secure with washers and

nuts.

6. Secure cabinet sides to each other at the top front and top back with 1/2 inch

bolts, washers and nuts from the field kit. Use the holes provide in the cabinet sides.

7. Attach a ground to the joined cabinets using the procedure “Grounding Joined

Cabinets” in this chapter.

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Grounding Joined Cabinets

Open the door of each cabinet. Locate the grounding stud at the front/side of each frame. Remove the top nut, lock washer, and flat washer from each stud (if attached, see Figures 5).

1. Locate the grounding cable (part of the field kit, located in a small bag which is

fastened to the UPS cabinet in the customer terminal area).

2. Mount the grounding cable as shown in Figure 5, attaching it to the frame of

each cabinet using the hardware previously removed.

HARDWARE REMOVED BEFORE PLACING LUG

GROUNDING CABLE

OVER GROUND STUD

FRONT

CABINET BASE

(side view)

Figure 5. Cabinet-to-Cabinet Grounding

PERMANENTLY ATTACHED HARDWARE

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Installing UPS Internal Power and Control Wiring

NOTE: The cables used in steps 2 through 12 are coiled inside the Environmental

cabinet and are attached at the factory to the terminals inside this cabinet. Wiring harness with connectors J20, J22, and J23 are coiled inside the UPS cabinet. Wiring harness with connectors P20, P22, and P23 are coiled inside the Environmental cabinet. Refer to Drawings 164201261 ---1 and 164201261 ---4 in Appendix A of this manual for wiring and termination requirements and terminal locations.

1. Remove the sheet metal shield covering the bottom half of the UPS cabinet.

2. Route DC input cables (cables 205 and 206) from the Environmental cabinet

through the cutout in cabinet sides to the DC UPS Input terminals in the UPS cabinet.

3. Connect positive DC power cable 205 to the DC input terminal E4. Refer to

Appendix A of this manual for terminal locations and tightening torque.

4. Connect negative DC power cable 206 to the DC input terminal E5. Refer to

Appendix A of this manual for terminal locations and tightening torque.

5. Route AC Input Bypass Transformer cables (cables 227, 228 and 229) from the

Environmental cabinet through the cutout in cabinet sides to the Bypass Transformer Input terminals in the UPS cabinet.

6. Connect phase A, B, and C power wiring cables 227, 228, and 229 to Bypass

Transformer Input terminals E13, E14, and E15 respectively. Refer to Appendix A of this manual for terminal locations and tightening torques.

7. Route AC Input to UPS Rectifier cables (cables 250, 251 and 252) from the

Environmental cabinet through the cutout in cabinet sides to the UPS Rectifier Input terminals in the UPS cabinet.

8. Connect phase A, B, and C power wiring cables 250, 251, and 252 to AC Input

to UPS Rectifier Input terminals E1, E2, and E3 respectively. Refer to Appendix A of this manual for terminal locations and tightening torques.

9. Route AC Output cables (cables 237, 238 and 239) from the Environmental

cabinet through the cutout in cabinet sides to the AC Output terminals in the UPS cabinet.

10. Connect phase A, B, and C power wiring cables 237, 238, and 239 to AC

Output terminals E9, E10, and E11 respectively. Refer to Appendix A of this manual for terminal locations and tightening torques.

11. Route two Neutral cables (cable 600) from the Environmental cabinet through

the cutout in cabinet sides to the Neutral terminal in the UPS cabinet.

12. Connect two Neutral power wiring cables 600 to Neutral terminal E12. Refer to

Appendix A of this manual for terminal locations and tightening torques.

13. Route wiring harness with connectors P20, P22, and P23 from the

Environmental cabinet through the cutout in cabinet sides.

14. Connect connectors P20, P22, and P23 to connectors J20, J22, and J23

respectively.

15. Reinstall UPS Cabinet sheetmetal shield.

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Installing UPS External Wiring

1. Install rectifier, bypass, and battery input power wiring to terminals in the

Environmental cabinet. Refer to Drawings 164201261---1 and 164201261---4 in Appendix A of this manual for wiring and termination requirements and terminal locations.

2. Install the critical load output power wiring to terminals in the Environmental

cabinet. Refer to Drawings 164201261---1 and 164201261---4 in Appendix A of this manual for wiring and termination requirements and terminal locations.

3. Reinstall cabinet doors.

Preparing the UPS for Installing Optional Accessories

If you are installing optional accessories, such as a Remot EPO or an RMP, you must prepare the UPS cabinet for the installation of these options.

To prepare the UPS for wiring to an RMP, RIM, SCM or Remote EPO:

1. Be sure the UPS is turned off and all power sources are removed. (See the

operator’s manual for instructions.)

2. Open the doors of the UPS.

3. Remove the lower sheetmetal shield. Set the shield and hardware aside for

later reuse.

Initial Startup

Startup and operational checks should be performed only by authorized service personnel. Contact service in advance (usually a two week notice is required) to reserve a preferred startup date.

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Completing the Installation Checklist

The final step in installing the UPS system is completing the following Installation Checklist. This checklist ensures that all hardware, cables, and other equipment have been completely installed . 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 the installation is complete, a service representative will be able to verify the operation of the UPS system and commission it to support the critical load. The service representative cannot perform any installation tasks other than verifying software and operating setup parameters. Service personnel may request a copy of the completed Installation Checklist to be sure you have completed all applicable equipment installation.

NOTE: The Installation Checklist MUST be completed prior to starting the UPS

system for the first time.

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Installation Checklist

All packing materials and restraints have been removed from each cabinet.

-Each cabinet in the UPS system is placed in its installed location.

-All cabinets are bolted together.

-A ground bond is installed between all cabinets that are bolted together.

-All switchboards, conduits, and cables are properly routed to the UPS.

-Power cables are terminated on AC Input terminals (UPS Cabinet) (E1---E3).

-Power cables are terminated on Bypass Transformer input terminals (UPS Cabinet)

( E1 3 --- E 1 5 ) .

-Power cables are terminated on AC Output terminals (UPS Cabinet) (E9 ---E12).

-Power cables are terminated on DC Input terminals (UPS Cabinet) (E4---E5).

-Power cables are terminated on bypass terminals (E19 ---E21).

-Power cables are terminated on the CB1 input breaker (E33---E35 ).

-Power cables are terminated on output terminals (E25---E27).

-A ground conductor is properly installed.

-If N is used, no other N ---G bonds exist downstream from the UPS.

-Battery cables and harness are terminated on the CB2 battery breaker E31 and E32.

-The area around the installed UPS system is clean and dust-free. (It is recommended

that the UPS be installed on a sealed concrete pad on a sealed concrete floor.)

-Adequate workspace exists around the UPS and other cabinets.

-Adequate lighting is provided around all UPS equipment.

-A 120V service outlet is located within 25 feet of the UPS equipment.

Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operation

164201261 Rev. F 111503

Notes

20 Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation

164291261 Rev. F 111503

Installing a Remote EPO Control

Twi

(2)

The Remote EPO control arrives as shown in Figure 6. See Drawing 164201261---7 in Appendix A for enclosure dimensions, side views, and knockout patterns.

to UPS to other equipment

Figure 6. Remote EPO Control

To install a Remote EPO control:

UNINTERRUPTIBLE POWER SYSTEM

EMERGENCY OFF

1. Securely mount the Remote EPO station. Recommended locations include

operator’s consoles or exit doors.

2. Install wiring from the Remote EPO station using ½-in. conduit through the

7/8-in. knockout in either the top or bottom of the UPS.

3. Connect the Remote EPO wiring as shown in Tables A and B:

TableA. RemoteEPOWireTerminations

To Communications

From REPO Station(s)

T B1 --- 4 T B2 --- 1

T B1 --- 5 T B2 --- 2

Powerware BPIII Harsh Environment UPS 50--75 kVA Installation and Operation

164201261 Rev. F 111503

Panel in UPS

Remarks

stedwires

1 4 --- 1 8 g a u g e

TableB. RemoteEPO

REMOTE

EPO

SWITCH

TB2

TWISTED

WIRES (2)

Remote EPO s witch rating is 24 VDC. 1 Amp minimum if supplied by user.

NOTE: This switch must be a dedicated switch not tied into any other circuits.

4. If installing multiple Remote EPO stations, wire additional stations in parallel

with the first Remote EPO.

5. If required, install ½-in. conduit and wiring from the Remote EPO station to trip

circuitry of upstream protective devices. A normally open contact is provided, asshowninTableB. RemoteEPOswitchwiringmustbeinaccordancewith UL Class II requirements.

6. Secure the UPS by reversing all steps taken to prepare it for Remote EPO

installation.

22 Powerware BPIII Harsh Environment UPS 50--75 kV Installation and Operation

164291261 Rev. F 111503

+ 132 hidden pages

Powerware 5075 kVA User Manual

Table of Contents

List of Figures

Introduction