Powerware 685, 1085 User Manual

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9350

Series 685 and 1085

Auxiliary Battery

Cabinets

Installation

Manual

164201408 Rev. P00

IMPORTANT SAFETY INSTRUCTIONS

Instructions Importantes Concernant La Sécurité

SAVE THESE INSTRUCTIONS

Conserver Ces Instructions

This manual contains important instructions for your battery system. You should follow these instructions during the installation and maintenance of the battery cabinets.

Cette notice contient des instructions importantes concernant la sécurité.

The installation of battery cabinets should be performed or supervised by personnel knowledgeable of batteries and their associated precautions. Keep unauthorized personnel away from battery cabinets.

Observe these precautions when working on or around battery cabinets:

Remove watches, rings, or other metal objects.

Use tools with insulated handles.

Wear rubber gloves and boots.

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

Disconnect the charging source prior to connecting or disconnecting terminals.

The battery cabinet frame is not referenced to the DC circuit.

When replacing batteries, use the same number and type of sealed, lead-acid batteries.

Refer to local codes for proper disposal requirements for used batteries.

CAUTION:

Do not dispose of battery or batteries in a fire.

The battery may explode.

CAUTION:

Do not open or mutilate the battery or batteries.

Released electrolyte is harmful to the skin and eyes, and may be toxic.

CAUTION:

A battery can cause electrical shock, burn from high short-circuit current, or fire. Observe proper precautions.

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ATTENTION:

Une batterie peut prêsenter un risque de choc êlectrique, de brulure, ou d’incendie. Suivre les précautions qui s’imposent.

Pour le remplacement, utiliser le même nombre et modéle des batteries.

L’élimination des batteries est règlementée. Consulter les codes locaux à cet effet.

General Notes About Installing Battery Cabinets

Each battery cabinet is packed and crated separately for shipping. You should unpack and inspect each cabinet, roll it to its final position, and join it to the UPS or other cabinets (refer to Chapter 3 or Chaper 4) before installing wiring.

These general installation notes apply to either the Series 685 Battery Cabinet or the Series 1085 Battery Cabinet:

Do not tilt battery cabinets more than 10˚ during installation.

The recommended minimum clearance over each battery cabinet is 305 mm (12 in.).

The conduit landing plates are removable to add conduit landing holes as required. The conduit landing plates should be removed when holes are added to keep metal particles from falling inside the battery cabinet. Plate material is 16 gauge steel (1.5 mm, 0.06 in. thick).

Low voltage signal wiring must be installed in a separate conduit from the power wiring.

Each battery cabinet can be installed as a stand-alone unit or as part of a redundant joined system.

The instantaneous trip circuit breakers for the Series 685 and Series 1085 Battery Cabinets must remain set at minimum (full counterclockwise).

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UPS Systems Using Series 685 and Series 1085 Battery Cabinets

Powerware 9350 (30 kVA---80 kVA)

Powerware 9350 (100 kVA---160 kVA)

Conventions Used in This Manual

The text in this manual uses these conventions:

Bold type highlights important concepts in discussions and key terms in procedures.

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

Rectangular boxes containing bold type are warnings or cautions that pertain to the battery system or its electrical connections.

In this manual, the term UPS refers only to the UPS cabinet and its internal elements. The term UPS system refers to your entire power protection system—the UPS cabinet plus battery cabinets that you have installed.

Read through each installation procedure before you begin it. Perform only those procedures that apply to the battery system you are installing.

NOTE: The term “Separate” refers to battery cabinets that are not physically attached to the UPS, are wired with external contractor supplied wiring, and use a single overcurent protection and disconnect device located near the batteries.

The term “Integral” refers to battery cabinets that are physically attached to the UPS and the wiring between them is internal. The power wiring is supplied with the system, and they use the UPS battery switch as the battery isolation device.

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Table of Contents

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

1

Typical Battery Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Identification of Your Battery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

For More Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Getting Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

2 Unpacking Your Battery Cabinet . . . . . . . . . . . . . . . . . . . . . . . . .

5

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

5

Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Preparing for Wiring the Battery Cabinet . . . . . . . . . . . . . . . . . . . . . . . . .

5

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

6

Unloading the Battery Cabinet from the Pallet . . . . . . . . . . . . . . . . . . . . .

7

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

9

NOTES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

3 Connecting to Powerware 9350 30 thru 160 . . . . . . . . . . . . . . .

11

The Powerware 9350 UPS with Integral Battery Cabinets . . . . . . . . . . .

11

Powerware 9350 UPS with Separately Located Battery Cabinets . . . .

20

Separate Installation of Series 685 Battery Cabinets . . . . . . . . . . . . . . .

21

Separate Installation of Series 1085 Battery Cabinets . . . . . . . . . . . . . .

23

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

27

Installation Checklist for Powerware 9350 30 through 160 . . . . . . . . . .

27

4 Connecting to Powerware 9350---80 and 160 . . . . . . . . . . . . . .

29

The Powerware 9350---80 or 160 with Separate Battery Cabinets . . . .

30

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

31

Installation Checklist for Powerware 9350---80 or 160 . . . . . . . . . . . . . .

32

5 Installing a Remote Battery Disconnect . . . . . . . . . . . . . . . . . .

33

Appendix A — Customer Information . . . . . . . . . . . . . . . . . . . . . . .

A---1

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Figure 1. Typical Battery Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Figure 2. UPS with Lineup and Match Battery Cabinet . . . . . . . . . . . . . . . . . . . . . . . .

2

Figure 3. UPS with Separate Battery Cabinets (Attached to Each Other) . . . . . . . .

3

Figure 4. Cabinet as Shipped, with Outer Packaging and Pallet . . . . . . . . . . . . . . . .

6

Figure 5. Removing Front and Rear Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Figure 6. UPS with Integral Battery Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Figure 7. Placement of Attaching Brackets, UPS to Battery Cabinet . . . . . . . . . . . .

13

Figure 8. Attaching UPS Base to Series 1085 Base . . . . . . . . . . . . . . . . . . . . . . . . . .

14

Figure 9. Attaching UPS Base to Series 685 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Figure 10. Series 685 Battery Cabinet Wiring Detail . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Figure 11. Series 685 and 1085 Battery Cabinet Hanger Brackets . . . . . . . . . . . . . .

18

Figure 12. Series 1085 Battery Cabinet Wiring Detail . . . . . . . . . . . . . . . . . . . . . . . . .

19

Figure 13. UPS with Separately Located Battery Cabinets . . . . . . . . . . . . . . . . . . . . .

20

Figure 14. Placement of Joining Brackets

 

(Two or More Series 685 Battery Cabinets) . . . . . . . . . . . . . . . . . . . . . . . . .

21

Figure 15. Connecting Two Series 685 Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

Figure 16. Placement of Joining Brackets

 

(Two or More Series 1085 Battery Cabinets) . . . . . . . . . . . . . . . . . . . . . . . .

23

Figure 17. Connecting Two Series 1085 Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

Figure 18. Battery Connections for a Powerware 9350---80 . . . . . . . . . . . . . . . . . . . .

29

Figure 19. Battery Connections for a Powerware 9350---160 . . . . . . . . . . . . . . . . . . .

30

Figure 20. Remote Battery Disconnect Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

Figure 21. Knockout Pattern for Remote Battery Disconnect . . . . . . . . . . . . . . . . . . .

35

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Installation Manual 164201408 Rev. P00 053002

Introduction

This manual describes how to install the Powerware 9350 Series 685 or Series 1085 Battery Cabinet (see Figure 1). It contains instructions for

unpacking and inspecting the battery cabinet, locating the battery cabinet with respect to the UPS, and electrically connecting the battery cabinet to the UPS. The information you will use depends on the type of UPS and series of battery cabinet that you purchased.

Typical Battery Cabinets

Series 685 Battery Cabinet

Series 1085 Battery Cabinet

Figure 1. Typical Battery Cabinets

Two basic battery cabinet configurations are possible:

The UPS and one or more battery cabinets in an integral configuration (see Figure 2).

The UPS and one or more battery cabinets separately installed (see Figure 3).

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Identification of Your Battery System

Refer only to the parts of this manual that apply specifically to your system configuration. See Figures 2 and 3 to determine where to find your system installation instructions in this manual.

UPS

Battery Cabinet

Figure 2. UPS with Lineup and Match Battery Cabinet

For installation instructions, refer to “The Powerware 9350 UPS with Integral Battery Cabinets” section of Chapter 3. Refer to Chapter 2, “Unpacking Your Battery Cabinet” for unpacking instructions.

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Installation Manual 164201408 Rev. P00 053002

UPS

Battery Cabinets

Figure 3. UPS with Separate Battery Cabinets (Attached to Each Other)

For installation instructions, refer to “The Powerware 9350 UPS with Separate Battery Cabinets” section of Chapter 3 or Chapter 4. Refer to Chapter 2, “Unpacking Your Battery Cabinet” for unpacking instructions.

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For More Information

This manual describes how to install your battery cabinet. For more information about the operation and communications capabilities of your UPS system, refer to the following:

164201407 Powerwarer 9350 (100 kVA---160 kVA) UPS Installation

Describes the UPS installation procedure; discusses optional accessories, environmental considerations, weight and point loading, connection diagrams, and information on other optional cabinets.

Also describes the UPS Cabinet Control Panel and Monitor Panel, and explains the functions of the UPS; discusses the standard features of the UPS and optional accessories; provides procedures for starting and stopping the UPS, and information about maintenance and responding to system events.

Contact your local Powerware Corporation Field Service office for information about how to obtain copies of these manuals.

Getting Help

If you have a question about any of the information in this manual, or if you have a question this manual does not answer, please call the Powerware Corporation Field Service office:

United States

1-800-843-9433

Canada

1-800-461-9166

Outside the U.S.

Call your local representative

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Unpacking Your Battery Cabinet

Each Powerware 9350 Series 685 or Series 1085 Battery Cabinet is shipped on a separate 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 you unload them from the pallets.

Battery cabinets must be installed in accordance with all applicable codes and regulations, including the National Electrical Code (NEC), Article 480.

NOTE: Startup and operational checks should be performed only by authorized service personnel. This service is offered as part of the sales contract for your battery system.

Preparing Your Site

The basic environmental requirements for the battery system are:

Ambient Temperature Range:

10---

40˚C (50---

104˚F)

Recommended Operating Range:

20---

25˚C (68---

77˚F)

Maximum Relative Humidity:

95% noncondensing

The Series 685 or Series 1085 Battery Cabinets use convection cooling to regulate internal component temperature. Air inlets are in the bottom and top of the cabinets. You must allow a minimum clearance of 305 mm (12 in.) above each cabinet for proper air circulation. Additionally, a clearance of 915 mm (36 in.) must be provided in front of the cabinet for component removal and maintenance . Maintaining this clearance provides adequate airflow to the front of the cabinet.

Environmental Considerations

The life of the battery system is adversely affected if the installation does not meet these guidelines:

The battery cabinet must be installed on a sealed concrete pad or a sealed concrete floor, or on a raised computer room floor.

The battery cabinet must be installed in a dust-free, nonconductive environment.

The battery cabinet must be installed in a humidity-controlled environment.

Preparing for Wiring the Battery Cabinet

For external wiring requirements, including the minimum AWG size of external wiring, refer to Appendix A, Table C.

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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 4.

OUTER

PACKAGING

PLY---FOAM CUSHIONS

Figure 4. Cabinet as Shipped, with Outer Packaging and Pallet

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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. CONTACT YOUR LOCAL SALES OR SERVICE OFFICE IMMEDIATELY.

2. Use appropriate material handling equipment to move the cabinet to a

convenient unpacking area. Space is provided between the pallets to insert pallet jack blades on the bottom of the unit.

DANGER:

RISK OF INSTABILITY. DO NOT TILT CABINETS MORE THAN 10 DEGREES

FROM VERTICAL OR THE CABINET MAY TIP OVER.

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 and remove the steel bands around each cabinet.

5. Remove the protective cardboard covering from the cabinets by vertically cutting one corner, using a knife blade no longer than 25 mm (1 in.).

6. Remove the corrugated corner protectors, box, plastic bag, and discard or recycle them in a responsible manner.

CAUTION:

IF YOU CAN SEE DAMAGE IN OR ON A CABINET, DO NOT INSTALL IT. REPORT ANY DAMAGE TO THE CARRIER. CONTACT YOUR LOCAL SALES OR SERVICE OFFICE IMMEDIATELY.

Unloading the Battery Cabinet from the Pallet

The battery cabinet is bolted to a pallet consisting of four angle metal supports secured to laminated plywood/foam cushions. The foam cushions act as shock absorbers for the cabinet during shipment.

1. Remove the doors. Remove the retaining screw located inside each door at the

bottom hinge pivot point, then lift the door off. Save the retaining screws for reinstallation of the doors.

2. Locate the field kit (packed inside of the cabinet). Locate the four 1/2 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 protect the floor from being marred by the jacking bolts.

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LEFT HAND

 

 

 

DOOR

 

 

FOAM

(Step 1)

 

SIDE

FRONT

CUSHION

2

SUPPORT

 

SUPPORT

 

 

 

 

1

 

 

 

FLOOR PROTECTOR

(Step 2)

2

2

 

2

 

 

 

1

 

 

 

JACKING

 

1

 

BOLT

 

2

(Step 2)

 

(Step 3)

(Step 8)

 

Figure 5. Removing Front and Rear Supports

3. Loosen, but do not remove, the hardware holding the foam cushions to the front and rear supports (labeled “1” in Figure 5).

WARNING: SERIOUS INJURY MAY OCCUR!

BATTERY CABINETS ARE EXTREMELY HEAVY. IF UNLOADING INSTRUCTIONS

ARE NOT CLOSELY FOLLOWED, CABINET MAY TIP.

4. Turn each jacking bolt consecutively, two full turns, until the foam cushions clear the floor by approximately 3 mm (1/8 in.).

DANGER: RISK OF INSTABILITY!

TURNING THE JACKING BOLTS UNEVENLY MAY CAUSE THE CABINET TO BECOME UNBALANCED. TO PREVENT TIPPING THE CABINET, RAISE AND LOWER THE JACKING BOLTS EVENLY.

DANGER: CABINET MAY TIP!

THE BATTERY CABINET SHOULD ONLY BE RAISED APPROXIMATELY 3 mm (1/8 in.) ABOVE THE FLOOR (JUST ENOUGH TO ALLOW REMOVAL OF THE FOAM CUSHIONS).

5. After the foam cushions clear the floor, remove the hardware loosened in Step 3.

Pull the foam cushions out from under the battery cabinet. Please discard or recycle them in a responsible manner.

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DANGER: CABINET MAY FALL!

DO NOT LOOSEN THE HARDWARE ATTACHING THE SIDE OR FRONT SUPPORTS TO THE CABINET BASE, OR THE FRONT AND SIDE SUPPORTS TO EACH OTHER, AT THIS TIME.

THE CABINET MUST BE LOWERED BY THE JACKING BOLTS BEFORE THE

SUPPORTS CAN BE REMOVED.

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

two full turns (maximum) until the supports contact the floor, and the cabinet is no longer supported by the jacking bolts.

7. After the battery cabinet is resting on the floor, remove the jacking bolts and discard or recycle them in a responsible manner.

8. Remove the hardware, labeled “2” in Figure 5, holding the front, rear and side

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

9. Replace the doors that were removed in Step 1. The battery cabinet is now ready to be rolled to its final location.

10. Repeat Steps 1 through 9 for each cabinet you are preparing to install.

Creating an Installation Plan

Before beginning to install your battery cabinet, you should be sure that you understand the portions of this manual that apply to your system. Use the procedures and illustrations in the following sections to create a logical plan for installing the battery cabinet you purchased. Refer to Chapter 3, “Connecting to Powerware 9350 30 ---160” to help plan your installation.

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NOTES:

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Connecting to Powerware 9350 30 ---160

The method you use to install your battery cabinets depends on which UPS you have. For the purpose of discussion, this chapter uses the term UPS

to refer to the UPS cabinet, and the term battery cabinet to refer to any battery cabinet. There are two different sizes of battery cabinets, but the procedure for connecting the cabinets to your UPS system is the same.

Joining one or more battery cabinets to the UPS

One or more battery cabinets separately located from the UPS.

The Powerware 9350 UPS with Integral Battery Cabinets

Use this procedure to attach a Powerware 9350 Series 685 or Series 1085 Battery Cabinet to any Powerware 9350 UPS cabinet (see Figure 6).

Figure 6. UPS with Integral Battery Cabinet

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