Tripp lite BP480V65-NIB, BP480V40-NIB, BP480V40, BP480V100-NIB, BP480V65 User Manual

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Owner’s Manual

Extended-Run

Battery Cabinet

Models: BP480V40, BP480V40-NIB, BP480V65,

BP480V65-NIB, BP480V100, BP480V100-NIB

Not suitable for mobile applications.

Este manual esta disponible en español en la página de Tripp Lite:

www.tripplite.com

Ce manuel est disponible en français sur le site Web de Tripp Lite :

www.tripplite.com

Русскоязычная версия настоящего руководства представлена на

веб-сайте компании Tripp Lite по адресу: www.tripplite.com

Dieses Handbuch ist in deutscher Sprache auf der Tripp Lite-Website verfügbar:

www.tripplite.com

1111 W. 35th Street, Chicago, IL 60609 USA • www.tripplite.com/support

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Table of Contents

1. Introduction 3

Features 3

2. Important Safety 4 Instructions

Installation and 4 Location Warnings

Connection Warnings 4 Battery Warnings 5

3. Battery Cabinet Installation 7

3.1 Preparation 7

3.2 Transportation 7

3.3 Mechanical Check 7

3.4 Internal Wiring (Typical) 8

3.5 Preliminary Electrical Check 8 (After Battery Installation)

3.6 Battery Cabinet Placement 8

3.7 Electrical Connection 9

3.8 Final Electrical Check 10

4. Operation and Charging 11

4.1 Determine Charging Voltages 11

4.2 Initial Charge 11

4.3 Operational Check 11

5. Maintenance 11

5.1 Maintenance Schedule 11

5.1.1 Quarterly Check 11

6. Mechanical Data 12

6.1 Physical Measurements 12

6.1.1 BP480V40/NIB 12 Measurements

6.1.2 BP480V65/NIB and 13 BP480V100/NIB Measurements

6.2 Battery Requirements 14

6.2.1 BP480V40/NIB Battery 14

6.2.2 BP480V65/NIB Battery 14

6.1.3 BP480V100/NIB Battery 14

7. Installation 15

7.1 Battery Pre-Installation 15

7.2 Cable Jumpers and 16 Internal Wiring

7.2.1 Included Cable 16 Jumpers Speciﬁcations

7.2.2 Installing Cable Jumpers 17 to Battery Terminals

7.2.3 Battery Cabinet 18 Internal Wiring

7.3 Battery Installation 21

7.4 Installation Speciﬁcations 33

7.4.1 Installation and 33 Floor Loading Information

7.4.2 Recommended Torque 33

8. Storage and Service 34

9. Warranty 35

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1. Introduction

Tripp Lite’s Extended-Run Battery Cabinets connect to SmartOnline® UPS Systems to provide long-lasting battery backup for data centers, telecommunications, networks, industrial facilities, security, emergency systems and other mission-critical applications that require high capacity, high availability and extended runtime.

Features

• Battery cabinets are available in six options: BP480V40, BP480V40-NIB, BP480V65, BP480V65-NIB, BP480V100 and BP480V100-NIB. The BP480V40, BP480V65 and BP480V100 models include jumpers, terminals, breaker, and 40 x CSB GP 12400, GP 12650 or GPL 121000 batteries in a separate pallet for a complete installation. The BP480V40-NIB, BP480V65-NIB and BP480V100-NIB models are a similar kit but without batteries, allowing users the ﬂexibility to purchase batteries for the cabinet separately.

• Battery cabinets are available in voltages of 480V DC and capacities option of 40Ah, 65Ah and 100Ah@C20 to 1.67VPC

• Battery cabinets contain multiple 12V DC batteries connected in series for higher voltages.

• Each battery cabinet contains 4 shelves with 10 individual batteries (maximum) per shelf.

• Hinged lockable door facilitates access to batteries for periodic maintenance.

• A minimum of 100 mm clearance is located above the individual batteries for access to terminals.

• Battery cabinet is constructed of heavy-gauge steel.

• Baked powder-coat ﬁnish provides chip and corrosion resistance.

• Battery cabinet ships bolted to pallet with a double layer of protective stretch wrap and integrated corner and top protection.

• Appropriate ventilation and convection cooling of individual batteries is provided via spacing between batteries. Front and rear vents allow the free ﬂow of warmer air out of the battery cabinet.

• A molded case circuit breaker is provided for overcurrent protection.

• User-supplied power output cables can be fed into the battery cabinet via built-in conduit knockouts on top of the cabinet.

• For improved safety, higher power density and minimized maintenance, the cabinet systems use Valve-Regulated Lead-Acid (VRLA) recombinant batteries. The electrolyte in these batteries is immobilized in either an absorbent mat separator or a gelling medium, eliminating the spilling hazards and maintenance requirements of free liquid electrolyte. There is no need to add water or measure speciﬁc gravity.

• Because the batteries are recombinant cells that employ an oxygen recombination cycle, minimal gasses are emitted during normal ﬂoat charging. Each cell contains an individual valve, which releases the gas products from overcharge and prevents pressure build-up within the cell.

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2. Important Safety Instructions

SAVE THESE INSTRUCTIONS

All sections of this manual contain instructions and warnings that must be followed during the installation and operation of the battery cabinet described in this manual. Read ALL instructions thoroughly before attempting to move, install or connect your battery cabinet.

Failure to heed these warnings may affect your warranty and cause serious property damage and/or personal injury.

DANGER! LETHAL HIGH-VOLTAGE HAZARD!

All wiring should be performed by a qualiﬁed electrician in accordance with the warnings in this manual and all applicable electrical and safety codes. Incorrect wiring may cause serious personal injury and property damage.

Installation and Location Warnings

• Install the battery cabinet in a controlled indoor environment, away from moisture, temperature extremes, ﬂammable liquids and gasses, conductive contaminants, dust and direct sunlight.

• Install the battery cabinet in a level, structurally sound location.

• The battery cabinet is extremely heavy. Exercise caution when moving or lifting the unit.

• Operate the battery cabinet at indoor temperatures between 0° C and 40° C only. For best results, maintain an ambient indoor temperature of 25° C.

• Allow adequate space around the front and rear of the battery cabinet for proper ventilation. Do not block, cover or insert objects into the battery cabinet’s external ventilation openings.

• Do not place any object on the battery cabinet, especially containers of liquid.

• Do not attempt to stack the battery cabinet. Attempting to stack the battery cabinet may cause permanent damage and create a potential for serious personal injury.

• Do not attempt to unpack or move the battery cabinet without assistance. Use appropriate handling equipment rated to bear the weight and bulk of the battery cabinet, such as freight elevators, pallet jacks and forklifts. (Fully extend forks under load. Spread forks to maximum possible width under load. Lift cabinet from bottom only. Wear safety shoes.)

• For emergency use, install a ﬁre extinguisher rated for energized electrical equipment ﬁres (Class C rating or exact equivalent, with a non-conductive extinguishing agent) near the battery cabinet.

Connection Warnings

• The battery cabinet contains hazardous high voltages that have the potential to cause personal injury or death from electric shock.

• The battery cabinet has its own energy source. The output terminals may be live, even when the battery cabinet is not connected to a UPS system.

• The battery cabinet must be suitably grounded according to all applicable electrical wiring regulations.

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2. Important Safety Instructions

• Use of this equipment in life support applications where failure of this equipment can reasonably be expected to cause the failure of the life support equipment or to signiﬁcantly affect its safety or effectiveness is not recommended.

• De-energize all input and output power sources before installing cables or making electrical connections.

• Use ﬂexible cable of sufﬁcient length to permit battery cabinet servicing.

• Use ferrule caps to cover termination cables and prevent frayed ends from shorting on terminal blocks. Use cabling rated VW-1, FT-1 or better. Use cable sleeves and connector clamps.

• Conﬁrm all cables are marked correctly according to their purpose, polarity and diameter.

• Observe proper polarity by following the positive and negative markings on the unit. Failure to observe proper polarity may damage the batteries and create a serious risk of personal injury and property damage.

• Wiring and assembly should be performed by trained, qualiﬁed electricians only. Refer to the UPS unit’s Owner’s Manual for wire sizing.

Battery Warnings

• The battery cabinet does not require routine maintenance by the user. There are no userserviceable parts inside. Only qualiﬁed, knowledgeable service personnel familiar with all required precautions should open the access panels for any reason. Keep unauthorized personnel away from batteries.

• The battery cabinet contains valve-regulated recombinant lead-acid (VRLA) batteries. Do not attempt to add water to these batteries or sample the electrolyte speciﬁc gravity.

• VRLA batteries can contain an explosive mixture of hydrogen gas. DO NOT SMOKE when near batteries. DO NOT cause ﬂames or sparks near batteries. Discharge static electricity from body before touching batteries. DO NOT open or mutilate batteries—released electrolyte is harmful to the skin and eyes and may be toxic. DO NOT dispose of batteries in a ﬁre—they may explode.

• Batteries present a risk of electrical shock and burns from high short-circuit current. Battery connection or replacement should be performed only by qualiﬁed service personnel observing proper precautions. Use tools with insulated handles. Remove watches, rings or other metal objects. Wear rubber gloves and boots. Do not short or bridge the battery terminals with any object. Do not lay tools or metal parts on top of batteries.

• Replace batteries with equivalent batteries (same number and type) available from Tripp Lite.

• The batteries are recyclable. Refer to local codes for disposal requirements. Do not dispose of batteries except through approved channels in accordance with all applicable local, state and national regulations.

• Do not connect or disconnect batteries when the UPS system is operating from the battery supply or when the unit is not in bypass mode. Disconnect the charging source prior to connection or disconnecting battery terminals.

• If the charging source remains off for an extended period of time, it should be turned on periodically to allow the batteries to recharge. The charging source should be turned on and the batteries should be recharged at least one uninterrupted 24-hour period every 3 months. Failure to recharge the batteries periodically may cause permanent battery damage.

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2. Important Safety Instructions

• Allow batteries to charge uninterrupted for 24 hours after installation.

• Do not attempt to service the integrated battery charger (included with “C” models only). Contact Tripp Lite if service is required.

Note on Labeling

These symbols may appear on the product label: V~: AC Voltage V : DC Voltage

: Ground +: Battery Positive –: Battery Negative

Refer to the product label for model numbers, voltage ratings and other important information.

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3. Battery Cabinet Installation

Read Section 2 – Important Safety

Instructions Before Installation

3.1 Preparation

• At your site, prepare to off-load the battery cabinet from the delivery truck and transport it to the ﬁnal installation location. Consider both the packaged weight and dimensions.

• Make sure the ﬂoor can support the load of the speciﬁc battery cabinet being installed. The battery cabinet must be installed in a structurally sound area with a level ﬂoor that is able to bear the weight of the battery cabinet and other equipment that will be installed nearby.

• Draw a wiring schematic representing the cables connected between the battery cabinet’s output terminal blocks and any external disconnect device, junction box and/or load/rectiﬁer.

• If you plan to store the battery cabinet for an extended period before or after installation, follow the instructions in Section 8. Storage and Service.

3.2 Transportation

1. Inspect the shipping container(s) for visible damage (do not remove the stretch wrap

around the unit until it has been transported to the ﬁnal installation location). Conﬁrm that the model name and rating match the unit you ordered. If you determine the unit has been damaged during shipping or if anything appears to be missing, contact Tripp Lite for assistance. Do not attempt to use the unit if it has been damaged or mishandled.

2. Do not attempt to move or unpack the battery cabinet without assistance. Use appropriate

handling equipment rated to bear the weight and bulk of the battery cabinet, such as freight elevators, pallet jacks and forklifts. (Fully extend forks under load. Spread forks to maximum possible width under load. Lift cabinet from bottom only. Wear safety shoes.) Conﬁrm load limits for freight elevators, handling equipment and ﬂoors along the transport route are not exceeded by the combined weight of the packaged battery cabinet, handling equipment and personnel. Conﬁrm that the packaged unit will pass through any doorways along the intended route.

3. The battery cabinet is secured with stretch wrap to protect it during shipping and

movement within a facility. Remove the stretch wrap from the battery cabinet when the unit is in the ﬁnal installation location—not before.

3.3 Mechanical Check

While the assembled cabinet battery system is still on the shipping pallet, inspect all sides for impact or other damage.

1. Open the front door of the battery cabinet.

2. Conﬁrm none of the individual batteries included on a separate pallet are damaged

(applies to BP480V40, BP480V65 and BP480V100 models only).

3. Conﬁrm none of the internal parts (terminal blocks, circuit breakers and other parts) have

been damaged.

4. Note the individual battery model number. Refer to Section 6.2 for the battery’s terminal

type and recommended torque.

Use insulated tools to tighten all battery terminal connections to the recommended torque.

6. Use insulated tools to tighten the cables from the positive and negative output terminals

at the end batteries to the circuit breaker.

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3. Battery Cabinet Installation

3.4 Internal Wiring (Typical)

• Battery cabinets use multiple 12V DC batteries connected in series to provide nominal DC voltage of 480V DC (±240V DC).

• Internal cabling is sized for speciﬁc application load currents. Do not use any other cable size other than the one provided in the battery cabinet.

• Each battery cabinet shelf includes a speciﬁc wiring diagram. Refer to Section 7. Installation for battery installation details.

• All circuit breakers are in the middle tier of the battery cabinet.

• All load connection polarities will be labeled as “+” (battery positive), “-“ (battery negative) and “N” (battery center tap) for ±240V DC strings.

• All battery cabinets are provided with a branch circuit overcurrent protection device and may be wired directly to the load or UPS.

3.5 Preliminary Electrical Check

(After Battery Installation)

1. With the circuit breaker OFF, measure the battery voltage at the line side of the circuit

breaker using a digital voltmeter. Refer to the diagrams in Section 7.2.3 Battery Cabinet Internal Wiring for more information.

2. Using a digital voltmeter, measure +240V between the “+” (battery positive) and “N”

(battery center tap). Conﬁrm the voltage measures a minimum of +220V DC.

3. Using a digital voltmeter, measure -240V between the “-” (battery negative) and “N”

(battery center tap). Conﬁrm the voltage measures a minimum of -220V DC.

4. Using a digital voltmeter, measure +480V between the “+” (battery positive) and the “-”

(battery negative). Conﬁrm the voltage measures a minimum of +440V DC.

5. If the measured voltage is signiﬁcantly different than anticipated, determine the cause

(e.g. low charge, shorted cell, reversed battery, faulty wiring) and correct the voltage disparity before proceeding.

6. Set the circuit breaker to the “off” position as a safety precaution during installation.

3.6 Battery Cabinet Placement

Place the battery cabinet in a cool location with free airﬂow and away from direct heat sources. The lifespan and performance of a battery may be dramatically affected by elevated temperature, decreasing 50% for each 8.25° C above 25° C.

1. Prepare the surface where the cabinet will be placed. The surface must be clean, ﬂat and

able to support the battery cabinet and other equipment installed nearby. See Section

7.4 for ﬂoor loading speciﬁcations.

2. Allow adequate clearance around the front and rear of the battery cabinet for ventilation

and maintenance. The front door must be accessible to allow easy access to internal batteries, internal fuses and other overcurrent protection devices. See Section 6.1 for dimensions and battery cabinet measurements.

3. If the cabinet will be anchored to the ﬂoor, install appropriate anchor bolts in the mounting

hole located at the bottom of the cabinet. Use washers to create a level surface between the mounting areas around the anchor bolts.

4. Using extreme caution, remove the bolts securing the battery cabinet to the shipping

pallet.

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3. Battery Cabinet Installation

5. Forklift forks should be at maximum width within the cabinet clearance opening and fully

inserted to prevent tipping. Lift cabinet from bottom only. Be careful not to damage the sheet metal ﬂoor of the cabinet with the forks.

6. If the battery cabinet will be secured to the ﬂoor, carefully align and lower the battery

cabinet down on the ﬂoor anchor bolts and secure it in place.

7. If the cabinet will not be secured to the ﬂoor, lower it into the designated space and then

level it using shims. Leveling does not affect performance, but does align the battery cabinet with other equipment in the facility.

3.7 Electrical Connection

DANGER! LETHAL HIGH-VOLTAGE HAZARD!

• The battery cabinet is connected to the load through a DC circuit breaker. This allows the battery to disconnect from the load and charger for maintenance and/or repair.

• The DC molded case circuit breakers are CE-approved for branch circuit protection. If replacement is required, CE-approved components with the same voltage and current rating must be used.

• The size of the load connection cables must consider maximum allowable voltage drop, as well as the cables’ continuous ampere capacity and anticipated ampere discharge rate of the individual battery cabinet. A maximum voltage drop of 1.5V DC in the load connection cables is recommended. Refer to the UPS unit’s Owner’s Manual for recommended wire sizes.

• Refer to all applicable local, state and national codes for appropriate cable size and ratings.

• External circuit protection devices (fuses or circuit breakers) must consider the discharge rate of the battery, the wiring to be protected and the DC short circuit current of the battery.

After performing the installation procedures in Section 7.:

1. Open the front door of the battery cabinet to access internal components. Use a digital

voltmeter when voltage measurements are required.

2. Determine if the battery has been inadvertently grounded by resetting the circuit breaker

to the “On” position and measuring the voltage between the battery cabinet grounding lug and the positive load connection point within the cabinet. This voltage should measure 0 (zero) VDC. If the measured voltage is not zero, determine the cause and correct before proceeding.

3. Return the internal circuit breaker to an open “Off” position as a safety precaution while

connecting the output cables. Doing so prevents damage in the event the cables are accidentally shorted.

4. The top of the battery cabinet includes knockouts for load connection cable entry. Punch

out the appropriate knockout and connect the conduit or cable bushing.

5. The output circuit breaker accommodates cables up to 300 mm2.

6. Connect an appropriate equipment grounding cable to the grounding lug located on the

top of the battery cabinet.

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3. Battery Cabinet Installation

7. Feed the positive and negative cables (and “N” center, if equipped) from the open external

disconnect switch or the UPS battery ﬁeld wiring terminals through the conduit/cable bushing. Connect to the respective output terminals inside the battery cabinet.

3.8 Final Electrical Check

Before closing any connecting circuit breaker or disconnect switch, complete these veriﬁcation steps:

1. Verify the battery cabinet output voltage is correct.

2. If battery cabinets will be operated in parallel, verify that the individual system output

voltages match within 2V DC.

3. Verify the voltage measured between either output terminal and the battery cabinet ground

is zero.

4. If any of the above veriﬁcation steps show an irregularity, determine and correct the cause

before proceeding.

5. Reset the circuit breaker to the “On” position.

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4. Operation and Charging

4.1 Determine Charging Voltages

Your Tripp Lite UPS is already set up for proper ﬂoat and boost voltages from the factory.

4.2 Initial Charge

Proper amp-hour rating and charge current must be manually input into the UPS setup. Refer to the Tripp Lite UPS Owner’s Manual for details.

4.3 Operational Check

1. Measure and record the total system ﬂoat voltage. Measure at the battery terminals.

2. Measure and record the system ﬂoat current using a clamp-on ammeter.

3. Measure and record the ﬂoat voltage of individual battery units.

4. Measure and record the temperature of several batteries. Measure battery temperature

with a digital thermometer by placing the surface thermocouple on the ﬂat surface of the negative terminal—not the “L” connection surface. An infrared temperature monitor may also be used.

5. Optional: Perform impedance and conductance tests on individual battery units. These

tests require special equipment, but the data can be useful in trending the system over time or identifying suspect units during later periodic checks. It may be necessary to disconnect the battery system from the charger/load during these checks.

5. Maintenance

The battery cabinet contains valve-regulated recombinant lead-acid (VRLA) batteries, which are maintenance-free relative to the electrolyte. You cannot add water to these batteries or sample the electrolyte-speciﬁc gravity. It is necessary, however, to periodically check the charging voltage, temperature and connections of the individual battery units.

5.1 Maintenance Schedule

5.1.1 Quarterly Check

Quarterly maintenance by qualiﬁed service personnel is recommended.

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