Vertiv Liebert NXC 0060kTJ1AFN02000 User Manual
Liebert® NXC 0kVA
User Manual
NXC 60kVA
UNINTERRUPTIBLE POWER SUPPLY
USER MANUAL
10H52246UM60 - rev. 1
2 User Manual 10H52246UM60 - Rev. 1 - 01/2017
SAFETY PRECAUTION
All rights, including rights of translation, reproduction in
any form or other usage of this document, or any part of it,
are reserved.
Transgressors will be liable for damages.
All rights, including rights created by patent grant or
registration of utility model or design, are reserved.
Delivery subject to availability. The Manufacturer reserves
the right to make changes and/or improvements to the
product without prior notice and without incurring
obligations.
NXC 60kVA may differ from the model displayed on the
front cover.
User Manual 10H52246UM60 - Rev. 1 - 01/2017 3
SPECIAL DECLARATION
Special Declaration
Personnel Safety
1. This product must be installed and commissioned by professional engineers designated by the manufacturer or its
authorized agent. Failure to comply with this condition could result in product malfunction and/or expose personnel
to safety hazards.
2. Take the time to read this product manual and the safety precautions thoroughly before installing and
commissioning this product. Failure to do this could result in product malfunction and/or expose personnel to
safety hazards.
3. This product may not be used as a power supply for life support equipment.
4. Never dispose of the external battery of this product in a fire, as it may explode and jeopardize personnel safety
when exposed to flame.
Product Safety
1. If this product is to be stored or remain de-energized for extended periods, it must be placed in a clean, dry
environment within the specified temperature range.
2. This product should be used in an appropriate operating environment. For details, refer to the section on the
environmental requirement in this manual.
3. The product must not be used in places:
Where the temperature and relative humidity are outside the specified limits
That are subject to vibrations or shocks
Where conductive dusts, corrosive gases, salts, or flammable gases are present
Near sources of heat or strong electromagnetic interference
Disclaimer
Vertiv disclaims any and all responsibility or liability for defects or malfunctions caused by:
Application range or operating environment outside the specified limits
Unauthorized modification, improper installation or operation
Force majeure
Other actions that do not comply with the instructions in this manual
4 User Manual 10H52246UM60 - Rev. 1 - 01/2017
SAFETY PRECAUTION
Safety Precaution
The following safety symbols are important, DO NOT ignore them!
Safety symbol Explanation
Used to alert the user to the risk of death or severe injury in
the event of failure to adhere to the instructions
Used to alert the user to the risk of injury or damage to the
equipment in the event of failure to adhere to the
instructions
Used to advise the user to read the instructions carefully and
adhere to them, irrespective of whether failure to do so
may result in damage and/or injury
This manual contains information explaining how to install and operate single UPS modules and parallel systems
consisting of Vertiv NXC 60kVA UPS.
Read this manual thoroughly before installing, using and servicing the UPS.
Important
This UPS has been designed for commercial and industrial applications in the second environment (see product standard
IEC/EN 62040-2:2006). Installation restrictions or additional measures may be necessary in order to prevent disturbances.
Conformity and standards
This product complies with 2014/35/EU (low voltage safety) and 2014/30/EU (EMC), EMC standards of Australia and New
Zealand (C-Tick), and the following UPS product standards:
* IEC/EN 62040-1+A1:2013 General safety requirements for UPS
* IEC/EN 62040-2:2006-EMC
* IEC/EN 62040-3 Performance requirements and test methods
For details, refer to Chapter 11 Specifications.
Continued compliance requires installation in accordance with these instructions and the use of manufacturer approved
accessories only.
Warning: high earth leakage current
Always connect the unit to earth before connecting the input supply (including both mains and battery supplies).
This equipment is fitted with an EMC filter.
Earth leakage current is 0 ~ 1000mA.
Transient and steady state earth leakage currents, which may occur when the equipment is started, should be taken into
account when selecting instantaneous RCCBs (Residual Current Circuit Breaker) or RCDs (Residual Current Device).
Select RCCBs which are sensitive to unidirectional DC pulses (class A) and insensitive to transient state current pulses.
Note also that the earth leakage currents of the load will be carried by the RCCBs or RCDs.
The equipment must be earthed in accordance with the local electrical authority codes of practices.
Warning: backfeeding protection
This UPS is fitted with a dry contact closure signal for use with an external automatic disconnecting device (not supplied) used
to protect against backfeeding electrical power into the electrical mains supply via the rectifier or bypass static switch circuit.
A label must be placed on the external bypass input supply disconnectng device warning service personnel that the circuit is
connected to a UPS. The text of the label must read as follows: Risk of voltage backfeed! Isolate the UPS, then check for
hazardous voltages between all terminals including the protective earth before working on this circuit.
User Manual 10H52246UM60 - Rev. 1 - 01/2017 5
SAFETY PRECAUTION
Warning
The UPS upstream distribution protection equipment shall be selected in accordance with the details in 3.1.4 Selecting the
UPS I/O Switch and shall comply with the local electrical regulations.
General safety precautions (For users)
Like other types of large power equipment, the UPS and battery circuit breaker box/battery cabinet contain high voltages.
Because components with high voltage can be accessed only by opening the front door (which must be kept locked), the risk
of contact with high voltage has been minimized. This equipment meets the IP20 standard, and other safety panels are
installed inside the equipment.
There will not be any danger if this equipment is operated according to the general instructions and the steps recommended
in this manual.
Multiple power inputs (For users)
This UPS system receives power from more than one source. Disconnect all AC sources and the DC source before servicing.
This UPS has several circuits that are energized by both high AC and DC voltages. Check for voltage with both AC and DC
voltmeters before working inside the UPS.
User serviceable components (For service personnel)
All the equipment maintenance and servicing procedures involving access to the internal parts of the unit require special tools
and should be carried out by trained personnel only. Components that may only be accessed by opening the protective cover
using tools/special key cannot be serviced by the user.
Battery voltage: 300Vdc ~ 564Vdc (For service personnel)
Physical maintenance and servicing work on the battery requires special tools and should be carried out only by trained
personnel.
Take special care when working with the batteries associated with this UPS. When the batteries are connected together, the
battery terminal voltage exceeds 300 Vdc and is potentially lethal.
Battery manufacturers supply details of the necessary precautions to be observed when working on or in the vicinity of battery
strings. These precautions should be adhered to strictly at all times. Particular attention should be paid to recommendations
concerning local environmental conditions and the provision of protective clothing, first aid and fire-fighting facilities.
Warning
When the internal fuse of the UPS is damaged, it must be replaced with a fuse having the same electric parameters by trained,
qualified personnel.
Important
The communication board is sensitive to electro-static discharge, implement ESD prevention measures when managing any
communication board.
Warning
When selecting the UPS system pre-stage distribution protection equipment, ensure that it complies with the local electric
regulations.
The specified upstream breakers are required to obtain the conditional short-circuit current rating, Icc at 10kA symmetrical
rms. The specified upstream breakers should comply with an IEC 60947 series standard.
6 User Manual 10H52246UM60 - Rev. 1 - 01/2017
This Manual Describes The Following Equipment
Product Model
Liebert NXC 60kVA NXC 0060kTJ1AFN02000
CONT ENTS
User Manual 10H52246UM60 - Rev. 1 - 01/2017 7
Contents
Chapter 1 Overview ................................................................................................................................................................................ 10
1.1 Features .................................................................................................................................................................................... 10
1.2 Design Concept ........................................................................................................................................................................ 10
1.2.1 System Design ............................................................................................................................................... 10
1.2.2 Bypass .......................................................................................................................................................... 11
1.2.3 System Control Principle ................................................................................................................................. 11
1.2.4 UPS Power Supply Switch Configuration ............................................................................................................ 12
1.2.5 Battery Circuit Breaker (BCB) ........................................................................................................................... 12
1.3 Parallel System ......................................................................................................................................................................... 12
1.3.1 Parallel System Features .................................................................................................................................. 12
1.3.2 Parallel System Requirements .......................................................................................................................... 12
1.4 Operating Modes ...................................................................................................................................................................... 13
1.5 Battery Management ................................................................................................................................................................. 15
1.5.1 Normal Function ............................................................................................................................................. 15
1.5.2 Advanced Function ......................................................................................................................................... 15
1.5.3 Battery Temperature Compensation.................................................................................................................. 16
1.6 Battery Protection .................................................................................................................................................................... 16
Chapter 2 Mechanical Installation ........................................................................................................................................................... 17
2.1 Precautions ............................................................................................................................................................................... 17
2.2 Shipping ................................................................................................................................................................................... 17
2.3 Tools ........................................................................................................................................................................................ 17
2.4 Unpacking ................................................................................................................................................................................ 18
2.5 Initial Inspection ....................................................................................................................................................................... 20
2.6 Environmental Requirements .................................................................................................................................................... 20
2.6.1 Selecting the UPS Location .............................................................................................................................. 20
2.6.2 Selecting the Battery Location.......................................................................................................................... 20
2.6.3 Storage ......................................................................................................................................................... 20
2.7 Mechanical Requirements ......................................................................................................................................................... 21
2.7.1 Moving the UPS .............................................................................................................................................. 21
2.7.2 Clearance ...................................................................................................................................................... 21
2.7.3 Cable Access Mode ......................................................................................................................................... 21
2.7.4 Final Positioning And Fixing ............................................................................................................................. 21
2.8 Installation Drawings ................................................................................................................................................................ 21
Chapter 3 Electrical Installation............................................................................................................................................................... 23
3.1 Power Cable Wiring ................................................................................................................................................................... 23
3.1.1 System Configuration ...................................................................................................................................... 23
3.1.2 Maximum Steady State AC And DC Currents ...................................................................................................... 23
3.1.3 Recommended UPS Cable Cross Sectional Area (CSA) ........................................................................................ 23
3.1.4 Selecting the UPS I/O Switch ............................................................................................................................ 23
3.1.5 Distance Between The UPS Connection Point And The Floor ................................................................................ 24
3.1.6 Notes ............................................................................................................................................................ 24
3.1.7 Power Cable Connection Terminals ................................................................................................................... 24
3.1.8 Protective Earth ............................................................................................................................................. 24
3.1.9 External Protective Device ............................................................................................................................... 24
3.1.10 Power Cable Connection Procedure ................................................................................................................ 25
3.2 Signal Cable wiring ................................................................................................................................................................... 29
3.2.1 Overview ....................................................................................................................................................... 29
3.2.2 Input Dry Contact Port .................................................................................................................................... 30
3.2.3 BCB Port ........................................................................................................................................................ 31
3.2.4 Backfeed Protection Dry Contact Port ............................................................................................................... 31
3.2.5 Remote EPO Input Port .................................................................................................................................... 32
3.2.6 RS232 Communication Port .............................................................................................................................. 32
3.2.7 USB Communication Port ................................................................................................................................. 32
3.2.8 Parallel And LBS Communication Ports .............................................................................................................. 32
3.2.9 RS485 Communication Port ............................................................................................................................. 32
3.2.10 Intellislot Port ............................................................................................................................................... 33
3.2.11 Signal Cable Connection Procedure ................................................................................................................ 33
Chapter 4 Operator Control And Display Panel ........................................................................................................................................ 36
4.1 Introduction .............................................................................................................................................................................. 36
4.1.1 LED Indicators ................................................................................................................................................ 36
4.1.2 Audible Alarm (Buzzer) .................................................................................................................................... 37
4.1.3 Control Keys .................................................................................................................................................. 37
4.1.4 LCD And Menu Keys ....................................................................................................................................... 37
4.2 LCD Screen Type ..................................................................................................................................................................... 38
4.2.1 Start Screen ................................................................................................................................................... 38
CONT ENTS
8 User Manual 10H52246UM60 - Rev. 1 - 01/2017
4.2.2 Main Screen ................................................................................................................................................... 38
4.2.3 Default Screen ................................................................................................................................................ 38
4.3 Detailed Description Of Menu Items .......................................................................................................................................... 39
4.4 Prompt Window ........................................................................................................................................................................ 41
4.5 Alarm List ................................................................................................................................................................................ 41
Chapter 5 UPS Operation Introduction .................................................................................................................................................... 44
5.1 Brief Introduction ...................................................................................................................................................................... 44
5.1.1 Precautions .................................................................................................................................................... 44
5.1.2 Power Switches .............................................................................................................................................. 44
5.2 UPS Startup Procedures ........................................................................................................................................................... 44
5.2.1 Startup Procedures In Normal Mode .................................................................................................................. 44
5.2.2 Startup Procedures In ECO Mode ...................................................................................................................... 45
5.2.3 Startup Procedures In Battery Mode (Battery Cold Start) ..................................................................................... 45
5.3 Procedures For Transfer Between Operation Modes .................................................................................................................. 46
5.3.1 Transfer From Normal Mode To Battery Mode .................................................................................................... 46
5.3.2 Transfer From Normal Mode To Bypass Mode .................................................................................................... 46
5.3.3 Transfer From Bypass Mode To Normal Mode .................................................................................................... 46
5.3.4 Transfer From Normal Mode To Maintenance Mode ............................................................................................ 46
5.3.5 Transfer From Maintenance Mode To Normal Mode ............................................................................................ 47
5.4 Battery Test Procedures ........................................................................................................................................................... 47
5.5 UPS Self-test Procedures ......................................................................................................................................................... 48
5.6 UPS Shutdown Procedures ....................................................................................................................................................... 48
5.6.1 Procedures For Shutting Down a UPS Completely ............................................................................................... 48
5.6.2 Procedures for Completely Shutting Down the UPS While Maintaining the Power Supply to the Load ........................ 49
5.7 EPO Procedures ....................................................................................................................................................................... 49
5.8 UPS Reset Procedures following an EPO ................................................................................................................................... 49
5.9 Automatic Restart .................................................................................................................................................................... 49
5.10 Selecting the Display Language .............................................................................................................................................. 49
5.11 Changing the Current Date and Time ....................................................................................................................................... 50
5.12 Control Password .................................................................................................................................................................... 50
Chapter 6 Battery ................................................................................................................................................................................... 51
6.1 Introduction .............................................................................................................................................................................. 51
6.2 Safety ...................................................................................................................................................................................... 51
6.3 UPS Battery ............................................................................................................................................................................. 53
6.4 Installation Design Precautions ................................................................................................................................................. 53
6.5 Battery Installation Environment And Number Of Batteries ....................................................................................................... 53
6.5.1 Installation Environment .................................................................................................................................. 53
6.5.2 Number Of Batteries ....................................................................................................................................... 54
6.6 Battery Protection .................................................................................................................................................................... 54
6.7 Battery Installation And Connection .......................................................................................................................................... 54
6.7.1 Battery Installation .......................................................................................................................................... 54
6.7.2 Battery Connection ......................................................................................................................................... 55
6.8 Design Of Battery Room ........................................................................................................................................................... 55
6.9 BCB Box (Optional) .................................................................................................................................................................. 56
6.10 BCB Reference Current And Connection ................................................................................................................................. 58
6.11 Battery Maintenance ............................................................................................................................................................... 59
6.12 Disposing of Used Batteries ..................................................................................................................................................... 59
Chapter 7 Parallel System and LBS System ............................................................................................................................................. 60
7.1 General ..................................................................................................................................................................................... 60
7.2 System Installation Procedures ................................................................................................................................................. 60
7.2.1 Preliminary Checks ......................................................................................................................................... 60
7.2.2 Cabinet Installation ......................................................................................................................................... 60
7.2.3 Power Cable ................................................................................................................................................... 60
7.2.4 Parallel Cable ................................................................................................................................................. 61
7.2.5 Remote EPO ................................................................................................................................................... 61
7.3 Parallel System Operating Procedures ...................................................................................................................................... 62
7.3.1 Startup Procedures In Normal Mode .................................................................................................................. 62
7.3.2 Maintenance Bypass Procedures ...................................................................................................................... 62
7.3.3 Procedures for Isolating One UPS Module in a Parallel System .............................................................................. 63
7.3.4 Procedures for Reintegrating an Isolated UPS Module into a Parallel System .......................................................... 64
7.3.5 Procedures for Shutting Down a UPS Completely in a Parallel System ................................................................... 64
7.3.6 Procedures For Complete UPS Shutdown While Maintaining Power To Load .......................................................... 64
7.4 LBS System .............................................................................................................................................................................. 64
7.4.1 Cabinet Installation ......................................................................................................................................... 64
7.4.2 External Protective Device ............................................................................................................................... 65
7.4.3 Power Cable ................................................................................................................................................... 65
7.4.4 LBS Cable ...................................................................................................................................................... 65
CONT ENTS
User Manual 10H52246UM60 - Rev. 1 - 01/2017 9
Chapter 8 Options .................................................................................................................................................................................. 67
8.1 Brief Description of Options ...................................................................................................................................................... 67
8.1.1 Bypass Load Sharing Inductor Kit ..................................................................................................................... 67
8.1.2 Internal Battery Kit .......................................................................................................................................... 70
8.1.3 Battery Temperature Compensation Kit ............................................................................................................. 74
8.1.4 IS-UNITY-DP Card .......................................................................................................................................... 76
8.1.5 IS-WEBL Card................................................................................................................................................. 76
8.1.6 IS-Relay Card ................................................................................................................................................. 77
8.1.7 IS-485L Card .................................................................................................................................................. 78
8.1.8 BCB Box ........................................................................................................................................................ 78
8.1.9 Parallel Cables ................................................................................................................................................ 78
8.1.10 LBS Cables .................................................................................................................................................. 78
8.1.11 Transformers ............................................................................................................................................... 79
Chapter 9 Communication ...................................................................................................................................................................... 80
9.1 SNMP Protocol Communication................................................................................................................................................. 80
9.2 Modbus Protocol Communication ............................................................................................................................................. 80
9.3 Dry Contact Communication ..................................................................................................................................................... 80
9.3.1 Communication via IS-Relay Card ..................................................................................................................... 80
9.3.2 Communication via Dry Contact Port ................................................................................................................. 80
Chapter 10 Service And Maintenance ..................................................................................................................................................... 81
10.1 Safety ..................................................................................................................................................................................... 81
10.2 Key Components and UPS Service Life .................................................................................................................................... 81
10.2.1 Service life parameters and proposed replacement intervals of key components ................................................... 81
10.2.2 Replacing Air Filters ...................................................................................................................................... 81
10.2.3 Replacing Fuses ........................................................................................................................................... 82
10.3 UPS And Options Maintenance Procedure ............................................................................................................................... 82
Chapter 11 Specifications ....................................................................................................................................................................... 83
11.1 Conformance And Standards .................................................................................................................................................... 83
11.2 Environmental Specifications ................................................................................................................................................... 83
11.3 Mechanical Specifications ........................................................................................................................................................ 83
11.4 Electrical Specifications (Rectifier Input) .................................................................................................................................. 83
11.5 Electrical Specifications (Intermediate DC Circuit) .................................................................................................................... 84
11.6 Electrical Specifications (Inverter Output) ................................................................................................................................ 84
11.7 Electrical Specifications (Bypass Input) .................................................................................................................................... 85
11.8 Efficiency And Losses .............................................................................................................................................................. 85
Appendix 1 Disposal Of Old Appliances .................................................................................................................................................. 86
Appendix 2 Glossary .............................................................................................................................................................................. 87
Appendix 3 Hazardous Substances or Elements Statement .................................................................................................................... 88
OVERVIEW
10 User Manual 10H52246UM60 - Rev. 1 - 01/2017
Chapter 1 Overview
This chapter provides a brief introduction to the features, appearance and components, design concept, parallel
system, operating mode, battery management and battery protection of the Liebert NXC 60kVA UPS (UPS for
short).
1.1 Features
The UPS is connected between a mains power source and a critical load (e.g. a computer) in order to provide a high
quality power supply for the latter. The UPS offers the following advantages:
Increased power quality
The UPS protects its output against variations in the input power supply by means of the internal voltage and
frequency controller.
Mains failure protection
If the input power fails, the UPS will switch to battery mode so that the power supply to the loads is not interrupted.
1.2 Design Concept
1.2.1 System Design
This section introduces the working principle of the single UPS module. The UPS is based on an AC-DC-AC
converter (as shown in Figure 1-1The first conversion stage (AC-DC) uses a three-phase, high frequency rectifier to
convert the three-phase main input (or rectifier input) voltage into the stable DC bus voltage.
Input
Maintenance bypass switch
Bypass input switch
Rectifier input switch
Bypass input
Mains input
Battery charger
Output switch
Automatic inverter switch
Inverter
Rectifier
Static switch
Maintenance bypass
UPS output
Battery
Output
Figure 1-1 Block diagram for working principle of UPS single module
The UPS has its own battery charger and adopts advanced temperature compensation technology to effectively
prolong the battery service life. The inverter mainly uses high power IGBTs, together with advanced SVPWM control
technology, to reconvert the DC bus voltage to AC voltage.
When the mains input is normal, the rectifier and inverter work together to supply the loads and charge the battery.
When the mains input is abnormal, the rectifier stops working, and the battery supplies power to the loads through
the inverter. If the battery voltage falls to the end of discharge (EOD) voltage and the mains has not yet been
restored, the UPS will shut down (if the system uses split bypass configuration and the bypass is normal, the system
will transfer to bypass). The battery EOD voltage is preset. When the mains is abnormal, the battery guaranteed
normal UPS operation until the battery reaches the EOD voltage, at which point the UPS shuts down: this time is
called 'Backup Time'. The length of backup time depends on the battery capacity and the loads.
OVERVIEW
User Manual 10H52246UM60 - Rev. 1 - 01/2017 11
1.2.2 Bypass
The 'Static Switch' module (as shown in Figure 1-1) contains the controllable electronic switch, and features an
intelligent control system that enables the loads to be supplied by the inverter or the bypass. Under normal
conditions, the loads are supplied by the inverter, and the automatic inverter switch on inverter line is closed. In the
event of an overload (the overload delay time expires) or inverter failure, the inverter switch is opened, and the
'Static Switch' module transfers the loads automatically to the bypass.
Under normal operating conditions, the inverter output must be synchronized with the bypass in order to ensure
that the load is transferred from the inverter to the bypass without interruptions.
Therefore, when the bypass frequency is within the synchronization range, the inverter control circuit will
synchronize the inverter output frequency with the bypass frequency and phase.
The UPS is also equipped with a manual maintenance bypass switch, which is used to de-energize the UPS during
maintenance work. In this condition, the bypass supplies the critical loads directly via the maintenance bypass line.
Note
When the load is supplied by the bypass or maintenance bypass, the quality of the power supply is not guaranteed.
1.2.3 System Control Principle
Normal operation
In normal operating mode the UPS mains input is within the acceptable limits, the rectifier and inverter are
operating normally, the load is supplied by the inverter, the battery circuit breaker is closed, and the battery is in
stable floating charge state.
(Parallel System) Note: As the individual UPS module outputs are connected in parallel, the system checks that
the inverter control circuits are perfectly synchronized with one another, and with the bypass, in terms of both
frequency and phase, and that their output voltages are the same. The current drawn by the load is divided
automatically between the UPS modules. A warning message appears while synchronization is in progress.
Abnormal mains
When the mains supply fails or goes outside the acceptable limits, the rectifier switches off automatically, and the
system transfers to battery output (via the inverter). The length of the operating time in battery mode depends on
the load and the battery capacity. During this period, if the battery voltage falls to the EOD voltage and the mains
supply has not yet returned within acceptable limits, the inverter switches off automatically, and the UPS operator
control and display panel display the corresponding alarm messages. If the system uses a separate bypass
configuration, and the bypass supply is normal, the system transfers to the bypass line
Mains recovery
When the main input returns within its normal operating limits inside the acceptable time interval, the rectifier
restarts automatically (at this point its output power starts to increase gradually), supplying the load and charging
the battery again. Therefore, the power supply to the load will not be interrupted
Disconnecting the battery
If it is necessary to disconnect the external battery when carrying out maintenance work, use the external isolating
switch. In this condition, the steady state performance of the UPS is not affected and all its functions are
guaranteed, with the exception of the battery backup supply in the event of a mains failure.
UPS module failure
In the event of an inverter failure, an automatic inverter switching failure, a blown output fuse or a bypass STS
failure, the load is transferred automatically to the bypass supply line, without interrupting the power supply to the
loads. If any of these fault conditions occur, please contact your local Vertiv customer service center for technical
support.
(Parallel System) If one of the UPS modules fails, it exits the parallel system automatically. If the system is still
capable of providing the required power, the remaining module continues to supply the load without interruption. If
the remaining modules are no longer capable of fulfilling power requirements, the load is transferred automatically
to the bypass line.
Overload
If the inverter is overloaded or the inverter current remains outside the specifications (refer to Table 11-6) longer
than the specified time, the load is transferred automatically to the bypass without interruption. If both the overload
and the current return to a level within the specified range, the load is transferred back to the inverter. In the event
of an output short circuit, the load is transferred to the bypass, and the inverter is shut down. Five minutes later, the
inverter restarts automatically. If the short circuit is no longer present, the load is transferred back to the inverter.
The transfer is determined primarily by the specifications of the system protection device.
In the two situations described above, alarm messages appear on the UPS operator control and display panel.
(Parallel System) The logic control system monitors load requirements constantly and controls the power supplied
by each UPS module. In the event that an overload condition persists for longer than a preset interval, and the
number of active modules is unable to satisfy the load power requirements, the load is transferred to the bypass.
The load is re-transferred to the inverter if the power requirement is reduced to a value that can be supplied by the
number of active modules remaining in the system.
Maintenance bypass
The UPS is also equipped with a maintenance bypass circuit, which provides a safe working environment for the
engineers when carrying out maintenance work or repairs on the UPS system, while supplying unregulated mains
OVERVIEW
12 User Manual 10H52246UM60 - Rev. 1 - 01/2017
power to the loads. The maintenance bypass can be manually selected using the maintenance bypass switch, and
disconnected by turning the switch to OFF.
Warning
If the UPS system consists of two or more UPS modules, and the load capacity exceeds the single module capacity, do not
use the internal maintenance bypass switch.
1.2.4 UPS Power Supply Switch Configuration
Figure 1-2 illustrates the UPS module block diagram. The UPS may be used in separate bypass (where the Rectifier
and Bypass inputs are connected to independent power sources) and common input configurations. In the separate
bypass configuration, the static bypass and maintenance bypass share the same independent bypass power supply.
When a separate power source is not available, the bypass input switch (Q2) and rectifier input switch (Q1)
connections are linked together (factory fitted) so that the bypass input and rectifier input use mains power from
the same source.
During normal UPS operation, all the switches are closed, with the exception of the maintenance bypass switch Q3.
UPS output
Bypass input
Mains input
Neutral line input
Battery
BCB
Shorting copper
Rectifier
Inverter
Charger
DC
bus
Neutral line
Neutral line
UPS
Maintenance bypass switch Q3
Bypass input switch Q2
bar of common
input configuration
Rectifier input
Static switch
Automatic
inverter switch
Output switch Q5
Neutral line
output
switch Q1
switch Q6
Figure 1-2 UPS power supply switch configuration
1.2.5 Battery Circuit Breaker (BCB)
The external battery must be connected to the UPS via the BCB. The BCB box, which is available as an option, must
be installed close to the battery. The BCB is closed manually or electrically. The box includes an under-voltage trip
coil and, in the event of a battery under-voltage, the UPS control circuit sends a signal to this coil, which trips the
BCB. It also features a magnetic overload protection trip function.
1.3 Parallel System
Up to four UPS modules can be parallel-connected to form a parallel system thus increasing the capacity and
reliability of the system. The load is shared equally between the paralleled UPS modules.
In addition, two UPS modules or parallel systems can be used to create a dual bus system (LBS). The independent
outputs of each UPS module or parallel system are synchronized via the LBS cable, thus guaranteeing seamless load
transfer between the two systems.
1.3.1 Parallel System Features
1. In parallel systems the UPS hardware and software are exactly the same as for individual modules, and the parallel
configuration is achieved by means of software settings or via the control panel.
2. Parallel cables are connected in a ring, in order to guarantee system reliability and redundancy. The LBS cables
are connected between any two UPS modules in each bus. The intelligent parallel logic provides maximum flexibility,
for example, it permits the user to shut down, or start-up, the UPS modules in any order. Transfers between normal
mode and bypass mode of operation are seamless and self-recoverable, i.e., as soon as the overload is cleared, the
system reverts automatically to its original operating mode.
3. The user can view the total load applied to the parallel system on each individual UPS module LCD.
1.3.2 Parallel System Requirements
A group of paralleled modules behaves as if it were one large UPS with the advantage that it provides higher
reliability. In order to ensure that the load is shared evenly by all the modules, and that the system complies with the
applicable wiring regulations, the following requirements must be satisfied:
1. All UPS modules must be of the same rating and must be connected to the same bypass source.
2. The bypass and rectifier input sources must be connected to the same neutral line input terminal.
3. If any RCDs are installed they must be set-up appropriately and located upstream of the common neutral line
input terminal. Alternatively, such devices must monitor the protective earth current of the system. Refer to Warning:
high earth leakage current before Contents.
OVERVIEW
User Manual 10H52246UM60 - Rev. 1 - 01/2017 13
4. For parallel system consisting of two or more UPS modules, the bypass load sharing inductors (optional) should
be selected.
1.4 Operating Modes
The UPS operating modes are as follows:
Normal mode
Battery mode
Automatic restart mode
Bypass mode
Maintenance mode
ECO mode
Parallel redundancy mode (system expansion)
LBS system mode
Common battery string mode
Frequency converter mode
Normal mode
As can be seen in Figure 1-3, the mains is rectified by the UPS rectifier and then inverted by the inverter to supply
uninterrupted AC power to the loads. At the same time, the charger will charge the battery.
Rectifier input switch
Mains input
Battery charger
Output switch
Inverter
Rectifier
UPS output
Battery
Automatic inverter switch
Figure 1-3 Schematic diagram of normal mode
Battery mode
Figure 1-4 illustrates battery mode, where the battery provides backup power supply to the loads through the
rectifier and inverter. Upon failure of the main input, the UPS will transfer automatically to battery mode without
interrupting the power supply to the loads. When the main input is restored, the UPS will automatically re-transfer to
normal mode without the need for any manual intervention, and without interrupting the power supply to the loads.
Output switch
Inverter
Rectifier
UPS output
Battery
Automatic inverter switch
Figure 1-4 Schematic diagram of battery mode
Note: The battery cold start function can be used to switch the UPS on directly in Battery mode (provided the battery is
charged) during a mains failure. Thus, the battery power supply can be used independently to improve the availability of
the UPS.
Automatic restart mode
The UPS is equipped with an automatic restart function. When the inverter shuts down due to a mains failure, and
the battery reaches the EOD voltage, when the mains is restored, the UPS will restart automatically after a certain
delay. This function, and the automatic restart type, can be set-up by Vertiv authorized service engineers.
During the automatic restart delay period, the UPS will charge the battery to protect the load against the risk of
power interruptions in the event of a new mains failure.
If the automatic restart function has not been set, the user can restart the UPS manually by pressing the FAULT
CLEAR key followed by the ON key.
Bypass mode
As can be seen in Figure 1-5, in the event of an inverter failure, an inverter overload or a manual inverter shutdown,
when the UPS is in normal operating mode the static switch will transfer the load from the inverter to the bypass
line, without interrupting the power supply to the loads. At this point, if the inverter and bypass are not
synchronized, the load power supply will be interrupted momentarily (< 20 ms).
OVERVIEW
14 User Manual 10H52246UM60 - Rev. 1 - 01/2017
Bypass input switch
Bypass input
Static switch
Output switch
UPS output
Figure 1-5 Schematic diagram of bypass mode
Maintenance mode
As illustrated in Figure 1-6, if it is necessary to service the UPS or carry out maintenance work on it, the manual
maintenance bypass switch may be used to transfer the load to maintenance bypass, with no interruption in power
to the load. This maintenance bypass switch is fitted in all UPS modules and rated at the full load of one module.
Maintenance bypass switch
Bypass input
Maintenance bypass
UPS output
Figure 1-6 Schematic diagram of maintenance mode
ECO mode
In ECO mode, UPS double-conversion operation is inhibited most of the time in order to save energy. In this
condition, the bypass is designated as the preferred source so that the critical AC load is transferred to the inverter
only when the bypass supply voltage and/or frequency is/are outside the pre-defined limits: if the inverter is
synchronized with the bypass source, the transfer will be instantaneous and during the transfer the output
waveform will not exceed the limits established by IEC/EN 62040-3 for a UPS to be classified as VFI-SS-111.
If the inverter is not synchronized with the bypass, in order to avoid hazardous cross current, the bypass/inverter
changeover is delayed for a few milliseconds (maximum 20ms) after the moment the bypass is disconnected from
the load. Then, once the bypass frequency and voltage have returned within the predefined limits for at least five
minutes, the load is automatically, and instantaneously, transferred back to the bypass line.
In this operating mode, the system can charge the battery as normal.
Bypass input switch
Rectifier input switch
Bypass input
Mains input
Battery charger
Output switch
InverterRectifier
Static switch
UPS output
Battery
Automatic inverter switch
Figure 1-7 Schematic diagram of ECO mode
If ECO mode is selected, adjust the corresponding parameters via the operator control and display panel.
The ECO mode operating method is the same as described in Chapter 5 UPS Operation Introduction. However, in
normal mode, the load is powered by the bypass, the inverter indicator flashes, the LCD displays 'Bypass mode', and
the transfer interval time is less than 20ms.
Warning
The load is not protected against distortion on the mains voltage waveform in ECO mode.
Parallel redundancy mode (system expansion)
In order to achieve higher capacity or higher reliability, or both, the outputs of multiple UPS modules can be
programmed for directly paralleling while a built-in parallel controller in each UPS module ensures automatic load
sharing. The parallel system can consist of up to four UPS modules. See Figure 7-1 for the diagram illustrating the
parallel redundancy operating principle.
LBS mode
A dual bus system consists of two independent UPS systems, each containing one or more UPS module connected
in parallel. The dual bus system provides high reliability and is suitable for connection to loads with multiple inputs.
Single-input loads may be supplied via an STS. See Figure 7-4 and Figure 7-5 for the diagram illustrating the LBS
operating principle.
Common battery string mode
In this case, when the UPS modules (up to four UPSs) are connected in parallel, each UPS module can use the same
battery string, thereby saving on costs and space.
OVERVIEW
User Manual 10H52246UM60 - Rev. 1 - 01/2017 15
Note
Do not mix batteries of different brands, types or ages in the same system. Common battery string mode is suitable for
parallel systems only, and is not compatible with LBS mode.
Frequency converter mode
The UPS can be operated in frequency converter mode in order to provide a stable 50Hz or 60Hz output frequency,
provided the input frequency remains between 40Hz and 70Hz. In this operating mode, the maintenance bypass
switch must be opened (set to "OFF") in order to disable static bypass operation, and the battery becomes optional,
depending on whether battery mode is required, or not.
1.5 Battery Management
The following battery management functions are set-up by the service engineer by modifying the Vertiv software
settings.
1.5.1 Normal Function
1. Constant current boost charge
This charging method uses the constant current (within battery charging limit) to charge the battery, and can be
used for fast battery capacity recovery. It is also possible to set-up the charging current.
2. Constant voltage boost charge
This charging method uses the constant voltage to charge the battery, and can be used for fast battery capacity
recovery. In the case of VRLA batteries, the maximum boost charge voltage should not exceed 2.4V/cell.
3. Float charge
This charging method is used to maintain the battery at full capacity. The float charge voltage is generally low. The
function compensates for the capacity loss due to battery self discharging, and can be used for battery capacity
recovery.
In the case of VRLA batteries, the float charge voltage should be between 2.2V/cell and 2.3V/cell.
4. Automatic transfer to float charge
When the charge current falls below 'Threshold of Equalize Charge to Float Charge' or 0.5A, the charger switches
automatically from boost charge to float charge. When the boost charge time exceeds the 'Equalize Charge Protect
Time Limit', the charger is transferred forcibly to float charge mode in order to protect the battery.
5. Float charge temperature compensation (optional)
The UPS system also features a battery charge temperature compensation function. When the ambient temperature
increases, the DC bus voltage (which charges the battery) is reduced correspondingly in order to provide the
optimal charging voltage for the battery, thus prolonging the battery service life time.
This function must be used together with the Vertiv battery temperature detection device (a standard option).
6. EOD protection
When the battery voltage falls to the EOD voltage level, the battery converter shuts down automatically and the
battery is isolated to avoid discharging it any further. The EOD voltage may be set to between 1.6V/cell and
1.85V/cell (VRLA).
7. Battery low pre-warning time
The Battery low alarm is activated a few minutes before the battery voltage reaches the EOD level in order to warn
the user that the battery capacity is low. The battery low pre-warning time is adjustable between 3min and 60min.
The default setting is 5min.
8. Maximum battery discharge time
Discharging the battery at a low current level for an extended period can result in over-discharging and may
damage it permanently; therefore it is essential to set a maximum discharge time in order to protect the battery. The
time limit is set-up by the service engineer by modifying the Vertiv software settings.
9. Maximum boost charge protection time
To protect the battery against overcharging damage caused by extended periods of boost charging, the Maximum
boost charge protection time function limits the boost charging duration. The time limit is set-up by the service
engineer by modifying the Vertiv software settings.
1.5.2 Advanced Function
The UPS includes a battery maintenance test function. At periodic intervals, 20% of the rated capacity of the battery
is discharged automatically, provided that the current load exceeds 20% of the nominal UPS capacity. If the load is
less than 20%, the automatic discharge cannot be executed. The test interval can be set from 30 to 360 days. The
battery maintenance test function can be disabled by modifying the Vertiv software settings.
Conditions: Battery at float charge for at least 5h, load equal to 20% ~ 100% of rated UPS capacity.
Trigger: Automatically, or manually via the battery maintenance test command on the LCD.
Interval: 30 ~ 360 days (default setting: 60 days).
The UPS also features a battery capacity self-test function, which tests battery activity and residual capacity at
regular intervals, evaluates the battery quality, and provides the corresponding measurements. The capacity
self-test is started by the user via the operator control and display panel. During the capacity self-test, the battery
discharges continuously until it reaches the battery under-voltage shutdown threshold. After the test is finished, the
system updates the battery curve table. The capacity self-test command is a standalone test, and no data are stored.
OVERVIEW
16 User Manual 10H52246UM60 - Rev. 1 - 01/2017
During the capacity self-test, if the battery maintenance requirements are satisfied, the system generates an
audible/visual alarm and provides the corresponding records.
Conditions: System load within 20% ~ 100% of nominal rated value, battery float charge at least 5h, and generator
not connected, system currently in float charge state.
Trigger: Start up via LCD.
Note:
1. The battery discharges continuously until it reaches the battery under-voltage shutdown threshold, at which point
it switches to the charging state. When the capacity self-test is finished, the system updates the battery curve table.
2. The user can stop the capacity self-test operation manually via the LCD.
1.5.3 Battery Temperature Compensation
The UPS system includes a battery charge temperature compensation function. When the ambient temperature
increases, the DC bus voltage (which charges the battery) will be reduced correspondingly to provide optimal
charging voltage for the battery, thus prolonging the battery service life time.
This function must be used together with the Vertiv battery temperature detection device (a standard option).
1.6 Battery Protection
The following battery protection functions are set-up by the service engineer by modifying the Vertiv software
settings.
Battery low pre-warning
The battery low pre-warning is activated before the battery voltage reaches the EOD point, it indicates that the
battery capacity is sufficient to supply the nominal load for another 3 minutes, after which it will be de-energized.
This interval may be set from 3min to 6min.
EOD protection
When the battery voltage drops to the EOD voltage, the battery converter shuts down automatically. The EOD
voltage is adjustable from 1.6V/cell to 1.85V/cell (VRLA).
BCB alarm
The BCB alarm occurs when the external BCB opens, if the UPS is fitted with the Vertiv BCB option.
The external battery is connected to the UPS via the BCB. The BCB is manually closed and tripped by the UPS
control circuit.
MECHANICAL INSTALLATION
User Manual 10H52246UM60 - Rev. 1 - 01/2017 17
Chapter 2 Mechanical Installation
This chapter provides a brief introduction to the UPS mechanical installation procedure, including the precautions,
pre-installation inspection, environmental and mechanical requirements and the installation diagram.
2.1 Precautions
The following paragraphs describe the environmental and mechanical requirements, and the mechanical
considerations that must be taken into account when planning the positioning and cabling of the UPS equipment.
Because no two sites are the same, this chapter does not provide detailed installation instructions, and is intended
solely as a guide to the general procedures and practices that should be observed by the installation engineers so
that they can handle the specific situation of the site correctly.
Warning: professional installation required
1. Do not remove the packaging without permission from an authorized service engineer.
2. The UPS should be installed by an authorized engineer in accordance with the information contained in this chapter.
Warning: battery hazard
Take special care when installing batteries. When connecting batteries, the voltage at the battery terminal reaches 320Vdc,
which is fatal to human beings.
1. Wear safety glasses or goggles to protect the eyes from being damaged by arcs.
2. Remove all the metal items, including rings, watches, etc.
3. Use tools with insulated handle.
4. Wear rubber gloves.
5. If the battery is damaged and/or electrolyte is leaking from it, it must be replaced. Place the battery into the container that
can withstand sulfuric acid and dispose of it in accordance with the local regulations.
6. If the electrolyte comes into contact with the skin, flush immediately with water.
2.2 Shipping
Ideally the UPS system should be shipped by rail or sea. If road transportation is unavoidable, choose roads that are
less bumpy in order to protect the equipment.
The UPS is heavy (see Table 11-3 for weight information), we recommended using mechanical equipment such as an
electric forklift when unloading and moving the equipment to the place closest to the installation site. If an electric
forklift is used, insert the forks below the bottom pallet (as shown in Figure 2-1) in order to prevent the equipment
from tipping over.
Figure 2-1 Inserting and movement
2.3 Tools
Warning
1. For safety reasons, use insulated tools only when working on live equipment.
2. The tools in Table 2-1 are for reference only; please select tools in accordance with the actual on-site installation and
connection requirements.
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MECHANICAL INSTALLATION
Table 2-1 Tools
Name Drawing Name Drawing
Electric hand drill Adjustable wrench
Flat blade screwdriver Cross head screwdriver
Stepladder
Forklift
Drill Wire cutting pliers
Claw hammer
Diagonal cutting pliers
Insulating shoes
Antistatic gloves
Electrician's knife
Cable tie
Insulating tape Insulating gloves
Crimping pliers
Heat shrinkable tube
Insulated torque wrench Torque screwdriver
Multimeter
Clip-on ammeter
2.4 Unpacking
Unpack the UPS and battery packages under the guidance of an authorized service engineer. Proceed as follows:
1. Remove the side panels and top cover.
Use a hammer or flat blade screwdriver to straighten the connection hooks used secure the side panels to the top
cover, as shown in Figure 2-2.
Figure 2-2 Straightening the hooks
First, straighten all the hooks that secure side panel I, and then remove it. Then straighten all the hooks that secure
side panel II, and then remove it. Finally, remove the top cover III, as shown in Figure 2-3.
MECHANICAL INSTALLATION
User Manual 10H52246UM60 - Rev. 1 - 01/2017 19
I
I
II
II
III
Figure 2-3 Removing side panels and top cover
2. Remove and store the bolts that secure the UPS to the pallet (see Figure 2-4). Then, use the forklift (inserting the
forks in the direction indicated in Figure 2-4) to move the cabinet to the place where it is to be installed.
Inserting direction
Bottom pallet
Fixing bolt
Figure 2-4 Removing bottom pallet
3. After moving the cabinet to the place where it is to be installed, raise the four adjustable feet, and use the casters
to move the cabinet to its final position.
To raise the adjustable feet, proceed as follows: as shown in Figure 2-5, first loosen the nut (factory installed ) by
unscrewing it downwards, then remove the foot fixing piece (do not throw this part away), and rotate the foot,
raising it so that the machine may be moved freely on its casters; repeat the same procedure for the other feet.
20 User Manual 10H52246UM60 - Rev. 1 - 01/2017
MECHANICAL INSTALLATION
Nut
Foot fixing piece
Foot
Figure 2-5 Diagram illustrating how to raise the feet
2.5 Initial Inspection
Before installing the UPS, carry out the following inspections:
1. Ensure that the UPS installation environment meets the environmental requirements indicated in the product
technical specifications, especially the ambient temperature, ventilation conditions and the dust levels.
2. Unpack the UPS under the guidance of an authorized service engineer. Inspect the UPS internally and externally
for signs of damage. If any damage is found, report it to the carrier immediately.
3. Check the UPS label attached to the inside of the unit front door, and confirm that the data (model, capacity and
main operating parameters) correspond to the UPS model.
2.6 Environmental Requirements
2.6.1 Selecting the UPS Location
The UPS should be installed in a cool, dry, clean-air indoor environment with adequate ventilation, and should be
positioned on a flat concrete floor or similar nonflammable surface. The surrounding environment should be free of
conductive powder (such as metallic powder, sulfide, sulfur dioxide, graphite, carbon fiber, conductive fiber, etc.),
acid mist or other conductive media (strongly ionized substances). The environment specifications should comply
with relevant international standards & specifications, and the operating range specified in this manual (see Table
11-2).
The UPS uses forced cooling by internal fans. Cooling air enters the UPS through the ventilation grills at the front
and is expelled through the ventilation grills at the back. Do not obstruct the ventilation grills. Leave a space of at
least 200 mm between the rear of the UPS and the wall in order to allow heat to dissipate properly, thus reducing
the UPS internal temperature and prolonging its working life. For exchanging the UPS Power Module or the Battery
Tray a front clearance of 1200mm is necessary.
If necessary, install indoor extractor fans to aid cooling-air flow in order to avoid local temperature buildup. Install air
filters (optional) when operating the UPS in a dirty environment.
Note 1: When the battery cabinet is installed near the UPS, the maximum permissible ambient temperature
depends on the battery rather than the UPS.
Note 2: When the UPS is in ECO mode, the power consumption is less than in Normal mode. Suitable air
conditioning systems shall be selected according to the normal operating mode.
2.6.2 Selecting the Battery Location
Batteries generate significant quantities of hydrogen and oxygen at the end of the charging cycle, therefore the
fresh air volume of the battery installation environment must meet the requirements of EN50272-2001.
The ambient temperature is the main factor that affects the battery capacity and life. The normal operating
temperature of the battery is 20°C. If the ambient temperature is higher than 20°C, the battery life will be reduced,
whereas if it is lower than 20°C, the battery capacity will be reduced. Under normal conditions, the permissible
ambient temperature range for the battery is 15°C to 25°C. Ensure that the ambient temperature of the battery
remains constant and that it is kept away from heat sources and UPS air outlets.
The battery can be installed inside a special battery cabinet located close to the UPS. Due to its weight, if the
battery is installed on a raised floor, the bracket must be installed under the floor, in the same way as the UPS. When
using a rack-mounted battery solution, or when the battery is installed at a distance from the UPS, irrespective of
the type of solution, position the battery circuit breaker close to the battery, and make sure that the connection
cables are as short as possible.
2.6.3 Storage
If the batteries are not to be installed immediately, they must be stored in their original packaging in an environment
where they are protected against excessive humidity and heat sources (see Table 11-2). The battery must be stored
in a dry and cool place with good ventilation. The most suitable storage temperature ranges from 20°C to 25°C.
Warning
During battery storage, charge the battery periodically in accordance with the battery manufacturer's instructions. During the
MECHANICAL INSTALLATION
User Manual 10H52246UM60 - Rev. 1 - 01/2017 21
charging process, connect the UPS to the mains temporarily and activate the battery by recharging it.
2.7 Mechanical Requirements
2.7.1 Moving the UPS
Warning
1. Ensure any any equipment used ot lift or move the UPS has sufficient lifting capacity.
2. The UPS is fitted with casters, take care to prevent it rolling away when removing it from the pallet. Ensure that the
available personnel and lifting equipment are sufficient to carry out this operation safely and correctly.
3. Due to the weight of the unit, the casters may be valid for moving it along flat surfacrs only.
4. The UPS has a high center of gravity, take precautions to prevent it from tipping over when moving it.
5. Never suspend the UPS in a vertical position.
Caution
When the batteries are already mounted in the cabinet, ensure that each battery string has been secured before attempting
to move it and make every effort to keep movement distances to a minimum.
Ensure that the UPS weight does not exceed the capacity of the lifting equipment. For UPS weight information, refer
to Table 11-3.
The UPS can be moved using a forklift or other similar lifting equipment.
The casters may be used when moving the UPS over short distances.
2.7.2 Clearance
The UPS has no lateral grills; therefore there are no special clearance requirements on the two sides.
In addition to the provisions of the local regulations, in order to enable routine tightening of the power terminals
within the UPS, we recommended that the clearance at the rear of the UPS be sufficient to enable the free passage
of personnel. In any event, as stated above, in order to allow heat to dissipate properly, there must be a space of at
least 200 mm between the rear of the UPS and the wall.
2.7.3 Cable Access Mode
The UPS is suitable for both top and bottom cable access configurations.
For more information, refer to 3.1.10 Power Cable Connection Steps and 3.2.11 Signal Cable Connection Steps.
2.7.4 Final Positioning And Fixing
Once the UPS has been moved to its final position, use the four adjustable feet to secure it to the floor, as shown in
Figure 2-6. To do this, proceed as follows:
1. Loosen the nuts by unscrewing them upwards.
2. Rotate the feet until they touch the floor.
3. Fit the foot fixing pieces that were put aside when removing the UPS from its pallet.
4. Align the foot fixing pieces with the pre-prepared installation holes, in with the dimensions indicated in Figure 2-7.
5. Rotate the nuts from top to bottom till they press firmly against the foot fixing pieces, and then use the M10
fixing bolts to secure the UPS to the floor.
Nut
Foot fixing piece
Foot
Installation hole
Figure 2-6 Diagram illustrating how to position and secure the UPS
2.8 Installation Drawings
Figure 2-7 illustrates the key mechanical characteristics of the UPS.
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MECHANICAL INSTALLATION
833
1433
46
262
Right side view
1528
860
Air
inlet
Front view
600
Left side view
Top view (door open)
Air
outlet
Air
outlet
Air
inlet
314
218
600
143
192
363
395
860
764
40
55
764
35
170
84
Cable access area
Ф11 foot installation hole
Ф36 signal cable inlet
Bottom view
Figure 2-7 Top/front/side/bottom view of the UPS (unit: mm)
ECLECTRICAL INSTALLATION
User Manual 10H52246UM60 - Rev. 1 - 01/2017 23
Chapter 3 Electrical Installation
This chapter provides an introduction to the UPS electrical installation procedures, including power and signal
cabling procedures and methods.
After completing the mechanical installation procedure, it is necessary to connect the UPS power and signal cables.
The signal cables, irrespective of whether they are shielded or not, must be kept away from the power cables.
Warning
1. Do not switch the UPS on before the authorized service engineer has arrived.
2. The UPS cables should be routed by an authorized engineer in accordance with the information contained in this chapter.
3.1 Power Cable Wiring
3.1.1 System Configuration
Select the size of the system power cables in order to satisfy the following requirements:
UPS input cable
The cable size of the UPS input cable differs according to the UPS power ratings and input AC voltages, and must
be selected so that it is capable of handling the maximum input current; including the maximum battery charge
current, see Table 3-1.
UPS bypass and output cable
The cable size of the UPS bypass and output cable differs according to the UPS power ratings and output AC
voltages, and must be selected so that it is capable of handling the nominal output or bypass current, see Table 3-1.
Battery cable
Each UPS is connected to its battery by the three cables, one for the positive pole, one for the negative pole, and
one for the neutral line. The battery cable size differs according to the UPS power ratings, and must be selected so
that it is capable of handling the battery discharge current as the battery reaches the EOD voltage, see Table 3-1.
3.1.2 Maximum Steady State AC And DC Currents
The power cable must be selected in accordance with the current and voltage values indicated in Table 3-1, and the
local wiring regulations, also taking environmental conditions (temperature and physical media) and the provisions
of Table 3B in IEC 60950-1 into consideration.
Table 3-1 Max. steady state AC and DC currents
UPS power
(kVA)
Rated current (A)
Bus stud bolt/nut
specification
Max. input
current
1,2
Output/bypass current
2
at full load
Battery discharge
current (+, -, N) at
min. battery voltage
Input/battery/o
utput/
bypass cable
Recommen
ded torque
(N.m)
380V 400V 415V
60 (3-in 3-out ) 103 91 87 84 195/195/59 M6/M8/M6/M6
4.8/12/4.8/4
.8
When selecting the battery cables, a max. volt drop of 4Vdc is permissible at the current ratings given in Table 3-1. Do not form
coils, so as to minimize the formation of EMI.
1. Input mains current for rectifier and bypass.
2. Non-linear loads (such as switch-mode power supplies) affect the design of the output and bypass neutral line, since the
neutral line current may be up to 1.5 times the rated phase current.
3.1.3 Recommended UPS Cable Cross Sectional Area (CSA)
The recommended UPS cable CSA values are listed in Table 3-2.
Table 3-2 Recommended UPS cable CSA (unit: mm2, ambient temperature: 25°C)
Model Input Output Bypass Neutral line Earth cable Battery
60kVA (3-in 3-out) 25 25 25 35 25 50
If the user’s cable CSA exceeds the value recommended in Table 3-2, please contact Vertiv service engineers.
3.1.4 Selecting the UPS I/O Switch
Note
The specified upstream breakers below are required to obtain the conditional short-circuit current rating, Icc at 10kA
symmetrical rms. The specified upstream breakers should comply with an IEC 60947 series standard.
Table 3-3 indicates the recommended UPS I/O switch capacity, so that the user can select it according to actual
needs.
Table 3-3 Selection of the UPS I/O switch
Model Input Recommended Breaking BCB Output port Recommended
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ECLECTRICAL INSTALLATION
port capacity of input
external switch
Capacity capacity of output
external switch
60kVA
(3-in 3-out)
Terminal
block
125A (3P), bypass
125A (3P)
10kA DC 200A (4P) Terminal blcok 125A (3P)
3.1.5 Distance Between The UPS Connection Point And The Floor
See Table 3-4 for details.
Table 3-4 Min. distance between UPS connection point and floor
UPS connection point
Min. distance（mm）
60kVA
Rectifier input 236
Bypass input 236
AC Output 236
Battery 265
PE terminal 220
3.1.6 Notes
The following points are for general guidance only. If there are any relevant local regulations, these shall prevail.
1. The neutral line cable size must be selected for a current 1.5 times greater than the output/bypass phase current.
2. The protective earth cable size shall be selected according to the AC power failure level, cable length and
protection type. The grounding wire connection must use the shortest possible connection path.
3. In the case of cables carrying large currents, it is possible to connect multiple cables with smaller current carrying
capacities in order to facilitate installation.
4. When selecting the battery cable size, refer to the current value indicated in Table 3-1, allowing a maximum
voltage drop of 4Vdc.
3.1.7 Power Cable Connection Terminals
The rectifier input, bypass input, output and battery power cables are connected to the corresponding terminals
shown in Figure 3-2.
3.1.8 Protective Earth
The protective earth cable must be connected securely to the PE input terminal (see Figure 3-2) using the fixing
bolt.
All the cabinets and cable troughs shall be grounded according to the local regulations. The grounding cables shall
be secured so as to prevent the tightening screws from being loosened when the grounding cables are pulled.
Warning
Failure to ground units correctly can cause EMI, electric shock or fire risk.
3.1.9 External Protective Device
To guarantee safety, it is necessary to install external circuit breakers on the UPS main, bypass and battery input
lines. Because of the differences between specific installations, this section is intended to provide general practical
information for the installation engineer only. Qualified installation engineers should have the knowledge of the local
wiring regulations that apply to the equipment to be installed.
Rectifier and bypass input power supply
1. Input over-current and short circuit protection
Install suitable protection devices on the input mains supply distribution line. Such devices should be selected in
order to protect the UPS against over current and short circuits, provide isolation protection and trip in the event of
back-feed. When selecting the protective devices, consider the power cable current-carrying capacity, system
overload capacity (see Table 11-6 and Table 11-7) and the short circuit capacity of the upstream power distribution
system. We normally recommend using a thermo-magnetic circuit breaker having an IEC60947-2 tripping curve C
(normal), when the current value reaches 125% of the current value listed in Table 3-1.
2. Separate bypass configuration
If the UPS is supplied by a separate bypass configuration, an independent protective device shall be installed on the
rectifier input and bypass input distribution lines.
Note
The rectifier input and bypass input must use the same neutral line.
3. Ground fault protection
If the pre-stage input power supply is fitted with an RCD, the transient state and steady state ground leakage
current upon the startup of the UPS must be taken into account.
The RCCB shall meet the following requirements:
Be sensitive to the DC unidirectional pulse (class A) of the whole distribution network
Be insensitive to transient state current pulses
Have an average sensitivity of 0.3A ~ 3A (adjustable)
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The RCCB symbols are shown in Figure 3-1.
Figure 3-1 RCCB symbols
The UPS has an internal EMC filter, therefore the protective earth cable leakage current is 0 ~ 1000mA. We
recommend verifying the RCD sensitivity of the upstream input distribution and the downstream distribution (to the
load).
External battery
The BCB is used to protect the external battery. The UPS may be supplied with an optional BCB box, which provides
over-current and short circuit protection and automatic tripping functions for the external battery. The rated
voltage of the BCB is 500Vdc, and its DC breaking current is 20kA.
This BCB is important for the battery maintenance, and is generally installed near the battery.
System output
The UPS output must be fitted with a protection device. This device must differ from the input distribution
protection switch and be able to provide overload protection (refer to Table 11-6 and Table 11-7).
3.1.10 Power Cable Connection Procedure
See para. 2.7.3 Cable Access Mode for information on the UPS cable access mode
Connection terminal and cable routing method
Figure 3-2 illustrates the UPS power cable connection terminals. Figure 3-3 and Figure 3-4 illustrate the power cable
entry and routing methods.
Note
1. The power cables should be routed through conduits or cable troughs to prevent damage due to mechanical stress and
reduce EMI into the surrounding environment.
2. When routing the cables inside the cabinets, they must be secured and fixed as illustrated in Figure 3-3 and Figure 3-4, in
order to prevent cable damage due to mechanical stress.
Note:
1. +, -, N: battery input terminals
2. PE: PE input terminal
3. mA, mB, mC: rectifier input terminals
4. bA, bB, bC, N: bypass input terminals
5. oA, oB, oC, oN: output terminals
+
mA mB mC bA bB bC N oN oA oB oC
N
-
PE
Shorting copper bar of
common input configuration
Figure 3-2 Power cable connection terminals
26 User Manual 10H52246UM60 - Rev. 1 - 01/2017
ECLECTRICAL INSTALLATION
Cover panel of switch area
Step 2
Step 4
Note:
Step 1: Remove the left top cover, lead battery input cable and
PE input cable into the cabinet, and route them along
Step 2: Remove the cover panel of switch area, respectively connect
cables to battery input terminals and PE input terminal.
Step 3: Remove the right top cover, lead rectifier input cable, bypass
input cable and output cable into the cabinet and route them
Step 4: Respectively connect cables to the cabinet rectifier input
terminals, bypass input terminals and output terminals.
Step 1
Step 3
left side panel to cabinet base.
along right side panel to cabinet base.
Figure 3-3 Power cables wiring route (top cable access)
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