9
Uninterruptible Power
Supply
500 kVA -- 750 kVA
315
Installation and Operation
Manual
164201244 Rev. D
------------------------------------------------------------------------
------------------------------------------------------------------------
----------------------------------
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.
WARNING:
This is a product for restricted sales distribution to informed partners. Installation
restrictions or additional measures may be needed to prevent disturbances.
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Tabl e of C onte n ts
Introduction xi...............................................
Basic System Configurations xii...................................
Using This Manual xii............................................
Conventions Used in This Manual xiv...............................
Safety Considerations xiv.........................................
For More Information xv..........................................
Getting Help xv..................................................
Section I Installation
Getting Started 1---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 SingleModuleInstallation 2---2...............................
2.2.1 Installing the UPS Cabinet Sections 2--- 2.......................
2.2.2 Installing UPS Internal Power and Control Wiring 2--- 2...........
2.2.3 Installing UPS External Power and Control Wiring 2--- 3..........
2.2.4 Installing Input/Rectifier Customer Connections 2--- 4............
2.2.5 Installing Output/Inverter Customer Connections 2--- 4...........
2.2.6 Prepare for Installing Optional Accessories 2--- 5................
2.3 Multi-Module Installation 2--- 5.................................
2.3.1 Installing the UPS Cabinet Sections 2--- 5.......................
2.3.2 Installing UPS Internal Power and Control Wiring 2--- 5...........
2.3.3 Installing UPS External Power and Control Wiring 2--- 6..........
2.3.4 Installing Input/Rectifier Customer Connections 2--- 6............
2.3.5 Installing Output/Inverter Customer Connections 2--- 6...........
2.3.6 Prepare for Installing Optional Accessories 2--- 6................
2.4 Initial Startup 2--- 7...........................................
2.5 Completing the Installation Checklist 2---7......................
2.5.1 Installation Checklist 2--- 8....................................
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3 Installing Batteries 3---1.......................................
4 Installing a Remote Battery Disconnect 4---1...................
5 Installing a Remote EPO Control 5---1..........................
6 Installing a Remote Monitor Panel 6---1........................
7 Installing a Relay Interface Module 7--- 1.......................
8 Installing a Supervisory Contact Module 8---1..................
Section II Operation
9
Understanding UPS Operation 9---1............................
9.1 Looking Inside the Parallel Capacity/Redundant System 9--- 1.....
9.2 Normal, Battery, and Bypass Modes 9---2......................
9.3 Normal Mode 9---3..........................................
9 . 4 B y p a s s M o d e 9 --- 4..........................................
9.5 Battery Mode 9---5..........................................
10 Operational Controls and Features 10---1......................
10.1 General 10---1...............................................
10.2 UPS Standard Features 10--- 1.................................
10.2.1 Control Panel 10--- 1..........................................
10.2.2 UPS Circuit Breakers 10--- 3...................................
10.2.3 EMERGENCY UPM OFF 10--- 3................................
10.2.4 Customer Interface 10--- 3.....................................
10.2.5 Automatic Battery Charge Current Limit 10---3...................
10.2.6 Customer Convenience Outlet 10--- 4...........................
10.2.7 Installation Features 10--- 4....................................
10.3 Options and Accessories 10---4................................
10.3.1 5% Input Filter 10--- 4.........................................
10.3.2 Battery 10--- 4................................................
10.3.3 External Fused Battery Disconnect 10---4.......................
10.3.4 Upgrade Capability 10---4.....................................
10.3.5 Remote Monitor Panel 10 ---4..................................
10.3.6 Relay Interface Module 10---5..................................
10.3.7 Modem 10---5...............................................
10.4 Safety Considerations 10---5...................................
10.5 Symbols, Controls, and Indicators 10---6........................
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11 U s i n g t h e C o n t r o l P a n e l 1 1 --- 1.................................
11.1 Description 11--- 1............................................
11.2 Using the LCD Screen 11--- 2..................................
11.3 Using the Pushbuttons 11 ---3..................................
11.4 Adjusting the Contrast 11---3..................................
11.5 Reading the Status Indicators 11---4............................
11.6 Using the Menu Options 11--- 5................................
11.6.1 System Meters Screen 11--- 6..................................
11.6.2 Load Amp Meters Screen 11--- 7...............................
11.6.3 Software Versions Screen 11---8...............................
11.6.4 System History Screen 11--- 9..................................
11.6.5 Active System Events Screen 11---10............................
11.6.6 Unit Statistics Screen 11---11...................................
11.6.7 Mimic Screen 11--- 12..........................................
11.6.8 T ime Setup Screen 11--- 13.....................................
11.6.9 Port Setup Screen 11--- 14......................................
12 UPS Operating Instructions 12--- 1.............................
12.1 Operation 12--- 1.............................................
12.2 Starting the UPS 12--- 1.......................................
12.3 Starting the UPS in Bypass Mode 12--- 3........................
12.4 Transfer to Bypass Mode 12---3................................
12.5 Transfer to Normal Mode 12 ---3................................
12.6 Transfer to Bypass with UPS Shutdown 12---4...................
12.7 UPS and Critical Load Shutdown 12--- 4.........................
12.8 Using the UPS EMERGENCY UPM OFF Pushbutton 12--- 4........
12.8.1 To Use the UPS EMERGENCY UPM OFF Pushbutton 12--- 5.......
12.8.2 Resetting the UPS System after an EMERGENCY UPM OFF 12---5.
13 Using Features and Options 13---1.............................
13.1 General 13---1...............................................
13.2 Building Alarm Monitoring 13 ---1...............................
13.3 General Purpose Relay Contacts 13--- 1.........................
13.4 Remote Monitor Panel 13---2..................................
13.5 Relay Interface Module 13---4..................................
13.6 Supervisory Contact Module 13--- 5.............................
13.7 Battery Racks 13--- 6..........................................
13.8 External Battery Disconnect 13--- 6..............................
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v
14 Responding to System Events 14---1...........................
14.1 General 14---1...............................................
14.2 System Event Horns 14---1....................................
14.3 System Event Lights 14---1....................................
14.4 System Event Messages 14---2................................
15 Serial Communications 15---1.................................
15.1 Description 15--- 1............................................
15.2 Locating the Communications Panel 15--- 1......................
15.3 Connecting Equipment to a Serial Port 15--- 1....................
15.4 Configuring the Serial Ports 15--- 4..............................
15.4.1 Modes 15--- 5................................................
15.4.2 Rate 15--- 5..................................................
15.4.3 Data/Stop 15--- 6.............................................
15.4.4 Handshaking 15--- 6..........................................
15.4.5 Save 15--- 6..................................................
15.4.6 Default Settings 15--- 6........................................
15.5 Terminal Mode 15--- 7.........................................
15.5.1 Printing Selected Information 15---7............................
15.5.2 Entire Log (Ctrl + P) 15---8....................................
15.5.3 Meters Printout (Ctrl + M) 15--- 9...............................
15.5.4 System Information Printout (Ctrl + A) 15--- 9....................
15.6 System Configuration 15 ---10...................................
15.6.1 System Configuration Mode Main Menu 15--- 10...................
15.6.2 Program Building Alarms 15--- 10................................
15.6.3 Enable/Disable Default Functions 15 ---11.........................
15.6.4 Customize Alarm Messages 15---12.............................
15.6.5 Program Unit Name 15---13....................................
15.6.6 Change Password 15---13......................................
15.6.7 Battery T est Setup 15---14......................................
15.6.8 Modify Low Battery Time 15 ---15................................
15.7 Calibration Mode 15--- 15.......................................
15.8 Computer Mode 15--- 15........................................
15.9 Remote Monitor Mode 15 ---15..................................
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16 Remote Notification 16---1....................................
16.1 Description 16--- 1............................................
16.2 Remote Notification Features 16---2............................
16.3 Description of Operation 16 ---3................................
16.3.1 Call Answer 16---3............................................
16.3.2 Call Out 16--- 3...............................................
16.3.3 Housekeeping 16--- 4.........................................
16.4 Hardware Requirements 16---5.................................
16.5 Configuring the Modem 16--- 6.................................
16.5.1 Basic Modem Configuration 16--- 6.............................
16.5.2 Configuring the Modem to Call a Remote Computer 16 ---6........
16.5.3 Configuring the Modem to Call a Numeric Pager 16--- 7...........
16.5.4 Final Modem Configuration 16---8..............................
16.6 UPS Setup Configuration 16---9................................
16.6.1 User Selected Events 16--- 9...................................
17 Maintaining the UPS System 17--- 1............................
17.1 General 17 ---1...............................................
17.2 Important Safety Instructions 17--- 1.............................
17.3 Performing Preventive Maintenance 17--- 3.......................
17.4 Maintenance Training 17---4...................................
18 Product Specifications 18---1..................................
18.1 Model Numbers 18--- 1........................................
18.2 UPS System Input 18---1......................................
18.3 UPS System Output 18 ---2....................................
18.4 Environmental Specifications 18 ---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 r e 4 --- 1 . R e mo t e B a t t er y D i s c o nn e c t E n c lo s u r e 4 --- 1.......................
F ig u r e 5 --- 1 . R e mo t e E P O C o n t r ol 5 --- 1......................................
F ig u r e 6 --- 1 . R e mo t e M o n i to r Pa n el (R M P ) 6 --- 2...............................
Figure 6---2. Terminal Block Bracket 6--- 3....................................
F ig u r e 7 --- 1 . R e la y I n t e rf a c e M o d ul e 7 --- 1....................................
Figure 7---2. Terminal Block Bracket 7--- 2....................................
F ig u r e 8 --- 1 . S up e r v i s o r y C o n t a c t Mo d u le 8 --- 1...............................
Figure 8---2. Terminal Block Bracket 8--- 2....................................
F ig u r e 8 --- 3 . S up e r v i s o r y C o n t a c t Mo d u le TB 2 8 --- 4...........................
F ig u r e 9 --- 1 . M ai n El e me n t s o f t h e U P S Sy s t e m 9 --- 1..........................
Figure 9---2. Path of Current Through the UPS in Normal Mode 9--- 3............
Figure 9---3. Path of Current Through the UPS in Bypass Mode 9---4............
Figure 9---4. Path of Current Through the UPS in Battery Mode 9--- 5.............
F ig u r e 1 0 --- 1 . U P S C o n tr o l s a n d I n d ic a t o rs 1 0 --- 2...............................
F ig u r e 1 1 --- 1 . U P S C o n tr o l P a n el 1 1 --- 1........................................
F ig u r e 1 1 --- 2 . Pa r t s o f th e L C D Sc r e e n 1 1 --- 2...................................
F ig u r e 1 1 --- 3 . S ys t e m M e t er s Sc r e en 11 --- 6....................................
F ig u r e 1 1 --- 4 . L o ad Am p s M e t er s Sc r e en 11 --- 7.................................
F ig u r e 1 1 --- 5 . Ve r s i o n s S c r e en 11 --- 8..........................................
F ig u r e 1 1 --- 6 . E ve n t H i s t or y Lo g S c r e en 1 1 --- 9..................................
Figure 11---7. Active System Events Screen 11 ---10...............................
F ig u r e 1 1 --- 8 . U n i t St a t i s ti c s S c r e en 1 1 --- 1 1......................................
F ig u r e 1 1 --- 9 . M im i c S c r ee n 1 1 --- 1 2............................................
F ig u r e 1 1 --- 1 0. Ti m e S e t up S c r e e n 1 1 --- 1 3........................................
F ig u r e 1 1 --- 1 1. Po r t S e t u p S c r ee n 1 1 --- 1 4........................................
F ig u r e 1 3 --- 1 . R e mo t e M o n i to r Pa n el 13 --- 2.....................................
F ig u r e 1 3 --- 2 . R e la y I n t e rf a c e M o d ul e 1 3 --- 4....................................
F ig u r e 1 3 --- 3 . S up e r v i s o r y C o n t a c t Mo d u le 1 3 --- 5...............................
F ig u r e 1 5 --- 1 . Po r t 1 P i n As s i gn m e nt s 1 5 --- 2....................................
F ig u r e 1 5 --- 2 . Po r t 2 P i n As s i gn m e nt s 1 5 --- 3....................................
F ig u r e 1 5 --- 3 . S e t u p S e r i al Po r t 1 Sc r e en 1 5 --- 4.................................
F ig u r e 1 5 --- 4 . E ve n t H i s t or y Lo g 1 5 --- 8.........................................
F ig u r e 1 5 --- 5 . S ys t e m M e t er s Sc r e en 15 --- 9....................................
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List of Tables
Table 4---1. Remote Battery Disconnect Power Terminations 4---3...................
Table 4---2. Remote Battery Disconnect Circuit Breaker Ratings 4---3................
Ta b le 5 --- 1 . Re m o t e E P O W i r e Te r mi n a t io n s 5 --- 2.................................
Ta b le 5 --- 2 . Re m o t e E P O 5 --- 2.................................................
Ta b le 6 --- 1 . Op t i o na l M o n i t or i n g A c ce s s o r i e s 6 --- 1................................
Ta b le 6 --- 2 . RM P W ir e Te rm i n a ti o n s 6 --- 4........................................
Ta b le 7 --- 1 . RI M W ir e Te r m i n a ti o n s 7 --- 3.........................................
Table 8 ---1. Supervisory Contact Module Wire Terminations 8--- 3...................
Ta b le 13 --- 1 . O p t io n a l M o n it o r i ng Ac c e s so r i e s 13 --- 2...............................
Ta b le 15 --- 1 . P i n A s s ig n m en t s f o r Po r t 1 ( D B --- 9 ) 1 5 --- 2.............................
Ta b le 15 --- 2 . P i n A s s ig n m en t s f o r Po r t 2 ( D B --- 2 5 ) 15 --- 3............................
Ta b le 15 --- 3 . O p t io n s Av ai l a b l e fo r E a c h C o m mu n i ca t i o n P o rt 1 5 --- 5..................
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Introduction
Congratulations on your purchase of a Powerware 9315 (500 kVA--- 750 kVA)
Uninterruptable Power Supply! The Powerware online power protection system is
used 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. And during brownouts, blackouts, and other power
interruptions, optional battery strings provide emergency power to safeguard your
operation.
The UPS system is housed in a free-standing cabinet, divided into three sections to
facilitate shipping. The cabinet sections line up and match in style and color, and have
safety shields behind the doors for hazardous voltage protection. The following
illustration depicts a typical Powerware 9315 (500 kVA---750 kVA) UPS System.
Powerware 9315 (500 kVA--750 kVA) Installation and Operation
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MODULE
BYPASS
CABINET
OUTPUT
INVERTER
CABINET
INPUT
RECTIFIER
CABINET
Typical Powerware 9315 (500 kVA--- 750 kVA) UPS System
xi
Basic System Configurations
These basic UPS system configurations are possible:
· Single Module UPS and one battery string
· Multi-Module (Parallel for Capacity/Redundancy) UPS System consisting of two
or more UPS modules, with one battery string for each module and a
Hot---Sync Capacity module
· Multi-Module (Parallel for Capacity/Redundancy) UPS System consisting of two
or more UPS modules, with one common battery string and a Hot ---Sync
Capacity module
The optional Hot---Sync Capacity system (Parallel for Capacity/Redundancy), using a
System Bypass Module (SBM), allows two or more UPMs to operate in parallel to
provide more capacity than a single UPM and as backup for each other. The Parallel
Capacity/Redundant system can supply up to 4000 Amps, depending on the SBM
used. In addition, when one UPM is taken out of service for maintenance or is not
operating properly, the redundant UPM continues to supply uninterrupted power to the
critical load.
You can enhance any of these system configurations by adding optional accessories,
such as a Remote Monitor Panel (RMP), Relay Interface Module (RIM), Supervisory
Contact Module (SCM), or Remote Emergency Power Off (EPO) control.
Using This Manual
Your UPMs function automatically and require 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 Emergency UPM Off procedure described in Chapter 7 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 the Introduction, Chapters 1 and 2 and Chapters 7 through 12.
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
· 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 and installation
information.
· Chapter 4 -- Installing a Remote Battery Disconnect -- describes how to
install the UPS battery disconnect.
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· Chapter 5 -- Installing a Remote EPO Control -- contains information for
installing the optional Remote Emergency Power Off (EPO) control.
· Chapter 6 -- Installing a Remote Monitor Panel -- contains information for
installing the optional Remote Monitor Panel (RMP).
· Chapter 7 -- Installing a Relay Interface Module -- contains information for
installing the optional Relay Interface Panel (RIM).
· Chapter 8 -- Installing a Supervisory Contact Module -- contains information
for installing the optional Supervisory Contact Module (SCM).
Section II
· Chapter 9 -- Understanding UPS Operation -- provides information on
understanding parallel operation.
· Chapter 10 -- Operational Controls and Features -- describes the standard
and optional operational features and controls of the UPS system.
· Chapter 11-- 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 12 -- UPS Operating Instructions -- contains startup and shutdown
procedures for the UPS system.
· Chapter 13 -- Using Features and Options -- contains descriptions and
instructions for the UPS system features and options.
· Chapter 14 -- Responding to System Events -- lists all the alarm, messages
and notices that occur during operation of the UPS system.
· Chapter 15 -- Serial Communications -- describes the serial communications
features of the UPS system.
· Chapter 16 -- Remote Notification -- contains instructions for using the
remote notification feature of the UPS system.
· Chapter 17 -- Maintaining the UPS System -- contains maintenance
instructions for the UPS system.
· Chapter 18 -- 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 operating.
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xiii
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 Parallel Capacity 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.
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 it s 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.
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For More Information
This manual describes how to install and operate your UPS system. For more
information about the installation and operation of the Powerware Hot Sync --Capacity system, refer to the following:
164201150 Powerware
and Operation
Provides installation instructions for the System Bypass Module
(SBM) cabinet, and optional components and accessories. Site
preparation, planning for installation, and wiring and safety
information are supplied. Detailed illustrations of cabinet and
optional accessories, including dimensional and connection point
drawings are provided.
Describes the SBM Control Panel and explains the functions of
the SBM; discusses the standard features of the SBM and
optional accessories; provides procedures for starting and
stopping the parallel for capacity redundancy system, and
information about maintenance and responding to system events.
A ls o de s c ri b e d a r e t h e R S --- 4 8 5 a n d R S --- 2 3 2 s e ri a l
communications capabilities of the SBM; discusses the two
communications ports on the Customer Interface Panel inside the
SBM and how to connect optional remote accessories to your
SBM; provides information about enabling, disabling, and
customizing building alarms.
Parallel Capacity/Redundant System Installation
Contact your local Powerware Field Service office for information on how to obtain
copies of this manual.
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 Corporation 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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Powerware 9315 (500 kVA--750 kVA) Installation and Operation
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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
164201244--- 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 size and weight requirements shown in
Drawing 164201244---8, and Table P of Appendix A.
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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%
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 top.
You must allow clearance in front of and above each cabinet for proper air
circulation.
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, sealed concrete pad or on a sealed
concrete floor.
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 for Wiring the UPS System
For external wiring requirements, including the minimum AWG size of external
wiring, refer to Table A or B in Appendix A. The power wiring connections for this
equipment are rated at 90˚C. Ifwireisruninanambienttemperaturegreaterthan
30˚C,highertemperaturewireand/orlargersizewiremaybenecessary.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.
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1.1.5 Inspecting and Unpacking Each Cabinet
The first task in preparing for installation is inspecting and unpacking the UPS
sections. The UPS sections are shipped bolted to wooden pallets and protected
with outer protective packaging material, as shown in Figure 1---1, and a plastic
inner covering.
WOODEN PALLET
OUTER
PACKAG I NG
Figure 1 ---1. Cabinets 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.
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.
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. If outer packaging is secured with steel bands, cut and remove the bands from
around each cabinet.
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5. Remove the protective cardboard covering from the cabinets, cutting where
indicated, using a knife blade no longer than 25 mm (1 in.).
6. Remove the plastic bag and foam packing material, and discard or recycle
them in a responsible manner.
7. 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 awaiting installation, protect the unpacked UPS cabinets from
moisture, dust, and other harmful contaminants. Failure to store and
protect the UPS properly may invalidate the warranty.
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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 UPS cabinet sections more than 10˚ during installation.
· The conduit landing plates are to be removed to add conduit landing holes as
required. Plate material is 14 gauge steel (0.075 in. thick).
· The EMERGENCY UPM OFF (EPO)andtheRemoteEmergencyPowerOff
(REPO) pushbuttons normally open all breakers in the UPS, shutdown the UPS,
and isolate power from the critical load. However, the EPO and REPO may be
configured to transfer the UPS to bypass and shutdown the UPS. Local
electrical codes may also require tripping protective devices upstream from the
UPS.
2
· The UPS cabinet sections must be installed on a level, sealed concrete pad or
floor.
· If perforated floor tiles are required for ventilation, place them in front of the
UPS. Refer to Table P in Appendix A for equipment weight and point loading.
· Details about control wiring are provided in each procedure for connecting
options and features. Drawing 164201244--- 2 and Tables K through O in
Appendix A identify the control wiring terminations.
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2.2 Single Module Installation
To install a single module UPS system, perform the procedures in the following
paragraphs. If a multi-module system is being installed, proceed to paragraph 2.3.
2.2.1 Installing the UPS Cabinet Sections
Each UPS cabinet section is bolted to a wooden pallet. To remove the pallets,
perform the following procedure:
WARNING:
The UPS cabinet sections are extremely heavy. Refer to Drawing
164201244 --3 in Appendix A for weight of sections. If unloading instructions
are not closely followed, the cabinet may tip and cause serious injury.
1. Move UPS cabinet sections to the final installed location using a forklift.
2. Remove hardware securing each cabinet section to respective pallet.
CAUTION:
Lift only with forklift or cabinet damage may occur.
3. Using forklift, raise the UPS cabinet section until the cabinet bottom clears the
pallet by approximately 3 mm (1/8 in.).
4. Once UPS cabinet section is clear of the pallet, pull the pallet from under the
UPS cabinet. Discard or recycle them in a responsible manner.
5. Carefully lower the UPS cabinet section until the cabinet base contacts the
floor.
6. Repeat steps 3 through 5 for remaining cabinet sections
2.2.2 Installing UPS Internal Power and Control Wiring
NOTE: The cables used in steps 2 through 4 are coiled inside the Input/Rectifier
cabinet and are attached at the factory to the output of the rectifier. The
cables used in steps 7 and 8 are coiled inside the Module Bypass Cabinet
(MBC) and are attached at the factory to the input of the MBC.
1. Remove the plastic shield covering the inverter input section of the
Output/Inverter cabinet.
2. Route DC Link cables from the rectifier output (Input/Rectifier cabinet) through
cutout in cabinet sides to the inverter input (Output/Inverter cabinet).
3. Connect positive DC Link power wiring to the inverter input. Connect two
cables to each inverter. Refer to Appendix A of this manual for terminal
locations and tightening torque.
4. Connect negative DC Link power wiring to the inverter input. Connect two
cables to each inverter. Refer to Appendix A of this manual for terminal
locations and tightening torque.
5. Reinstall inverter input section plastic shield.
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6. Remove the plastic shield covering the inverter output section of the
Output/Inverter cabinet.
7. Route the MBC input cables from the MBC through cutout in cabinet sides to
the inverter output (Output/Inverter cabinet).
8. Connect phase A, B, and C and Neutral power wiring from MBC to the
respective inverter output. Refer to Appendix A of this manual for terminal
locations and tightening torques.
9. Route ground braid from top of Output/Inverter cabinet to Input/Rectifier
cabinet through cabinet cutouts. Braid is secured at the factory to the
Output/Inverter cabinet mounting stud.
10. Connect ground braid to Input/Rectifier cabinet mounting stud and secure.
11. Route ground braid from top of MBC to Output/Inverter cabinet through
cabinet cutouts. Braid is secured at the factory to the MBC mounting stud.
12. Connect ground braid to Output/Inverter cabinet mounting stud and secure.
13. Reinstall inverter output section plastic shield.
14. Connect the Output/Inverter 15-pin control wiring harness connector to the
Input/Rectifier 15-pin control wiring harness connector. Refer to Appendix A of
this manual for connector locations.
15. Connect the MBC 15-pin control wiring harness connector to the
Output/Inverter 15-pin control wiring harness connector. Refer to Appendix A
of this manual for connector locations.
16. Connect 3-pin control wiring harness connector P6 from the MBC to connector
J6 on Inverter number 2 control board. Refer to Appendix A of this manual for
connector locations.
2.2.3 Installing UPS External Power and Control Wiring
1. Remove the sheetmetal shield covering the input terminal area in the
Input/Rectifier cabinet to gain access to the Battery I/O Customer Interface
and CB2TB. Refer to Appendix A for location of the shield.
NOTE: Remove Input/Rectifier cabinet conduit landing plate to punch conduit holes.
2. Connect phase A, B, and C power wiring from source to respective rectifier
inputs in the Input/Rectifier cabinet. Refer to Appendix A of this manual for
wiring and termination requirements and wiring access information.
3. Connect positive and negative DC power wiring from batteries to the
respective DC inputs in the Input/Rectifier cabinet. Refer to Appendix A of this
manual for wiring and termination requirements and wiring access information.
NOTE: Remove entire MBC top panel to punch conduit holes.
4. Connect phase A, B, and C power wiring from bypass source to respective
bypass inputs in the MBC cabinet. Refer to Appendix A of this manual for
wiring and termination requirements and wiring access information.
5. Connect phase A, B, and C and Neutral power wiring from MBC output to
critical load. Refer to Appendix A of this manual for wiring and termination
requirements and wiring access information
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6. Connect control wiring (battery breaker open and close signals and shunt
DC disconnect) between external battery disconnect and the UPS. Refer to
Appendix A of this manual for wiring requirements and wiring access
information.
7. After wiring the UPS system to the facility power and critical load, be sure to
ground the system according to local and/or national electrical wiring codes.
8. Install batteries in accordance with all applicable codes and regulations,
including the National Electrical Code (NEC), Article 480.
2.2.4 Installing Input/Rectifier Customer Connections
If you are installing connections to the Battery I/O terminal connections and
terminal board CB2TB you must install conduit between each device and the UPS
cabinet for wiring these options. Refer to Appendix A for the location of the
interface points within the UPS cabinet.
To prepare the UPS for wiring to Customer Connec tions:
1. Be sure the UPS system is turned off and all power sources are removed.
(See the operation section of this manual for shutdown instructions.)
2. Remove the sheetmetal shield covering the input terminal area in the
Input/Rectifier cabinet to gain access to the Battery I/O Customer Interface
and CB2TB. Refer to Appendix A for location of the shield.
3. Refer to Appendix A of this manual for terminal assignments, and wiring and
termination requirements.
2.2.5 Installing Output/Inverter Customer Connections
If you are installing connections to a Remote Emergency Power Off (EPO) device,
Building Alarm or Relay contacts, conduit must be installed between each device
and the UPS cabinet. Refer to Appendix A for the locations of the interface points
within the UPS cabinet.
To prepare the UPS for wiring to Customer Connec tions:
1. Be sure the UPS system is turned off and all power sources are removed.
(See the operation section of this manual for shutdown instructions.)
2. Refer to Appendix A of this manual for terminal assignments, and wiring and
terminal requirements.
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2.2.6 Prepare for Installing Optional Accessories
If you are installing optional accessories, such as a Remote Monitor Panel (RMP), a
Relay Interface Module (RIM), or a Supervisory Contact Module (SCM), you must
install conduit between each device and the UPS cabinet for wiring these options.
Refer to Appendix A for the location of the Customer Interface Panel within the UPS
cabinet.
To prepare the UPS for wiring to an RMP, RIM, or SCM:
1.
Be sure the UPS system is turned off and all power sources are removed.
(See the operation section of this manual for shutdown instructions.)
2. Remove the access plate on top of the UPS Input/Rectifier cabinet to gain
access to the Customer Interface Panel (refer to Appendix A for location of
the access plate).
3. Refertochapters6,7,or8asapplicableforinstallationinstructions.
2.3 Multi-Module Installation
To install a multi-module UPS system using a System Bypass Module, perform the
procedures in the following paragraphs.
2.3.1 Installing the UPS Cabinet Sections
Refer to paragraph 2.2.1 for procedure.
2.3.2 Installing UPS Internal Power and Control Wiring
NOTE: The cables used in steps 2 through 4 are coiled inside the Input/Rectifier
cabinet and are attached at the factory to the output of the rectifier.
1. Remove the plastic shield covering the inverter input section of the
Output/Inverter cabinet.
2. Route DC Link cables from the rectifier output (Input/Rectifier cabinet) through
cutout in cabinet sides to the inverter input (Output/Inverter cabinet).
3. Connect positive DC Link power wiring to the inverter input. Connect two
cables to each inverter. Refer to Appendix A of this manual for terminal
locations and tightening torque.
4. Connect negative DC Link power wiring to the inverter input. Connect two
cables to each inverter. Refer to Appendix A of this manual for terminal
locations and tightening torque.
5. Reinstall inverter input section plastic shield.
6. Route ground braid from top of Output/Inverter cabinet to Input/Rectifier
cabinet through cabinet cutouts. Braid is secured at the factory to the
Output/Inverter cabinet mounting stud.
7. Connect ground braid to Input/Rectifier cabinet mounting stud and secure.
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8. Connect the Output/Inverter 15-pin control wiring harness connector to the
Input/Rectifier 15-pin control wiring harness connector. Refer to Appendix A
of this manual for connector locations.
9. Remove the plastic shield covering the inverter output section of the
Output/Inverter cabinet.
10. Refer to the applicable SBM Installation and Operation manual referenced in
the Introduction of this manual for SBM input wiring procedures.
11. Reinstall inverter output section plastic shield.
2.3.3 Installing UPS External Power and Control Wiring
1. Remove the sheetmetal shield covering the input terminal area in the
Input/Rectifier cabinet to gain access to the Battery I/O Customer Interface and
CB2TB. Refer to Appendix A for location of the shield.
NOTE: Remove Input/Rectifier cabinet conduit landing plate to punch conduit holes.
2. Connect phase A, B, and C power wiring from source to respective rectifier
inputs in the Input/Rectifier cabinet. Refer to Appendix A of this manual for
wiring and termination requirements and wiring access information.
3. Connect positive and negative DC power wiring from batteries to the
respective DC inputs in the Input/Rectifier cabinet. Refer to Appendix A of this
manual for wiring and termination requirements and wiring access information.
4. Connect control wiring (battery breaker open and close signals and shunt DC
disconnect) between external battery disconnect and the UPS. Refer to
Appendix A of this manual for wiring requirements and wiring access
information.
5. Refer to the applicable SBM Installation and Operation manual referenced in
the Introduction of this manual for SBM output wiring procedures.
6. After wiring the UPS system to the facility power and critical load, be sure to
ground the system according to local and/or national electrical wiring codes.
7. Install batteries in accordance with all applicable codes and regulations,
including the National Electrical Code (NEC), Article 480.
2.3.4 Installing Input/Rectifier Customer Connections
Refer to paragraph 2.2.4 for procedure.
2.3.5 Installing Output/Inverter Customer Connections
Refer to paragraph 2.2.5 for procedure.
2.3.6 Prepare for Installing Optional Accessories
Refer to paragraph 2.2.6 for procedure.
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2.4 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.
2.5 Completing the Installation Checklist
The final step in installing your UPS system is completing the following Installation
Checklist. This checklist ensures that you have completely installed all hardware,
cables, and other equipment. Completing all items listed on the checklist will
ensure a smooth installation. You should make a copy of the Installation Checklist
before filling it out, and retain the original.
After your installation is complete, a service representative will be able to verify the
operation of your UPS system and commission it to support your 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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2.5.1 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.
-A ground bond is installed between any cabinets that are bolted together.
-All switchboards, conduits, and cables are properly routed to the UPS and auxiliary
cabinets.
-All power cables are properly sized and terminated.
-A ground conductor is properly installed.
-If bypass input neutral connection is used, no other N ---G bonds exist downstream
from the UPS.
-Battery cables and harness are terminated on E4 and E5.
-Internal battery cabinet connections have been completed (bus bars, plugs, etc.).
-Shunt trip signal wiring is connected from UPS to battery breaker(s).
-Air conditioning equipment is installed and operating correctly.
-The area around the installed UPS system is clean and dust-free. (It is recommended
that the UPS be installed on a level, sealed concrete pad or 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.
-Each Remote Monitor Panel (RMP) is mounted in its installed location. (OPTIONAL)
-The control wiring for each RMP is terminated inside the UPS cabinet. (OPTIONAL)
-The Remote Emergency Power Off (EPO) device is mounted in its installed location
and its wiring terminated inside the UPS cabinet. (OPTIONAL)
-Summary alarms and/or building alarms are wired appropriately. (OPTIONAL)
-A Relay Interface Module (RIM) is mounted in its installed location and its wiring is
terminated inside the UPS cabinet. (OPTIONAL)
-A remote battery disconnect control is mounted in its installed location and its wiring is
terminated inside the UPS and battery cabinet. (OPTIONAL)
-Debris shields covering ventilation grills removed from all cabinets.
-Startup and operational checks performed by authorized service personnel.
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