UPS
BPIV
INSTALLATION & OPERATION MANUAL
10–15 kVA/20–30 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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Table o f Contents
Introduction xiii...............................................
System Configurations xiv........................................
Using This Manual xv............................................
Conventions Used in This Manual xvi...............................
Safety Considerations xvii.........................................
For More Information xviii..........................................
Getting Help xviii..................................................
Section I Installation
1
Getting Started 1---1..........................................
1.1 Installing the UPS 1---1......................................
1.1.1 Creating an Installation Plan 1---1.............................
1.1.2 Preparing Your Site 1---1.....................................
1.1.3 Environment Considerations 1---2.............................
1.1.4 Preparing for Wiring the UPS System 1---2.....................
1.1.5 Inspecting and Unpacking Each Cabinet 1---3..................
2 Installing the UPS System 2---1................................
2.1 Preliminary Installation Information 2---1........................
2.2 UPS Cabinet Installation 2---2.................................
2.2.1 Unloading the Powerware BPIV (10 kVA---15 kVA)
UPS Cabinet from the Pallet 2 ---2.............................
2.2.2 Unloading the Powerware BPIV (10 kVA---15 kVA) Options
Cabinet with Optional Distribution Housing from the Pallet 2---5...
2.2.3 Unloading the Powerware BPIV (20 kVA---30 kVA)
UPS Cabinet from the Pallet 2 ---9.............................
2.2.4 Installing UPS External and Optional Remote Battery
Power Wiring 2---13..........................................
2.2.5 Installing Customer Connections 2---15.........................
2.2.6 Prepare for Installing Accessories 2---15........................
2.3 Battery Cabinet Installation 2---16..............................
2.3.1 Unloading the Battery Cabinet from the Pallet 2---16..............
2.3.2 Joining the Battery Cabinet to the UPS Cabinet 2---16............
2.3.3 Joining Additional Battery Cabinets 2---21.......................
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2.4 Options Cabinet Installation 2---23..............................
2.4.1 Unloading the Options Cabinet from the Pallet 2---23.............
2.4.2 Joining the Options Cabinet to the UPS Cabinet 2---23............
2.4.3 Installing Options Cabinet Internal and Optional Remote
Battery Power Wiring 2---28....................................
2.4.4 Installing Options Cabinet External Power Wiring 2---30...........
2.5 Initial Startup 2--- 32...........................................
2.6 Completing the Installation Checklist 2---32......................
2.6.1 Installation Checklist 2---33....................................
3 Installing and Connecting Batteries 3---1.......................
3.1 Important Safety Instructions 3---1............................
3.2 Battery Type 3--- 2...........................................
3.3 Battery Installation 3---2......................................
3.3.1 Installing Internal Batteries in the UPS Cabinet 3---2.............
3.3.2 Installing Internal Batteries in the Battery Cabinet 3---5...........
3.4 Connecting Batteries 3---5....................................
3.4.1 Electrically Connecting Internal Battery Strings 3---5.............
3.4.2 Electrically Connecting Battery Cabinet Battery Strings 3---6......
3.5 Installing and Connecting Remote Battery System 3--- 8..........
4 Installing a Remote Emergency Power Off (EPO) Control 4---1...
4.1 Installation Procedures 4---1..................................
4 .2 To i ns t al l a R e mo t e E PO : 4 --- 1................................
5 Installing a Remote Monitor Panel 5---1........................
5.1 Installation Procedures 5---1..................................
5 .2 To i ns t al l a n R M P: 5 --- 2......................................
6 Installing an Industrial Relay Card 6---1........................
6.1 Installation Procedures 6---1..................................
6 .2 To i ns t al l a n I R C : 6 --- 2.......................................
Section II Operation
7
Understanding UPS Operation 7---1............................
7.1 Looking Inside the UPS System 7 ---1..........................
7 .2 U PS M o de s 7 --- 3............................................
7.2.1 Normal Mode 7 ---4..........................................
7.2.2 Bypass Mode 7--- 6..........................................
7.2.3 High Efficiency Mode 7---8...................................
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7.2.4 Battery Mode 7---9..........................................
7.2.5 Test and Maintenance Bypass Modes 7---11.....................
7.3 Functional Description 7---12..................................
7.3.1 Input Rectifier 7---12..........................................
7.3.2 Boost Converter and Neutral Regulator 7---13....................
7.3.3 Inverter and Filter 7---13.......................................
7.3.4 Battery and Battery Charger 7--- 13.............................
7.3.5 Bypass 7---13................................................
7.3.6 Maintenance Bypass 7---13....................................
7.3.7 External Batteries 7---13.......................................
8 Operational Controls and Features 8---1........................
8.1 General 8---1...............................................
8.2 UPS Operational Controls 8---1...............................
8.2.1 Control Panel 8---1..........................................
8.2.2 UPS Circuit Breakers 8---4...................................
8.2.3 Smart LOAD OFF 8---4.......................................
8.2.4 Maintenance Bypass Switch 8---4.............................
8.2.5 Cold Start Switch 8 ---4.......................................
8.3 UPS Standard Features 8---4.................................
8.3.1 Customer Interface 8 ---4.....................................
8.3.2 Advanced Battery Management 8---5..........................
8.3.3 High Efficiency Mode 8---5...................................
8.3.4 Customer Convenience Outlet 8---5...........................
8.3.5 Installation Features 8---5....................................
8.3.6 Auto Restart 8---5...........................................
8.4 Options and Accessories 8---6................................
8.4.1 Remote EMERGENCY POWER OFF 8---6......................
8.4.2 Remote Monitor Panel 8---6..................................
8.4.3 Industrial Relay Card 8---6....................................
8.4.4 Options Cabinet 8---6........................................
8.4.5 Battery Cabinets 8---7.......................................
8.4.6 Parallel Cabinet 8--- 7........................................
8.4.7 Communications 8---7.......................................
8.5 Safety Considerations 8--- 8...................................
8.6 Symbols, Controls, and Indicators 8---9........................
9 U s i n g t h e Co n t r o l P a n e l 9 --- 1..................................
9 .1 D es c r ip t io n 9 --- 1............................................
9.2 Using the LCD Screen and Pushbuttons 9---2..................
9 .3 U si n g t h e M a in M e nu 9 --- 3...................................
9.3.1 Mimic Screen 9---3..........................................
9.3.2 System Event Screens 9---4..................................
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9.3.3 Unit Meter Screens 9---6.....................................
9.3.4 System Meter Screens 9---9..................................
9.3.5 Setup Menu Level 0 Screens 9---11.............................
9.3.6 Setup Menu Level 1 Screens 9---13.............................
9.4 System Controls Screen 9---19.................................
9.4.1 Charger Controls Screen 9---21................................
9.5 Unit Shutdown Screen 9--- 22..................................
9.6 Reading the Status I ndicators 9---23............................
10 UPS Operating Instructions 10---1.............................
10.1 Operation 10---1............................................
10.2 Starting the UPS in Normal Mode 10---1.......................
10.3 Starting the UPS in Bypass Mode 10---2.......................
10.4 Starting the Power Processing Unit 10---3.....................
10.5 Cold Starting the UPS 10---4.................................
10.6 T ransfer from Normal to Bypass Mode 10---5...................
10.7 T ransfer from Bypass to Normal Mode 10---6...................
10.8 Transfer from Normal to High Efficiency Mode 10---6............
10.9 Transfer from High Efficiency to Normal Mode 10--- 6............
10.10 T ransfer from Normal to Bypass Mode with UPS Shutdown 10---7
10.11 UPS and Critical Load Shutdown 10---7.......................
10.12 UPS Maintenance Bypass Transfer 10 ---7......................
10.13 Options Cabinet Maintenance Bypass Transfer 10---8...........
10.14 Using the Power Distribution Module 10---8....................
10.15 Using the LOAD OFF Pushbutton 10---8.......................
10.15.1 To Use the LOAD OFF Pushbutton 10---8......................
10.16 Using the REMOTE EMERGENCY POWER OFF Switch 10---9...
10.16.1 To Use the REPO Switch 10---9...............................
11 U s i n g F e a t u r e s 1 1 --- 1.........................................
11.1 General 11--- 1...............................................
11.2 Building Alarm Monitoring 11---1...............................
11.3 General Purpose Relay Contacts 11---1.........................
11.4 Optional Remote Monitor Panel 11 ---2..........................
11.5 Optional Industrial Relay Card 11---3...........................
12 Responding to System Events 12---1...........................
12.1 General 12--- 1...............................................
12.2 System Event Horns 12 ---1....................................
12.3 System Event Lights 12---1....................................
12.4 System Event Messages 12---2................................
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13 Communications 13---1.......................................
13.1 Description 13---1............................................
13.2 Standard Serial Port 13--- 1....................................
13.3 Configuring the Serial Port 13---2...............................
13.4 X-Slot Cards 13 ---2...........................................
13.5 Remote Notification 13 ---3.....................................
13.6 Remote Notification Features 13--- 4............................
13.7 Terminal Mode 13---4.........................................
13.7.1 Display UPS Control Panel 13---4..............................
13.7.2 Event History Log 13---13......................................
14 Maintaining the UPS System 15---1............................
15.1 General 15--- 1...............................................
15.2 Important Safety Instructions 15---1.............................
15.3 Performing Preventive Maintenance 15---3.......................
15.4 Maintenance Training 15 ---4...................................
15 Product Specifications 16---1..................................
16.1 Model Numbers 16---1........................................
16.2 UPS System Input 16---1......................................
16.3 UPS System Output 16---2....................................
16.4 Environmental Specifications 16---3............................
A p p e n d i x A --- C u s t o m e r I n f o r m a t i o n A --- 1.........................
Warranty W---1..................................................
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List of Figures
F ig u re 1 --- 1 . Po w er w ar e B P I V ( 1 0 k VA --- 1 5 k V A)
Cabinet as Shipped on Pallet 1---3...............................
F ig u re 1 --- 2 . Po w er w ar e B P I V ( 2 0 k VA --- 3 0 k V A)
Cabinet as Shipped on Pallet 1---4...............................
Figure 2 ---1. Removing Front Shipping Bracket
( Po we r wa r e B PI V (1 0 k V A --- 1 5 k VA )) 2 --- 3.........................
Figure 2 ---2. Removing Rear Shipping Bracket
( Po we r wa r e B PI V (1 0 k V A --- 1 5 k VA )) 2 --- 4.........................
Figure 2 ---3. Removing Options Cabinet Front Shipping Bracket
( Po we r wa r e B PI V (1 0 k V A --- 1 5 k VA )) 2 --- 7.........................
Figure 2---4. Removing Options Cabinet Rear Shipping Bracket
( Po we r wa r e B PI V (1 0 k V A --- 1 5 k VA )) 2 --- 8.........................
Figure 2 ---5. Removing Front Shipping Bracket
( Po we r wa r e B PI V (2 0 k V A --- 3 0 k VA )) 2 --- 1 0.........................
Figure 2 ---6. Removing Rear Shipping Bracket
( Po we r wa r e B PI V (2 0 k V A --- 3 0 k VA )) 2 --- 1 1.........................
F ig u re 2 --- 7 . B at t er y C a bi n e t I n s ta l la t i on --- P ow e rw a re B PI V ( 1 0 k VA --- 1 5 k V A)
(Non–Permanent Mounting) 2 ---17.................................
F ig u re 2 --- 8 . B at t er y C a bi n e t I n s ta l la t i on --- P ow e rw a re B PI V ( 1 0 k VA --- 1 5 k V A)
(Permanent Mounting) 2---18.....................................
F ig u re 2 --- 9 . B at t er y C a bi n e t I n s ta l la t i on --- P ow e rw a re B PI V ( 2 0 k VA --- 3 0 k V A)
(Non–Permanent Mounting) 2 ---19.................................
F ig u re 2 --- 1 0 . B a tt e ry C a bi n et I ns t a ll a ti o n --- Po we r wa r e B PI V (2 0 k V A --- 3 0 k VA )
(Permanent Mounting) 2---20.....................................
F ig u re 2 --- 1 1 . O p t io n s C a bi n et I ns t a ll a ti o n --- Po we r wa r e B PI V ( 1 0 k VA --- 15 k VA )
(Non–Permanent Mounting) 2 ---24.................................
F ig u re 2 --- 1 2 . O p t io n s C a bi n et I ns t a ll a ti o n --- Po we r wa r e B PI V ( 1 0 k VA --- 15 k VA )
(Permanent Mounting) 2---25.....................................
F ig u re 2 --- 1 3 . O p t io n s C a bi n et I ns t a ll a ti o n --- Po we r wa r e B PI V ( 2 0 k VA --- 30 k VA )
(Non–Permanent Mounting) 2 ---26.................................
F ig u re 2 --- 1 4 . O p t io n s C a bi n et I ns t a ll a ti o n --- Po we r wa r e B PI V ( 2 0 k VA --- 30 k VA )
(Permanent Mounting) 2---27.....................................
F ig u re 3 --- 1 . B at t er y S c h e m a ti c --- Po w er w ar e B P IV ( 10 k VA --- 1 5 k V A) U PS
and Battery Cabinet 3--- 3........................................
F ig u re 3 --- 2 . B at t er y S c h e m a ti c --- Po w er w ar e B P IV ( 20 k VA --- 3 0 k V A) U PS 3 --- 4...
Figure 3 ---3. Battery String Connection 3---7..................................
F ig u re 4 --- 1 . R em o t e E P O C o nt r o l 4 --- 1......................................
Figure 4---2. Remote EPO Control
(inside view of cover and enclosure bottom) 4---2..................
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F ig u re 5 --- 1 . R em o t e M o n it o r P an e l ( RM P ) 5 --- 1...............................
Figure 5---2 Remote Monitor Card 5---3......................................
F ig u re 5 --- 3 . R em o t e M o n it o r P an e l ( RM P ) --- Top I nt e r na l V i ew 5 --- 3.............
F ig u re 6 --- 1 I nd u st r i al R e l ay C ar d 6 --- 1.......................................
F ig u re 7 --- 1 . M ai n E l em e nt s o f t h e U P S S y st e m 7 --- 2...........................
Figure 7 ---2. Path of Current Through the UPS in Normal Mode 7---4.............
Figure 7 ---3. Path of Current Through the UPS in Bypass Mode 7---6.............
Figure 7 ---4. Path of Current Through the UPS in High Efficiency Mode 7---8......
Figure 7 ---5. Path of Current Through the UPS in Battery Mode 7 ---9.............
Figure 7 ---6. Path of Current Through the UPS in Test Mode 7---11................
Figure 7 ---7. Path of Current Through the UPS in Maintenance Bypass Mode 7---12.
F ig u re 8 --- 1 . Po w er w ar e B P I V ( 1 0 k VA --- 1 5 k V A) U PS C o nt r o ls a nd I nd i ca t o rs 8 --- 2.
F ig u re 8 --- 2 . Po w er w ar e B P I V ( 2 0 k VA --- 3 0 k V A) U PS C o nt r o ls a nd I nd i ca t o rs 8 --- 3.
F ig u re 9 --- 1 . U PS C o nt r o l P a ne l 9 --- 1.........................................
F ig u re 9 --- 2 . Pa r t s o f t he L C D S c re e n 9 --- 2....................................
F ig u re 9 --- 3 . M im i c S c r ee n 9 --- 3.............................................
F ig u re 9 --- 4 . E ve n t S im p le H is t o ry L og S c re e n 9 --- 4............................
F ig u re 9 --- 5 . E ve n t H is t o ry (A l l) L o g S c r ee n 9 --- 5...............................
Figure 9 ---6. Active System Events Screen 9---5...............................
Figure 9 ---7. Input Meter Screen 9---6........................................
F ig u re 9 --- 8 . O ut p ut M e te r S c re e n 9 --- 7.......................................
F ig u re 9 --- 9 . B yp a ss M et e r S c re e n 9 --- 7......................................
F ig u re 9 --- 1 0 . B a tt e ry M et e r S c re e n 9 --- 8......................................
F ig u re 9 --- 1 1 . O u t pu t C u rr e nt ( L oa d ) M et e r S cr e en 9 --- 8.........................
Figure 9 ---12. System Input Meter Screen 9---9.................................
F ig u re 9 --- 1 3 . S y s t e m O u tp u t M et e r S c re e n 9 --- 1 0...............................
Figure 9---14. System Bypass Meter S creen 9---10...............................
Figure 9 ---15. Setup Menu Level 0 Screen 9 ---11.................................
Figure 9---16. Contrast Adjust Menu Screen 9---11...............................
F ig u re 9 --- 1 7 . V er s io n s S c re e n 9 --- 1 2...........................................
F ig u re 9 --- 1 8 . U n it Ty pe S cr e en 9 --- 1 2..........................................
F ig u re 9 --- 1 9 . E n te r P a ss w or d S c r ee n 9 --- 1 3....................................
Figure 9 ---20. Setup Menu Level 1 Screen 9 ---14.................................
F ig u re 9 --- 2 1 . C h an g e P as s wo r d S c re e n 9 --- 1 5..................................
F ig u re 9 --- 2 2 . C h an g e P as s wo r d S a ve S c re e n 9 --- 1 6.............................
F ig u re 9 --- 2 3 . D a t e & T im e S c re e n 9 --- 1 7.......................................
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F ig u re 9 --- 2 4 . P o rt S et u p S c re e n 9 --- 1 8.........................................
Figure 9 ---25. System Controls Screen in Normal Mode 9---19.....................
Figure 9 ---26. System Controls Screen in High Efficiency Mode 9---20..............
F ig u re 9 --- 2 7 . C h ar g er C o nt r o l s S cr e en 9 --- 2 1...................................
F ig u re 9 --- 2 8 . S h ut d o wn S cr e en 9 --- 2 2.........................................
F ig u re 1 1 --- 1 . R e mo t e M o ni t o r P a ne l 1 1 --- 2.....................................
F ig u re 1 1 --- 2 . I n du s t ri a l R e l ay C ar d 1 1 --- 3.......................................
Figure 13 ---1. Serial Port Pin Assignments 13 ---1.................................
F ig u re 1 3 --- 2 . O p t io n al X- Sl o t C a rd s 13 --- 3......................................
F ig u re 1 3 --- 3 . M a in S c re e n --- U PS N o rm a l M im i c 1 3 --- 5..........................
F ig u re 1 3 --- 4 . M a in S c re e n --- U PS O n B a tt e ry M im i c 1 3 --- 5.......................
F ig u re 1 3 --- 5 . M a in S c re e n --- U PS O n B y pa s s M im i c 1 3 --- 6.......................
F ig u re 1 3 --- 6 . S y s t e m C o nt r o ls 1 3 --- 6..........................................
F ig u re 1 3 --- 7 . L o a d O f f 1 3 --- 7..................................................
F ig u re 1 3 --- 8 . E v en t s --- H i st o ry 1 3 --- 7..........................................
F ig u re 1 3 --- 9 . E v en t s --- A c ti v e 1 3 --- 8...........................................
F ig u re 1 3 --- 1 0. I np u t M et e r 13 --- 8...............................................
F ig u re 1 3 --- 1 1. O ut p ut M e te r 1 3 --- 9.............................................
F ig u re 1 3 --- 1 2. B yp a ss M et e r 1 3 --- 9.............................................
F ig u re 1 3 --- 1 3. O ut p ut C u rr e nt ( Lo a d ) M e t er 13 --- 1 0................................
F ig u re 1 3 --- 1 4. S et u p 1 3 --- 1 0....................................................
Figure 13 ---15. Contrast Adjust 13---11...........................................
Figure 13 ---16. Date and Time Setup 13---11......................................
Figure 13 ---17. Serial Port Setup 13---12..........................................
Figure 13 ---18. Versions 13---12..................................................
F ig u re 1 3 --- 1 9. E ve n t H is t o ry L og 13 --- 1 4.........................................
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List of Tables
Ta b le 4 --- 1 . R em o t e E P O W i r e Te r m i na t i on s 4 --- 3.................................
Ta b le 4 --- 2 . R em o t e E P O 4 --- 3.................................................
Ta b le 5 --- 1 . R MP W i re Te r mi n at i o ns 5 --- 2........................................
Ta b le 6 --- 1 . I RC W i r e Te rm i na t i on s 6 --- 2.........................................
Ta b le 1 3 --- 1 . P i n A s s ig n me n ts f o r S e r ia l P or t (D B --- 9) 1 3 --- 3.........................
Ta b le 1 3 --- 2 . S e ri a l C om m un i ca t i on s P o rt 1 3 --- 3...................................
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Introduction
Powerware BPIV UPS true double conversion 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 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 your building’s electrical system, the UPS
System supplies clean, consistent power that your sensitive electronic equipment
requires for reliable operation. During brownouts, blackouts, and other power
interruptions, internal and optional external battery strings provide emergency power to
safeguard your operation.
The UPS system is housed in free-standing cabinets. The cabinet sections line up and
match in style and color, and have safety shields behind the front panels for hazardous
voltage protection. The following illustrations depict a typical Powerware BPIV
(10 kVA---15 kVA) UPS System and a typical Powerware BPIV (20 kVA--- 30 kVA) UPS
System
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BATTERY
CABINET
(OPTIONAL )
UPS
CABINET
OPTIONS
CABINET
(OPTIONAL )
Ty p i c a l P o w e r w ar e B P I V ( 1 0 k VA --- 1 5 k VA ) U P S S y s t e m
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OPTIONS
CABINET
(OPTIONAL )
Ty p i c a l P o w e r w ar e B P I V ( 2 0 k VA --- 3 0 k VA ) U P S S y s t e m
System Configurations
These UPS system configurations are possible:
• Single Module UPS with integral battery
• Single Module UPS with integral battery and optional options cabinet
UPS
CABINET
BATTERY
CABINET
(OPTIONAL )
• Single Module UPS with integral battery and optional battery cabinet
• Single Module UPS with integral battery, optional battery cabinet, and optional
options cabinet
• Single Module UPS with remote battery
• Single Module UPS with remote battery and optional options cabinet
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• Parallel System with one to four UPS modules with remote battery and optional
options cabinet
• Paral l el System with one to four UPS modules and integral battery
• Paral lel System with one to four UPS modules, integral battery, and optional
battery cabinet
• Parallel System with one to four UPS modules and remote battery
You can enhance any of these system configurations by adding an optional
accessories, such as a Remote Emergency Power Off (EPO) control, a Remote Monitor
Panel (RMP), and X-Slot
t communications connectivity features.
Using This Manual
Your UPS functions automatically and requires very little attention during normal
operation. However, you should read and understand the procedures described in this
manual to ensure trouble-free operation. In particular, you should be thoroughly
familiar with the Remote Emergency Power Off procedure described in Chapter 10 of
this manual.
The information in this manual is divided into the sections and chapters listed.
The system you are installing dictates which parts of this manual you should read.
Everyone should read, at a minimum, the Introduction, Chapters 1, 2, 8, 9, and 10.
Introduction
The Introduction provides a brief description of the UPS system, a description of the
content of each chapter, text conventions used in the manual, safety, and reference
information.
Section I
• 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 UPS System -- describes how to install the UPS
cabinets and optional equipment.
• Chapter 3 -- Installing Batteries -- provides battery safety, installation and
connection information.
• Chapter 4 -- Installing a Remote EPO Control -- contains information for
installing the optional Remote Emergency Power Off (EPO) control.
• Chapter 5 -- Installing a Remote Monitor Panel -- contains information for
installing the optional Remote Monitor Panel (RMP).
• Chapter 6 -- Installing an Industrial Relay Card-- contains information for
installing the optional Industrial Relay Card (IRC).
Section II
• Chapter 7 -- Understanding UPS Operation -- provides information on
understanding UPS operation.
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• Chapter 8 -- Operational Controls and Features -- describes the standard
and optional operational features and controls of the UPS system.
• Chapter 9 -- Using the Control Panel -- describes the controls and indicators
found on the Control Panel and shows the various information screens
displayed on the LCD screen.
• Chapter 10 -- UPS Operating Instructions -- 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.
• Chapter 13 -- Communications -- describesthecommunicationsfeaturesof
the UPS system.
• Chapter 14 -- Maintaining the UPS System -- contains maintenance
instructions for the UPS system.
• Chapter 15 -- 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.
• Warranty -- provides the Powerware warranty for this product.
Read through each procedure before you begin. Perform only those procedures
that apply to the UPS system you are installing or o perating.
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.
• Italic type highlights notes and new terms where they are defined.
• Rectangular boxes containing bold type are warnings or cautions that pertain to
the UPS 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 the entire power protection system—the UPS modules,
battery strings and options or accessories installed.
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Safety Considerations
The UPS cabinet is designed for industrial or computer room applications, and contain
safety shields behind the doors. 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 and locked to ensure proper cooling airflow
and to protect personnel from dangerous voltages inside the unit.
• The UPS system contains its own power source. Lethal voltages are
present even when the UPS is disconnected from utility power.
WARNING:
Only AUTHORIZED SERVICE PERSONNEL should perform maintenance on or
service the UPS 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.
• Battery maintenance or battery replacement should be performed only by
authorized service personnel.
• Observe all DANGER, CAUTION, and WARNING notices affixed to the
inside and outside of the equipment.
Powerware BPIV (10 kVA-- 30 kVA) Installation and Operation
164201406 Rev. C 013004
xvii
For More Information
This manual describes how to install and operate the UPS modules. For more
information about the installation and operation of a Parallel System, refer to the
following:
164201409 Powerware
Manual
The Installation section, provides installation instructions for the
Parallel cabinet. Site preparation, planning for installation, and
wiring and safety information are supplied. Detailed illustrations
of the cabinet, including dimensional and connection point
drawings are provided.
The Operation section, explains the functions of the Parallel
System; ; provides procedures for operating the Parallel System,
and information about maintenance and responding to system
events.
Contact your local Invensys Powerware Field Service office for information on how
to obtain copies of this manual.
BPIV Parallel Cabinet Installation and Operation
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
xviii
Powerware BPIV (10 kVA-- 30 kVA) Installation and Operation
164201406 Rev. C 013004
Section I
Installation
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Powerware BPIV (10 kVA-- 30 kVA) Installation and Operation
164201406 Rev. C 013004
n
Getting Started
1.1 Installing the UPS
The cabinet sections of the UPS are shipped on separate pallets. Use a forklift or
pallet jack, rated to handle the weight of the cabinets (refer to Drawing
164201406---3 in Appendix A for cabinet weights), to move the packaged cabinet
sections to the installation site, or as close as possible to the site, before unloading
from the pallet.
This is the basic sequence of the installation steps:
1. Create an installation plan for the UPS system (Chapter 1).
2. PrepareyoursitefortheUPSsystem(Chapter1).
3. Inspect, unpack, and unload the UPS cabinet sections (Chapter 1).
4. Wire the system (Chapter 2).
1
5. Install features, accessories, and/or options, as applicable (Chapter 3).
6. Complete the Installation Checklist (Chapter 2).
7. Have authorized service personnel perform preliminary operational checks and
startup.
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. Contact service in advance (usually a two week
notice is required) to reserve a preferred startup date.
1.1.1 Creating an Installation Plan
Before beginning to install the UPS system, read and understand how this manual
applies to the system being installed. Use the procedures and illustrations in the
following chapters to create a logical plan for installing the system.
1.1.2 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 system 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 weight, airflow, size and clearance,
requirements specified in Appendix A.
Powerware BPIV (10 kVA-- 30 kVA) Installation and Operation
164201406 Rev. C 013004
1--1
The basic environmental requirements for operation of the UPS system are:
Ambient Temperature Range: 0 --- 4 0 ˚C (32---104˚F)
Recommended Operating Range: 20 ---25˚C (68---77˚F)
Maximum Relative Humidity: 95%, noncondensing
The UPS cabinets use forced air cooling to regulate internal component
temperature. Air inlets are in the front of the cabinet, and outlets are in the rear of
the cabinet. You must allow clearance in front of and behind each cabinet for
proper air circulation. Refer to Drawing 164201406---3 of Appendix A for clearance
requirements.
1.1.3 Environment Considerations
The life of the UPS system is adversely affected if the installation does not meet the
following guidelines:
1. The system must be installed on a level floor suitable for computer or
electronic equipment.
2. The system must be installed in a temperature-controlled indoor area free of
conductive contaminants.
Failure to follow guidelines may invalidate UPS warranty.
1.1.4 Preparing to Wire the UPS System
For external wiring requirements, including the minimum AWG size of external
wiring, refer to Tables A through E in Appendix A for the Powerware BPIV (10
kVA---15 kVA) UPS or T ables NO TAG through K in Appendix A for the Powerware
BPIV (20 kVA--- 30 kVA) UPS. The power wiring connections for this equipment are
rated at 90˚C. Control wiring for EPO and optional accessories (such as building
alarms and monitoring interface) should be connected at the customer interface
panels and terminal blocks located inside the UPS using class 1 wiring methods.
1--2
Powerware BPIV (10 kVA-- 30 kVA) Installation and Operation
164201406 Rev. C 013004
1.1.5 Inspecting and Unpacking Each Cabinet
The first task in preparing for installation is inspecting and unpacking the UPS
sections. The UPS and accessory cabinets are shipped bolted to wooden pallets,
as shown in Figures 1---1 or 1---2, and protected with outer protective packaging
material.
Figure 1 ---1. Powerware BPIV (10 kVA --- 15 kVA) UPS Cabinet as Shipped on Pallet
Powerware BPIV (10 kVA-- 30 kVA) Installation and Operation
164201406 Rev. C 013004
1--3
Figure 1 ---2. Powerware BPIV (20 kVA--- 30 kVA) UPS Cabinet as Shipped on 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.
2. Use a forklift or other material handling equipment to move the cabinet to a
convenient unpacking area. Insert the forklift jacks between the pallet
supports on the bottom of the unit.
CAUTION:
Do not tilt cabinets more than 10 degrees from vertical.
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Powerware BPIV (10 kVA-- 30 kVA) Installation and Operation
164201406 Rev. C 013004
3. Set each pallet on a firm, level surface, allowing a minimum clearance of
3m (10 ft) on each side for removing the cabinets from the pallets.
4. Remove the protective covering from the cabinets.
5. Remove the packing material, and discard or recycle 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 Lading. If damage
has occurred or shortages are evident, contact the Powerware, Inc. Customer
Service Department immediately to determine the extent of the damage and its
impact upon further installation.
NOTE: While waiting for installation, protect the unpacked UPS cabinets from
moisture, dust, and other harmful contaminants. Failure to store and
protect the UPS properly may void the warranty.
Powerware BPIV (10 kVA-- 30 kVA) Installation and Operation
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Powerware BPIV (10 kVA-- 30 kVA) Installation and Operation
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Installing the UPS System
2.1 Preliminary Installation Information
WARNING:
Installation should be performed only by qualified personnel.
Refer to the following while installing the UPS system:
• Refer to Appendix A of this manual for installation drawings and additional
installation notes.
• Dimensions in this manual are in millimeters and inches.
• Do not tilt the cabinets more than 10˚ during installation.
• The conduit landing plates are to be removed to add conduit landing holes as
required. Plate material is 16 gauge steel (0.060 in. thick).
• The cabinets must be installed on a level floor suitable for computer or
electronic equipment.
2
• If perforated floor tiles are required for ventilation, place them in front of the
UPS. Refer to Table X in Appendix A for equipment weight and point loading.
• Details about control wiring are provided in each procedure for connecting
options and features. Drawing 164201406---2 and Tables U and V in
Appendix A identify the control wiring terminations.
Powerware BPIV (10 kVA-- 30 kVA) Installation and Operation
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2--1
2.2 UPS Cabinet Installation
To install an UPS cabinet, perform the procedures in the following paragraphs.
2.2.1 Unloading the Powerware BPIV (10 kVA --- 15 kVA) UPS
Cabinet from the Pallet
The UPS cabinet is bolted to a wooden pallet supported by wood skids. To
remove the pallet, perform the following procedure:
WARNING:
The UPS cabinet is heavy. Refer to Drawing 164201406--3 in Appendix A for
weight of cabinets. If unloading instructions are not closely followed, the
cabinet may cause serious injury.
CAUTION:
Do not tilt cabinets more than 10 degrees from vertical.
1. Use a forklift or other material handling equipment to move the cabinet to the
installation area. Insert the forklift jacks between the skids on the bottom of
the unit.
2. Remove left front solid panel, and right front vented panel from UPS cabinet.
Front panels are secured with magnetic latches and are removed by pulling
panels straight forward to disengage magnetic latches (see Figure 2 ---1).
3. If the leveling feet are not fully retracted, turn the leveling feet until they are
retracted.
4. Remove three bolts, (1) in Figure 2 ---2, securing the rear shipping bracket (3)
to the cabinet and three bolts (2) securing the bracket to the pallet. Remove
the rear shipping bracket. If installing cabinet permanently, retain shipping
brackets and securing hardware for later use.
5. Remove three bolts, (1) in Figure 2 ---1, securing front shipping bracket (3) to
the pallet. Do not remove bolts (2) securing the bracket to the cabinet.
6. Remove three bolts, (4) in Figure 2 ---2, securing removable skid (5) and
remove skid.
NOTE: In the following step the pallet will tilt and act as a ramp once the cabinet is
rolled beyond the the center of the pallet. Make sure to restrain the cabinet
as it continues to roll down the pallet/ramp. The front shipping bracket will
act as a brake to assist restraining the cabinet.
WARNING:
Do not stand directly behind the pallet while unloading the cabinet If
unloading instructions are not closely followed, the cabinet may cause
serious injury.
7. Slowly roll the cabinet toward the rear of the pallet. Once the pallet tilts,
continue rolling the cabinet down the pallet until the cabinet is clear of the
pallet.
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Powerware BPIV (10 kVA-- 30 kVA) Installation and Operation
164201406 Rev. C 013004
PALLET
VENTED
FRONT
PANE L
SHIPPING
BOLTS (2)
SOLID
FRONT
PANE L
SHIPPING
BOLTS (1)
FRONT
SHIPPING
BRACKET (3)
F i g u r e 2 --- 1 . R e m o v i n g F r o n t S h i p p i n g B r a c k e t ( P o w e r w a r e B P I V ( 1 0 k V A --- 1 5 k V A ) )
Powerware BPIV (10 kVA-- 30 kVA) Installation and Operation
164201406 Rev. C 013004
FRONT VIEW
2--3
PALLET
REAR
SHIPPING
BRACKET (3)
SKID BOLTS (4)
(3 PLACES)
REMOVABLE
SKID (5)
SHIPPING
BOLTS (1)
SHIPPING
BOLTS (2)
Figure 2 ---2. Removing Rear Shipping Bracket (Powerware BPIV (10 kVA --- 15 kVA))
2--4
REAR VIEW
Powerware BPIV (10 kVA-- 30 kVA) Installation and Operation
164201406 Rev. C 013004
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