AC Power
For Business-Critical Continuity™
Liebert Series 610™ UPS
Installation Manual - 500-750kVA, 60Hz, Three Phase Single-Module
BATTERY CABINET PRECAUTIONS
The following warning applies to all battery cabinets supplied with UPS systems. Additional
warnings and cautions applicable to battery cabinets may be found in:
• Important Safety Instructions—page 1
• Section 2.0 - Unloading and Handling
• Section 5.0 - Battery Installation
!
WARNING
Internal battery strapping must be verified by manufacturer prior to moving a battery cabinet
(after initial installation).
• Battery cabinets contain non-spillable batteries.
• Keep units upright.
• Do not stack.
• Do not tilt.
Failure to heed this warning could result in smoke, fire or electric hazard.
Call 1-800-LIEBERT prior to moving battery cabinets (after initial installation).
CONTACTING LIEBERT FOR SUPPORT
To contact Liebert Global Services for information or repair service in the United States, call
1-800-LIEBERT (1-800-543-2378). Liebert Global Services offers a complete range of start-up
services, repair services, preventive maintenance plans and service contracts.
For repair or maintenance service outside the 48 contiguous United States, contact Liebert Global
Services, if available in your area. For areas not covered by Liebert Global Services, the
authorized distributor is responsible for providing qualified, factory-authorized service.
For LGS to assist you promptly, please have the following information available:
Part numbers: _________________________________________________________________
Serial numbers:________________________________________________________________
Rating: _______________________________________________________________________
Date purchased: _______________________________________________________________
Date installed:_________________________________________________________________
Location: ______________________________________________________________________
Input voltage/frequency: ________________________________________________________
Output voltage/frequency: ______________________________________________________
Battery reserve time:___________________________________________________________
TABLE OF CONTENTS
BATTERY CABINET PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSIDE FRONT COVER
CONTACTING LIEBERT FOR SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSIDE FRONT COVER
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.0
INSTALLATION CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.0
UNLOADING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.0
INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.1
External Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2
Internal Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.0
EQUIPMENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
5.0
BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
5.1
Battery Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2
Battery Safety Precautions in French Per CSA Requirements . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3
Battery Cabinets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.4
Open-Rack Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.0
CONFIGURING YOUR NEUTRAL AND GROUND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . 12
6.1
Preferred Grounding Configuration, Wye-Connected Service . . . . . . . . . . . . . . . . . . . . . . . . 13
6.2
Alternate Grounding Configuration, Wye-Connected Service . . . . . . . . . . . . . . . . . . . . . . . . 14
6.3
Preferred Grounding Configuration With Isolated Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.4
Alternate Grounding Configuration, Non-Isolated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.5
Grounding Configuration, Corner-Grounded Delta or Impedance-Grounded Wye . . . . . . . 17
6.6
Preferred Grounding Configuration, Battery Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.0
WIRING CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
7.1
Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.2
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.3
Battery Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.0
WIRING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.1
Specific Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.0
WIRING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10.0
INSTALLATION DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
APPENDIX A - SITE PLANNING DATA, SERIES 610, 500-750KVA, SINGLE-MODULE SYSTEMS . . . . 81
i
FIGURES
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
Figure 24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
Figure 34
Figure 35
Figure 36
Figure 37
Figure 38
Figure 39
Preferred grounding configuration, wye-connected service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternate grounding configuration, wye-connected service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preferred grounding configuration with isolated bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternate grounding configuration, non-isolated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding configuration, corner-grounded delta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding configuration, impedance-grounded wye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preferred battery cabinet grounding configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power single-line diagrams*. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power single-line diagram, optional 12-pulse rectifier* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline drawing, 500kVA, Single-Module UPS, 6-pulse rectifier, 480V input - 480/277V
output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal details, 500kVA, Single-Module UPS, 6-pulse rectifier, 480V input - 480/277V
output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline drawing, 500kVA, Single-Module UPS, 6-pulse rectifier, 600V input - 600/346V
output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal details, 500kVA, Single-Module UPS, 6-pulse rectifier, 600V input - 600/346V
output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline drawing, 500kVA, Single-Module UPS, 12-pulse rectifier . . . . . . . . . . . . . . . . . . . . . . . .
Terminal details, 500kVA, Single-Module UPS, 12-pulse rectifier . . . . . . . . . . . . . . . . . . . . . . . .
Outline drawing, 625-750kVA, Single-Module UPS, 6-pulse rectifier. . . . . . . . . . . . . . . . . . . . . .
Terminal details, 625-750kVA, Single-Module UPS, 6-pulse rectifier. . . . . . . . . . . . . . . . . . . . . .
Outline drawing, 625-750kVA, Single-Module UPS, 12-pulse rectifier. . . . . . . . . . . . . . . . . . . . .
Terminal details, 625-750kVA, Single-Module UPS, 12-pulse rectifier. . . . . . . . . . . . . . . . . . . . .
Outline drawing, 500kVA, Single-Module UPS, 12-pulse rectifier with bottom entry
wireway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal details, 500kVA, Single-Module UPS, 12-pulse rectifier with bottom entry
wireway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline drawing, 625-750kVA, Single-Module UPS, 6-pulse rectifier with bottom entry
wireway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal details, 625-750kVA, Single-Module UPS, 6-pulse rectifier with bottom entry
wireway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline drawing, 625-750kVA, Single-Module UPS, 12-pulse rectifier with bottom entry
wireway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal details, 625-750kVA, Single-Module UPS, 12-pulse rectifier with bottom entry
wireway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal details, 750kVA/675kW, Single-Module UPS, 12-pulse rectifier with bottom entry
wireway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base mounting patterns, 500kVA module, 6-pulse rectifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base mounting patterns, 500kVA module, 12-pulse rectifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base mounting patterns, 500kVA module, 12-pulse rectifier with bottom entry wireway . . . . .
Base mounting patterns, 625-750kVA module, 6-pulse rectifier . . . . . . . . . . . . . . . . . . . . . . . . . .
Base mounting patterns, 625-750kVA module, 6-pulse rectifier with bottom entry wireway . . .
Base mounting patterns, 625-750kVA module, 12-pulse rectifier . . . . . . . . . . . . . . . . . . . . . . . . .
Base mounting patterns, 625-750kVA module, 12-pulse rectifier with bottom entry wireway . .
Shipping split detail, 500kVA, 12-pulse rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping split detail, 500kVA, 12-pulse rectifier with bottom entry wireway . . . . . . . . . . . . . . .
Shipping split detail, 625-750kVA, 6-pulse rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping split detail, 625-750kVA, 6-pulse rectifier with bottom entry wireway. . . . . . . . . . . . .
Shipping split detail, 625-750kVA, 12-pulse rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping split detail, 625-750kVA, 12-pulse rectifier with bottom entry wireway. . . . . . . . . . . .
ii
13
14
15
16
17
17
18
21
22
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
Figure 40
Figure 41
Figure 42
Figure 43
Figure 44
Figure 45
Figure 46
Figure 47
Figure 48
Figure 49
Figure 50
Figure 51
Figure 52
Figure 53
Figure 54
Figure 55
Figure 56
Figure 57
Figure 58
Figure 59
Figure 60
Battery power pack system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery power pack, Size A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line-up detail, 300-500kVA, Single- or Multi-Module System with battery cabinets . . . . . . . . .
Control connection location diagram, Single-Module System, 300-500kVA . . . . . . . . . . . . . . . . .
Control connection location diagram, Single-Module System, 625-750kVA . . . . . . . . . . . . . . . . .
Control wiring, external interconnect diagram, Single-Module System, 300-750kVA . . . . . . . . .
Control wiring, external interconnect diagram, Single-Module System with maintenance
bypass cabinet, 300-750kVA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control wire list, external interconnections, standard wiring, Single-Module System,
300-750kVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control wire list, external interconnections, standard wiring, Single-Module System with
maintenance bypass cabinet, 300-750kVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Module control wiring, alarm status contacts option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COM PWA, remote terminal (RS232) option, SiteScan option, internal modem option. . . . . . . .
Control wiring, customer alarm interface option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control wiring, SNMP interface option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control wiring, remote status panel interface option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control wiring, battery temperature sensor interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control wiring, maintenance bypass interlock option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control wiring, maintenance bypass cabinet option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline drawing, single-breaker module battery disconnect,
300, 450, 600, 800, 1000, 1200A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline drawing, single-breaker module battery disconnect,
1400AT/1600AT/2000AT/2500AT 600VDC circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline drawing, dual-breaker module battery disconnect, 600, 800, 1000, 1200A . . . . . . . . . . .
Outline drawing, remote status panel, surface mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
TABLES
Table 1
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7
Abbreviations for circuit breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power wiring terminals - factory supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field-supplied lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 310-16, National Electrical Code (Reprint) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Site planning data—600V input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Site planning data—480V input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iii
21
26
26
27
28
82
83
iv
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions that should be followed during installation of your
Series 610 UPS and batteries.
!
WARNING
Exercise extreme care when handling UPS cabinets to avoid equipment damage or injury to
personnel. The UPS module weight ranges from 5775 to 12100 lbs. (2619 to 5488kg),
including input transformer. The battery cabinets weigh from 3060 to 5300 lbs. (1388 to
2404kg).
Locate center of gravity symbols
and determine unit weight before handling each
cabinet. Test lift and balance the cabinets before transporting. Maintain minimum tilt from
vertical at all times.
Slots at the base of the modules and battery cabinets are intended for forklift use. Base slots
will support the unit only if the forks are completely beneath the unit.
Follow all battery safety precautions when installing, charging or servicing batteries. In
addition to the hazard of electric shock, gas produced by batteries can be explosive and
sulfuric acid can cause severe burns.
In case of fire involving electrical equipment, use only carbon dioxide fire extinguishers or
those approved for use in fighting electrical fires.
Extreme caution is required when performing maintenance.
Be constantly aware that the UPS system contains high DC as well as AC voltages.
Check for voltage with both AC and DC voltmeters prior to making contact.
Read this manual thoroughly, paying special attention to the sections that apply to your installation,
before working with the UPS. Retain this manual for use by installing personnel.
!
WARNING
Under typical operation and with all UPS doors closed, only normal safety precautions are
necessary. The area around the UPS system should be kept free of puddles of water, excess
moisture and debris.
Special safety precautions are required for procedures involving handling, installation and
maintenance of the UPS system and the battery. Observe all safety precautions in this
manual before handling or installing the UPS system. Observe all precautions in the
Operation and Maintenance Manual, before as well as during performance of all maintenance
procedures. Observe all battery safety precautions before working on or near the battery.
This equipment contains several circuits that are energized with high voltage. Only
test equipment designed for troubleshooting should be used. This is particularly true for
oscilloscopes. Always check with an AC and DC voltmeter to ensure safety before making
contact or using tools. Even when the power is turned Off, dangerously high potential electric
charges may exist at the capacitor banks and at the batteries.
All power and control wiring should be installed by a qualified electrician. All power
and control wiring must comply with the NEC and applicable local codes.
ONLY qualified service personnel should perform maintenance on the UPS system.
When performing maintenance with any part of the equipment under power, service
personnel and test equipment should be standing on rubber mats. The service personnel
should wear insulating shoes for isolation from direct contact with the floor (earth ground).
One person should never work alone, even if all power is removed from the equipment. A
second person should be standing by to assist and summon help in case an accident should
occur.
1
!
CAUTION
This unit complies with the limits for a Class A digital device, pursuant to Part 15 Subpart J
of the FCC rules and EN550022. These limits provide reasonable protection against harmful
interference in a commercial environment. This unit generates, uses and radiates radio
frequency energy and, if not installed and used in accordance with this instruction manual,
may cause harmful interference to radio communications. Operation of this unit in a
residential area may cause harmful interference that the user must correct at his own
expense.
NOTE
Liebert Corporation neither recommends nor knowingly sells this product for use with life
support or other FDA-designated “critical” devices.
2
Installation Considerations
1.0
INSTALLATION CONSIDERATIONS
Install your Series 610 UPS in accordance with the submittal drawing package and the following procedures.
A Liebert authorized representative must perform the initial system check-out and start-up to ensure
proper system operation. Equipment warranties will be voided unless system start-up is performed by
a Liebert authorized representative. Contact your local Liebert sales representative or Liebert Global
Services at 1-800-LIEBERT to arrange for system start-up.
!
CAUTION
Read this manual thoroughly before attempting to wire or operate the unit. Improper
installation is the most significant cause of UPS start-up problems.
Do not install this equipment near gas or electric heaters. It is preferable to install the UPS in
a restricted location to prevent access by unauthorized personnel.
1. Proper planning will speed unloading, location and connection of the UPS. Refer to Figures 10
through 60 and Appendix A.
2. Be certain that the floor at the final equipment location and along the route (inside the facility) to
the installation site can support the cabinet weight and the weight of any moving equipment. The
UPS modules can weigh from 5775 to 12100 lbs. (2619 to 5488kg). The battery cabinets weigh
from 3060 to 5300 lbs. (1388 to 2404kg) each. Refer to Appendix A.
!
WARNING
Locate center of gravity symbols
and determine unit weight before handling cabinet.
3. Plan the route to ensure that the unit can move through all aisleways and doorways and around
corners without risking damage. If the modules and batteries must be moved by elevator, check
the size of the door openings and the weight-carrying capacity of the elevator.
4. Refer to information later in this manual regarding the optional battery cabinet(s), Maintenance
Bypass Cabinet and Transformer Cabinet. Observe all battery safety precautions when
working on or near the battery.
5. Use the shortest output distribution cable runs possible, consistent with logical equipment
arrangements and with allowances for future additions if planned.
6. Recommended ambient operating temperature is 77°F (25°C). Relative humidity must be less
than 95%, non-condensing. Note that room ventilation is necessary, but air conditioning may not
be required. Maximum ambient operating temperature is 104°F (40°C) without derating. The
batteries should not exceed 77°F (25°C). At elevations above 4000 ft. (1219m), temperature
derating may be required for full power output—consult your Liebert sales representative or call
1-800-LIEBERT.
7. Even though your Liebert UPS unit is 92 to 94% efficient, the heat output is substantial. For more
specific information, see Appendix A. Be sure environmental conditioning systems can
accommodate this BTU load, even during utility outages.
8. The installer should attempt to balance the load between the three output phases. The UPS will
operate safely with an unbalanced load, but will give optimum performance if the three output
phases are loaded within 20 percent of each other.
9. During normal UPS operations, short-term overload current demand from the bypass source may
reach 10x the UPS output current rating. This overload current demand may be caused by the
magnetizing inrush current of one or more downstream transformers or faults on downstream
branch circuits. The instantaneous trip point(s) of the upstream bypass feeder breaker(s) must be
set to support these temporary overloads. The magnitude of short-term overload bypass current
demand is typically six to eight times the UPS current rating, but must be determined by analysis
on a per-site basis. This analysis, generally known as an End-to-End Fault Coordination Study,
must be done by a Registered Professional Engineer experienced in this activity and familiar with
local codes and related requirements.
NOTE
While Liebert can provide typical guidelines, the responsibility for the proper breaker trip
settings outside of the Liebert-manufactured UPS equipment resides with the owner. Contact
Liebert Global Services at 1-800-LIEBERT for further details.
3
Installation Considerations
10. A breaker coordination study should be performed to ensure proper handling of fault currents.
NOTE
The instantaneous trip setting of the breaker feeding the UPS bypass input should be high
enough to accommodate short-duration overloads. The bypass static switch inside the UPS can
draw up to 10 times the system’s rated current for up to three cycles.
4
Unloading and Handling
2.0
UNLOADING AND HANDLING
The UPS module is shipped in one cabinet to allow ease of handling at the site. Because the weight
distribution in the cabinet is uneven, use extreme care during handling and transport. Your installation may also include battery cabinets, a Maintenance Bypass Cabinet and an optional transformer
cabinet.
!
WARNING
Exercise extreme care when handling UPS cabinets to avoid equipment damage or injury to
personnel. The UPS module weight ranges from 5775 to 12100 lbs. (2619 to 5488kg), not
including the optional transformer cabinet. Battery cabinets weigh from 3060 to 5300 lbs.
(1388 to 2404kg).
Locate center of gravity symbols before handling cabinet. Test lift and balance the cabinet
before transporting. Maintain minimum tilt from vertical at all times.
Slots at the base of the unit and battery cabinets are intended for forklift use. Base slots will
support the unit only if the forks are completely beneath the unit.
To reduce the possibility of shipping damage, cabinets are shored with 2x4 bracing, secured with
screw-type nails. This shoring must be carefully removed prior to unloading.
!
CAUTION
Extreme care is necessary when removing shoring braces. Do not strike cabinet with
hammers or other tools.
5
Inspections
3.0
INSPECTIONS
3.1
External Inspections
1. While the UPS system is still on the truck, inspect the equipment and shipping container(s) for
any signs of damage or mishandling. Do not attempt to install the system if damage is apparent.
If any damage is noted, file a damage claim with the shipping agency within 24 hours and contact
Liebert Global Services at 1-800-LIEBERT to inform them of the damage claim and the condition
of the equipment.
2. Locate the bag containing the keys for the front access door. The bag is attached to the cabinet.
3. Compare the contents of the shipment with the bill of lading. Report any missing items to the
carrier and to Liebert Global Services immediately.
4. Check the nameplate on the cabinet to verify that the model number corresponds with the one
specified. Record the model number and serial number in the front of this installation manual. A
record of this information is necessary should servicing become required.
3.2
Internal Inspections
1.
2.
3.
4.
5.
Verify that all items have been received.
If spare parts were ordered, verify arrival.
Open doors and remove cabinet panels to check for shipping damage to internal components.
Check for loose connections or unsecured components in the cabinet(s).
Check for installation of circuit breaker line safety shields. There should be no exposed circuit
breaker terminals when the cabinet doors are opened.
6. Check for any unsafe condition that may be a potential safety hazard.
7. UPS modules are shipped with internally mounted shipping brackets. The shipping brackets
(painted orange) must be removed from the rear (remove rear panels). The installer must remove
the orange shipping brackets before final equipment placement, particularly if rear access will be
restricted.
!
CAUTION
Failure to remove orange shipping brackets from transformers may cause restricted airflow
within the UPS. This could cause overheating or reduction of UPS capacity. In some cases, it
could cause damage to the UPS module, and such damage would not be covered under the
factory warranty. If you foresee a situation where the UPS will be relocated in the near
future, the brackets should be removed and stored elsewhere until they are needed.
6
Equipment Location
4.0
EQUIPMENT LOCATION
1. Handle cabinet(s) in accordance with the safety precautions in this manual, especially in these
sections:
• Battery Cabinet Precautions—inside front cover
• Important Safety Instructions—page 1
• 2.0 - Unloading and Handling—page 5
• 5.0 - Battery Installation—page 8
Use a suitable material handling device to move cabinet to its final location. Exercise extreme
care because of the uneven weight distribution. Carefully lower the cabinet to the floor.
2. Verify that the UPS system is installed in a clean, cool and dry location.
3. Installation and serviceability will be easier if adequate access is provided on all sides of the
equipment, but only front access is required.
a. Verify that there is adequate clearance to open cabinet doors—4 ft. (1.2m) is recommended.
NEC requires sufficient clearance in front of the equipment to fully open all doors without
restriction. See drawings and local codes.
b. Verify that there is adequate area in front of circuit breakers to perform maintenance. Check
installation drawings for location of breakers. Check with local codes.
c. Verify that there is adequate clearance above all cabinets to allow exhaust air to flow without
restriction. The minimum clearance is 2 ft. (0.6m), unobstructed by conduit or any other
items. Liebert recommends against using top-feed air conditioning systems.
4. Align the UPS cabinet, battery cabinets (if used) and optional transformer and maintenance
bypass cabinets, as shown in the Line-Up Detail drawing (Figure 42) and your submittal
package.
5. Connect the cabinets, internal cables and busbars, if applicable. Internal control connections
should be left disconnected for later installation by Liebert LGS Customer Engineers.
7
Battery Installation
5.0
BATTERY INSTALLATION
5.1
Battery Safety Precautions
Servicing of batteries should be performed or supervised by personnel knowledgeable of batteries and
the required precautions. Keep unauthorized personnel away from batteries.
Be sure to observe the grounding recommendations in 6.0 - Configuring Your Neutral and
Ground Connections when installing batteries. When replacing batteries, use the same number
and type of batteries.
!
CAUTION
Lead-acid batteries contain hazardous materials. Batteries must be handled, transported and
recycled or discarded in accordance with federal, state and local regulations. Because lead is a
toxic substance, lead-acid batteries must be recycled rather than discarded.
Do not open or mutilate the battery or batteries. Released electrolyte is harmful to the skin
and eyes. It is toxic. Do not dispose of battery or batteries in a fire. The battery may explode.
Do not install any batteries that are cracked, leaking or show other signs of damage. Contact
Liebert Global Services or your local Liebert representative.
A battery can present a risk of electrical shock and high short circuit current. The following
precautions should be observed when working on batteries:
•
•
•
•
•
•
Remove watches, rings and other metal objects.
Use tools with insulated handles.
Wear rubber gloves and boots.
Do not lay tools or metal parts on top of batteries.
Disconnect charging source prior to connecting or disconnecting battery terminals.
Determine if battery is inadvertently grounded. If inadvertently grounded, remove source
of ground. Contact with any part of a grounded battery can result in electrical shock. The
likelihood of such shock will be reduced if such grounds are removed during installation
and maintenance.
Lead-acid batteries can present a risk of fire because they generate hydrogen gas. The
following procedures should be followed:
• DO NOT SMOKE when near batteries.
• DO NOT cause flame or spark in battery area.
• Discharge static electricity from body before touching batteries by first touching a grounded
metal surface.
• After replacing battery jars in a battery cabinet, replace the retaining straps that hold the
jars in place on the shelves. This will limit accidental movement of the jars and connectors
should the cabinet ever need to be repositioned or relocated. Regular maintenance of the
battery module is an absolute necessity. Periodic inspections of battery and terminal voltages, specific gravity and connection resistance should be made. Strictly follow the procedures outlined in the battery manufacturer’s manual, available on the manufacturer’s Web
site.
8
Battery Installation
5.2
Battery Safety Precautions in French Per CSA Requirements
Instructions Importantes Concernant La Sécurité
Conserver Ces Instructions
!
AVERTISSEMENT
Respecter toutes les consignes de sécurité applicables à l'installation, le chargement ou
l'entretien des batteries. En plus du danger de chocs électriques, le gaz produit par les
batteries peut exploser dégageant de l'acide sulfurique qui peut entraîner de très graves
brûlures.
Toute opération d'entretien/réparation des batteries doit être exécutée ou supervisée par un
personnel qualifié dans le domaine et en prenant toutes les précautions nécessaires. Tenir le
personnel non autorisé à l’écart des batteries.
!
ATTENTION
Les batteries acide-plomb contiennent des substances toxiques dangereuses. Les batteries
doivent être manipulées, transportées et recyclées ou jetées conformément à la
réglementation en vigueur aux niveaux national et local. Le plomb étant toxique, les batteries
acide-plomb doivent être recyclées et non jetées.
Ne pas ouvrir ni endommager la ou les batteries. Les électrolytes diffusés sont dangereux
pour la peau et les yeux. Ils sont toxiques. Ne pas jeter la ou les batteries dans le feu. Risque
d'explosion.
Ne jamais installer de batteries avec des cellules fissurées ou endommagées. Contacter
Liebert Global Services ou le représentant agréé Liebert local.
Une batterie peut poser un risque de choc électrique et de courant élevé provoqué par un
court-circuit. Respecter les précautions suivantes lors de travaux sur les batteries:
•
•
•
•
•
Enlever montres, bagues ou autres objets métalliques.
Utiliser des outils dont les poignées sont isolées.
Porter des gants et des bottes en caoutchouc.
Ne pas poser d'outils ou d'objets métalliques sur les batteries.
Déconnecter la source de chargement avant de connecter ou de déconnecter les bornes de
batterie.
• Vérifier que la batterie n'a pas été mise à la masse par inadvertance. Si elle est mise à la
masse, éliminer la source de masse. Tout contact avec des composants de batterie mise à la
masse peut entraîner un choc électrique. Éliminer le risque de chocs électriques potentiels
en retirant les sources de masse avant l'installation et la maintenance.
Les batteries acide-plomb peuvent représenter un risque d'incendie puisqu'elles génèrent de
l'hydrogène. Respecter les procédures suivantes:
• NE PAS FUMER près des batteries.
• NE PAS générer de flammes ou d'étincelles près des batteries.
• Éliminer l'électricité statique du corps avant de manipuler les batteries en touchant d'abord
une surface métallique mise à la terre.
L’électrolyte est un acide sulfurique dilué qui est dangereux au contact de la peau et des yeux.
Ce produit est corrosif et aussi conducteur electrique. Les procédures suivantes devront être
observées:
• Porter toujours des vêtements protecteurs ainsi que des lunettes de protection pour les yeux.
• Si l’électrolyte entre en contact avec la peau, nettoyer immédiatement en rincant avec de l’eau.
• Si l’électrolyte entre en contact avec les yeux, arroser immédiatement et généreusement
avec de l’eau. Demander pour de l’aide médicale.
• Lorsque l’électrolyte est renversée, la surface affectée devrait être nettoyée en utilisant un
agent neutralisant adéquat. Une pratique courante est d’utiliser un mélange d’approximativement une livre (500 grammes) de bicarbonate de soude dans approximativement un gallon (4 litres) d’eau. Le mélange de bicarbonate de soude devra être ajouté jusqu’à ce qu’il n’y
ait plus apparence de réaction (mousse). Le liquide résiduel devra être nettoyé à l’eau et la
surface concernée devra être asséchée.
9
Battery Installation
5.3
Battery Cabinets
Optional battery cabinets are available from Liebert and other qualified vendors. Consult your submittal package for details.
Several models of optional battery cabinets with varying run times are available. Each model is 78"
(1981mm) high and has forklift slots. Refer to Figure 40 and 41. The battery cabinet cells range from
90 to 150 ampere-hours. The same model battery cabinet may be paralleled in multiple cabinet
strings for additional capacity. Battery capacity (in minutes) at your installation will depend on cabinet model, number of cabinets, and amount of critical load on the UPS.
1. Handling. The battery cabinet weighs from 3060 to 5300 lbs. (1388 to 2404kg). Forklift slots are
provided for ease of handling.
2. Cabinet Inspection. Remove all panels and visually inspect the batteries, bus connections, and
cabinet for any damage. If any foam blocks were placed between shelves to restrain movement
during shipment, remove them now. Exercise caution—voltage is present within the
battery cabinet even before installation. If there are signs of damage, do not proceed. Call
Liebert Global Services at 1-800-LIEBERT.
3. Battery Storage. The batteries used in the battery cabinet retain their charge well. The
batteries can be stored indoors in a temperature-controlled environment, for up to six months
without any appreciable deterioration. Self-discharge rate of the batteries is approximately 3%
per month when the batteries are stored in temperatures of 59°F to 77°F (15-25°C). If the battery
cabinet must be stored for longer than six months, contact Liebert Global Services. The battery
cabinet should never be stored outdoors or on a loading dock.
4. Installation. The battery cabinet(s) can be located conveniently next to the UPS module. The
front-access-only-design eliminates side and rear service clearance requirements.
5. Reinstallation. If at any time it becomes necessary to move the battery cabinet to another
location, contact Liebert Global Services to inspect the internal battery hold-down straps.
6. Environment. Locate the battery cabinet in a clean, dry environment. Recommended
temperature range for optimum performance and lifetime is 68°F to 77°F (20-25°C).
7. Service Clearance. Allow front access to the battery cabinet at all times for maintenance and
servicing. Electrical codes require that the battery cabinet be installed with no less than 3 ft. (1m)
of clearance at the front of the cabinet when operating. Side and rear panels do not require service
clearance.
8. Side Panels. To connect battery cabinets together, remove the protective side panels by
removing the retaining screws that hold the side panels in place.
9. Cables. Multiple battery cabinets may be bolted together in a daisy-chain configuration. Cables
for this setup may be run between paralleled battery cabinets through cutouts in the top of the
cabinets, eliminating the need for external conduit runs. Route cables before moving
cabinets into final position for bolting together. Low voltage control wiring must be kept
separate from the power wiring. Remove top panels for access. No top or bottom entry cables are
required, except for remotely located cabinets, which require conduits. Refer to Figures 40
and 41 or your submittal drawings for instructions on wiring cabinets in parallel.
NOTE
The 300-750kVA UPS module is approximately 2 to 6 in. (51-152mm) deeper than the battery
cabinet and is not designed to bolt directly to it.
10. Grounding. The battery cabinets have ground studs near the busbar connections. Use an
equipment grounding conductor to connect the lugs of the cabinets together and to connect the
cabinets to the ground busbar in the UPS module.
10
Battery Installation
5.4
Open-Rack Batteries
When batteries other than Liebert battery cabinets are used, a remote battery disconnect switch with
overcurrent protection is required per the National Electrical Code. Refer to Required Battery Disconnect Rating in the site planning data tables in Appendix A for recommended overcurrent protection
ratings. Contact your Liebert sales representative for more information.
1. Install battery racks/cabinets and batteries per manufacturer’s installation and maintenance
instructions.
2. Verify battery area has adequate ventilation and battery operating temperature complies with
manufacturer’s specification. Installations using vented lead-acid batteries MUST have adequate
ventilation to remove explosive gases per local and national codes.
3. Low voltage control wiring must be kept separate from power wiring and run in separate
conduits.
4. Ensure that battery racks are properly grounded according to code requirements in your area.
If you have any questions concerning batteries, battery racks or accessories, contact your local sales
representative or Liebert Global Services at 1-800-LIEBERT.
!
CAUTION
Cables between batteries and the UPS should be run in matched pairs,
positive-with-negative, within each conduit or cable run. Grouping
like-polarity cables together (i.e., positive-with-positive and
negative-with-negative) can cause stress or damage to the cables,
conduit or buswork.
11
Configuring Your Neutral and Ground Connections
6.0
CONFIGURING YOUR NEUTRAL AND GROUND CONNECTIONS
Improper grounding is the largest single cause of UPS installation and start-up problems. This is not
an easy subject, since grounding techniques vary significantly from site to site, depending on several
factors. The questions you should ask are:
• What is the configuration of the input power source? Most of the recommended schemes for UPS
grounding require grounded-wye service. The UPS system requires a bypass neutral for sensing
and monitoring the quality of the bypass input. If the building service is ungrounded delta or corner-grounded delta, contact your Liebert representative for details about Isolated Neutral kits.
A Power-Tie or distributed redundant system has different grounding requirements from standalone UPS modules. If using one of those systems, refer to Liebert’s Power-Tie configuration user
manual, SL-30030.
• Does the system have a bypass isolation transformer? Systems with 480 VAC (or 600 VAC) input
and 208 VAC output require a bypass isolation transformer. In some cases, it may be necessary to
treat that transformer as a “separately derived source” with its own grounding electrode.
• What are the UPS input and output voltages? Systems with 480 VAC input and output have significantly different needs from systems with 480/208 VAC or 208/208 VAC.
• What is the connected load? Does the critical load consist of one or more Power Distribution Units
(PDUs)? Do the PDUs have isolation transformers?
Proper grounding should be based on NEC Section 250, but safe and proper equipment operation
requires further enhancements. The following pages detail Liebert’s recommendations for grounding
various system configurations to ensure optimal UPS system performance.
NOTE
Some UPS modules are equipped with input isolation transformers. However, these
transformers have no effect upon any system grounding considerations. These modules will be
grounded exactly as shown in Figures 1 through 7.
!
CAUTION
The UPS ground lug must be solidly connected to the service entrance ground by an
appropriately sized wire conductor per NEC Article 250. Each conduit or raceway containing
phase conductors must also contain a ground wire, both for UPS input and output, which are
solidly connected to the ground terminal at each termination point. Conduit-based grounding
systems tend to degrade over time. Therefore, using conduit as a grounding conductor for UPS
applications may degrade UPS performance and cause improper UPS operation.
12
Configuring Your Neutral and Ground Connections
6.1
Preferred Grounding Configuration, Wye-Connected Service
One of the most common configurations of Series 610 UPS Single-Module Systems is with 480 VAC
input, 480 VAC output and a connected load consisting of multiple Power Distribution Units (PDUs)
with isolation transformers in the PDUs to produce 208 VAC. For Canadian customers, the UPS modules usually have 600 VAC input and output. The same principles apply if the connected load is an
isolation transformer feeding various loads. Figure 1 shows a typical installation.
Notice that the UPS module main input and bypass input are connected to a grounded-wye service. In
this configuration, the UPS module is not considered a separately derived source. The UPS module
output neutral is solidly connected to the building service neutral, which is bonded to the grounding
conductor at the service entrance equipment.
The isolation transformers in the PDUs are considered a separately derived source. Therefore the
PDU neutral should be bonded to the PDU grounding conductor and connected to a local grounding
electrode in compliance with NEC 250-26.
Figure 1
Preferred grounding configuration, wye-connected service
GROUNDING
ELECTRODE
PER NEC 250-24
Advantages of this configuration include:
• A measure of common-mode noise attenuation, since the isolation (common-mode rejection) occurs
as close to the load as practical (i.e., at the PDU).
• The UPS module can be located remotely from the PDU without compromising common-mode
noise performance.
• By using UPS modules with 480 VAC input and output and creating 208 VAC at the PDU,
smaller and less costly power feeders can be used and less voltage drop (as a percent of nominal)
occurs.
NOTE
Impedance-grounded wye sources must be grounded in accordance with 6.5 - Grounding
Configuration, Corner-Grounded Delta or Impedance-Grounded Wye.
NOTE
Some UPS modules are equipped with input isolation transformers. However, these
transformers have no effect upon any system grounding considerations. These modules will be
grounded exactly as shown in these pages.
NOTE
If there is a 4-pole Automatic Transfer Switch (ATS) between the service entrance and the UPS,
this configuration cannot be used. Refer to 6.2 - Alternate Grounding Configuration, WyeConnected Service or 6.3 - Preferred Grounding Configuration With Isolated Bypass
to determine a suitable configuration.
13
Configuring Your Neutral and Ground Connections
6.2
Alternate Grounding Configuration, Wye-Connected Service
This configuration must NOT be used when single-phase loads are directly connected to the UPS.
The alternate configuration is similar to that shown in 6.1 - Preferred Grounding Configuration,
Wye-Connected Service, except that the service entrance neutral is not brought into the UPS module. In this configuration, the UPS output transformer is considered a separately derived source. The
UPS module neutral is bonded to the UPS ground, which is connected to a local grounding electrode
in accordance with NEC 250-26.
Please note that this configuration represents a price/performance trade-off. Whenever the UPS module transfers to or from bypass, two AC sources (input and bypass) are briefly connected together and
circulating current must flow. In the previous configuration, the current flows through the neutral
conductor. In this configuration, the current flows through the ground path, possibly tripping ground
fault interrupters (GFIs) and distorting the bypass waveform reference.
Proper adjustment of ground fault interrupters is necessary to avoid unwanted tripping.
Figure 2
Alternate grounding configuration, wye-connected service
This configuration is reserved for applications that meet all the following criteria:
• The facility has wye-connected service.
• The module rectifier input and bypass input are fed from the same source.
• The connected load is strictly 3-wire (such as one or more PDUs) and does not require a neutral
from the UPS.
• Special precautions are taken to prevent tripping the ground fault interrupters. The time delay
should be set to at least 0.2 seconds to prevent tripping when the UPS performs a transfer or
retransfer operation.
!
CAUTION
Failure to properly set the ground fault interrupters could cause loss of power to the critical
load.
14
Configuring Your Neutral and Ground Connections
6.3
Preferred Grounding Configuration With Isolated Bypass
Another configuration in this power range is the Single-Module System with 480 or 600 VAC input,
208 VAC output, a Bypass Isolation Transformer and a connected load consisting of multiple distribution panelboards or switchboards. Figure 3 shows a typical installation.
The Bypass Transformer provides isolation and may step down the voltage to the bypass input. The
Bypass Transformer and the UPS module together constitute a separately derived system, since there
is no direct electrical connection between the input (service entrance) circuit conductors and the output circuit conductors.
NOTE
Figure 3 shows a wye-connected source, but the same grounding scheme would apply for a
delta source at the service entrance.
The bonding of the neutral to the grounding conductor can theoretically be done at either the UPS
module or the Bypass Transformer. However, we recommend bonding at the Bypass Transformer
because the UPS module will sometimes be powered down for maintenance and its output transformer will be out of the circuit. The neutral should be bonded to ground and a local grounding electrode should be installed at the Bypass Transformer, per NEC 250-30.
Figure 3
Preferred grounding configuration with isolated bypass
LOCAL GROUNDING
ELECTRODE
PER NEC 250-30
GROUNDING
ELECTRODE
PER NEC 250-24
Features of this configuration include:
• The UPS receives its bypass neutral from the Bypass Transformer
• The output is isolated from the input circuit conductors, and
• Some amount of common-mode noise attenuation can be obtained for sensitive loads if the
UPS module and Bypass Transformer are located close to sensitive loads.
15
Configuring Your Neutral and Ground Connections
6.4
Alternate Grounding Configuration, Non-Isolated
A few applications in this power range have 208 VAC input and output, and a connected load consisting of multiple Power Distribution Units (PDUs), panelboards, switchboards or other items of load
equipment which do not have isolation transformers.
Notice in Figure 4 that the UPS module main input and bypass input are connected to a groundedwye service. In this configuration, the UPS module is not considered a separately derived source.
The UPS module output neutral and the load neutral are solidly connected to the building service
neutral, which is bonded to the grounding conductor at the service entrance equipment.
Figure 4
Alternate grounding configuration, non-isolated
GROUNDING
ELECTRODE
PER NEC 250-24
This arrangement may be used for systems with 208 VAC input and output. However, it does not provide any isolation or common-mode noise attenuation for sensitive loads. For this reason, this configuration is not a preferred installation method.
NOTE
If there is a 4-pole Automatic Transfer Switch (ATS) between the service entrance and the UPS,
this configuration cannot be used. Refer to 6.3 - Preferred Grounding Configuration With
Isolated Bypass to determine a suitable configuration.
16
Configuring Your Neutral and Ground Connections
6.5
Grounding Configuration, Corner-Grounded Delta or Impedance-Grounded Wye
As previously mentioned, Series 610 UPS modules require a bypass input neutral for sensing and
monitoring. With a wye-connected input source, the installer should always connect the building service neutral to the module output neutral to achieve this. When the building service is delta-connected, however, the installer must take special steps to ensure reliable UPS functioning.
If the building service is corner-grounded delta or impedance-grounded wye, the UPS requires the
Series 610 Isolated Neutral Kit. This kit uses control isolation transformers to create a reference
point. For this application, the UPS output neutral must not be bonded to the UPS ground.
Figure 5
Grounding configuration, corner-grounded delta
LOCAL
GROUNDING
ELECTRODE
PER NEC 250-30
GROUNDING
ELECTRODE
PER NEC 250-24
Figure 6
Grounding configuration, impedance-grounded wye
GROUNDING
ELECTRODE
PER NEC 250-24
These configurations have the same restrictions as explained in 6.2 - Alternate Grounding Configuration, Wye-Connected Service, except for the wye input. The UPS input and bypass must be fed
from the same source. The load must be strictly 3-wire. And the GFI time delay should be set to at
least 0.2 seconds to prevent tripping during transfer or retransfer operations.
!
CAUTION
Failure to properly set the ground fault interrupters could cause loss of power to the critical
load.
17
Configuring Your Neutral and Ground Connections
6.6
Preferred Grounding Configuration, Battery Systems
Open-rack battery systems, depending on local code requirements and customer preference, are
normally:
1. Floating (ungrounded),
2. Center-tapped and floating or
3. Center tapped and grounded.
Battery cabinet systems must be connected as floating (ungrounded) systems—Option 1 above.
Center-tapped or grounded battery systems are not possible with battery cabinet systems.
Whether the battery system is open-rack or cabinet, the metal rack parts or cabinet must be grounded
to the UPS module ground bus.
Figure 7 illustrates how a simple, one-cabinet system would be grounded. For systems with multiple
cabinets, the same configuration would apply. However, for simplicity, the installer can connect all
the battery cabinet grounds for a particular module together and run a single ground conductor to
that UPS module ground (in the same conduit as the phase conductors).
Figure 7
Preferred battery cabinet grounding configuration
TO OUTPUT
DISTRIBUTION
GROUNDING
ELECTRODE
PER NEC 250-24
18
Wiring Considerations
7.0
WIRING CONSIDERATIONS
!
WARNING
All power connections must be completed by a licensed electrician experienced in wiring this
type of equipment. Wiring must be installed in accordance with all applicable national and
local electrical codes. Improper wiring may cause damage to the equipment or injury to
personnel.
Verify that all incoming high and low voltage power circuits are de-energized and locked out
before installing cables or making any electrical connections.
Refer to Appendix A and drawings in 10.0 - Installation Drawings. Determine AC currents for
your system (kVA, voltage and options). Also refer to the equipment nameplate for the model number,
rating and voltage. For wire termination data, refer to Tables 2 through 4.
NOTE
Use 75°C copper wire. Select wire size based on the ampacities in Table 5 of this manual, a
reprint of Table 310-16 and associated notes of the National Electrical Code (NFPA 70).
!
CAUTION
The weight of power cables must be adequately supported to avoid stress on busbars and lugs.
In addition to weight support, the following restraining method is recommended to control
cable movement during external fault conditions:
• Wrap line cables together at 6 and 12 in. (152 and 305mm) from the terminals with five
wraps of 3/8 in. (9.5mm) nylon rope or equivalent (tensile strength of 2000 lbs.; 907kg).
• Support the remainder of the cable with five wraps every 6 in. (152mm) or one wrap every
1 in. (25mm).
19
Wiring Considerations
7.1
Power Wiring
1. Power wiring—rectifier input, bypass input, UPS output and battery cables—must be run in
individual, separate conduits or cable trays. Refer to the Outline and Terminal Details drawings
(Figures 10 through 26 and Figures 57 through 60) for locations of the various power
connections within the UPS and ancillary equipment. In particular, note the location of the
rectifier input power connections.
!
CAUTION
Power and control wiring must be separated!
2. Observe local, state and national electrical codes. Verify utility power and its overcurrent
protection rating will accommodate the UPS input rating, including battery recharging.
3. A safety ground wire must be run from the building ground to a ground point in the UPS Module
Cabinets, ancillary equipment, and the Power-Tie Cabinet (if applicable). See 6.0 - Configuring
Your Neutral and Ground Connections. The grounding conductor shall comply with the
following conditions of installation:
a. An insulated grounding conductor must be sized in accordance with the NEC and local codes.
It must be green (with or without one or more yellow stripes) and be installed as part of the
branch circuit that supplies the unit or system.
b. The grounding conductor described above is to be grounded to earth at the service equipment
or, if supplied by a separately derived system, at the supply transformer or motor-generator
set in accordance with the instructions in 6.0 - Configuring Your Neutral and Ground
Connections.
c. The attachment-plug receptacles in the vicinity of the unit or system are all to be of a
grounding type, and the grounding conductors serving these receptacles are to be connected to
earth ground at the service equipment.
4. Observe clockwise phase rotation of all power wiring. Phase A leads Phase B leads Phase C.
A qualified electrician should check the phase rotation.
5. AC power cables must be rated for less the NEC-rated line drop at the maximum rated system
current. DC power cables from the UPS to the battery terminals and return must be sized for less
than 2 volts total loop drop at the maximum rated system current.
6. If site equipment includes a backup generator and automatic transfer switch(es), consult the
manufacturers of those devices for information on sizing and interfacing to the UPS system.
7. Removable access plates are available for power wiring. Refer to the Outline Drawings
(Figures 10, 12, 14, 16, 18, 20, 22 and 24 and Figures 57 through 60) for your particular model.
!
CAUTION
After cutting holes in the access plates, be certain that no foreign matter (metal shavings,
sawdust, insulation or wire fragments, etc.) remains inside the UPS. Likewise be certain to
block any “extra” holes in the plates through which foreign matter could later enter the UPS.
20
Wiring Considerations
Figure 8
Power single-line diagrams*
* These configurations are for illustrative purposes only. They represent only a sample of the possible
configurations. Refer to the submittals supplied with your order for more information or for order-specific details.
Three-breaker maintenance bypass switchboard
BFB
Critical load
AC output
MBB
BIB
MIB
UPS module
Static
bypass
switch
Static
switch
disconnect
Bypass CB
Control power
RIB
Main input
switchgear
Input
CB
Rectifier/
charger
Inverter
Output CB
MBD
Battery
Two-breaker maintenance bypass switchboard
MBFB
Critical load
AC output
MBB
MIB
UPS module
Static
switch
disconnect
BIB
Static
bypass
switch
Bypass CB
Control power
RIB
Main input
switchgear
Input
CB
Rectifier/
charger
Inverter
Output CB
MBD
Table 1
BFB
BIB
MBB
MBD
MBFB
MIB
RIB
Abbreviations for circuit breakers
Bypass Feeder Breaker
Bypass Input Breaker
Maintenance Bypass Breaker
Module Battery Disconnect
Maintenance Bypass Feeder Breaker
Maintenance Isolation Breaker
Rectifier Input Breaker
21
Battery
Wiring Considerations
Figure 9
Power single-line diagram, optional 12-pulse rectifier*
* This configuration is for illustrative purposes only. It represents only a
sample of the possible configurations. Refer to the submittals supplied
with your order for more information or for order-specific details.
Four-breaker maintenance bypass switchboard
FB
MBB
BIB
RIB
Critical load
AC output
MIB
UPS module
Static
bypass
switch
Static
switch
disconnect
Bypass CB
Control power
Input
CB
*Rectifier
isolation
Xfmr
Rectifier/
charger
Inverter
Output CB
Main input
switchgear
*Part of 12-pulse rectifier option
22
MBD
Battery
Wiring Considerations
7.2
Control Wiring
Control wiring must be flexible stranded, tinned copper and run in individual separate steel conduits.
Control wiring must be separated from power wiring. In addition, each control wiring cable group
should be run in a separate conduit to minimize control signal interference.
If your system has any installed options, special wire lists will be included in your Submittal Drawing
Package. Contact your Liebert Sales Representative for assistance if the submittal drawings have
been lost or misplaced.
All control cable groups are connected to different Interface Modules (IFMs) and/or terminal blocks
inside the UPS. Figures 43 and 44 show the typical location of each IFM inside the UPS. The position of a particular IFM may be different for your UPS, depending on the model and the installed
options.
NOTE
The UPS control and communication wiring are considered Class 2 circuits by NEC
standards. However, NEC Class 1 wiring methods are required for these circuits to ensure
proper operation of the UPS.
7.3
Battery Wiring
Power wiring to the battery cabinet connects positive, negative, and ground power cables from the
battery cabinet to the associated UPS. Connection of the UPS to the battery cabinet serves to both
charge and discharge the batteries (when needed). The battery disconnect (circuit breaker) requires a
control cable. Except for interconnect wiring between multiple battery cabinets, power and control
cables are field supplied. Refer to Figures 40 and 41.
!
WARNING
!
CAUTION
!
CAUTION
A battery intercell connection on each tier of the Liebert battery cabinet is disconnected for
safety during shipment. Do not complete these connections. A Liebert Global Services
representative will complete these connections as part of start-up. An improperly installed
unit can result in injury to personnel or damage to equipment.
Be sure polarity is correct when wiring the battery cabinet to the connected equipment
(positive to positive; negative to negative). If polarity is not correct, fuse failures or equipment
damage can result.
Cables between batteries and the UPS should be run in matched pairs,
positive-with-negative, within each conduit or cable run. Grouping
like-polarity cables together (i.e., positive-with-positive and
negative-with-negative) can cause stress or damage to the cables,
conduit or buswork.
Call Liebert Global Services to schedule installation check-out, final battery intercell connections and
start-up.
NOTE
A Liebert Battery Specialist can perform a detailed inspection of the entire battery system to
ensure it meets current IEEE standards. This inspection service is recommended because
batteries are a very critical part of the UPS system.
23
Wiring Connections
8.0
WIRING CONNECTIONS
!
WARNING
Verify that all incoming high and low voltage power circuits are de-energized and locked out
before installing cables or making electrical connections.
All power connections must be completed by a licensed electrician experienced in wiring UPS
equipment and in accordance with all applicable national and local electrical codes.
Improper wiring may cause damage to the UPS or injury to personnel.
!
CAUTION
All shielded cables, non-shielded cables, non-shielded control wires, non-shielded battery
breaker control wires and non-shielded remote control wires must be housed in individual,
separate, steel conduits. Placing multiple cables in the same conduit with other control or
power wiring may cause system failure.
NOTE
Use appropriately sized wire as a grounding conductor. Solid metal conduit is not a suitable
ground conductor for UPS systems and could negatively affect system performance.
24
Wiring Connections
8.1
Specific Connections
Refer to the drawings in this manual and any other drawings provided by Liebert for this installation.
NOTE
If your installation includes a Maintenance Bypass Panelboard or a Transformer Cabinet,
some or all power cables will be terminated in these cabinets. Make sure all required wiring
between the UPS module and the optional cabinets is completed per the submittal drawings.
Observe phase rotation.
Make all of the following connections:
1. AC power cables from input power source circuit breaker (RIB) to UPS Module Input. Observe
phase rotation.
2. AC power cables from bypass power source circuit breaker (BIB) to UPS Module Bypass input.
Observe phase rotation.
!
CAUTION
If there are line-to-neutral loads connected to the UPS output, the bypass input source must
be wye connected and have three phases plus neutral plus ground. If the specified input is not
available, an isolation transformer is required. Refer to 6.1 - Preferred Grounding
Configuration, Wye-Connected Service, 6.3 - Preferred Grounding Configuration
With Isolated Bypass and 6.4 - Alternate Grounding Configuration, Non-Isolated.
See 6.0 - Configuring Your Neutral and Ground Connections for an explanation of
proper grounding techniques.
3. AC power cables from UPS Module Output to critical load. Observe phase rotation.
!
CAUTION
UPS bypass and output neutral must be connected to only one common point in the UPS. This
neutral line must be grounded at the source. See 6.0 - Configuring Your Neutral and
Ground Connections.
4. For battery cabinets: DC power cables and ground from battery cabinet to UPS module and
between battery cabinets. Observe polarity. When multiple conduits are used, an equal number of
positive and negative cables should be contained in each conduit.
NOTE
DC power and battery circuit breaker control cables are provided with Liebert battery cabinets
for use between multiple cabinets when bolted together. Power cables are sized for
interconnecting battery cabinets. Battery cabinets specified for bolting up to the UPS are
shipped with power cables to connect the battery cabinet system to the UPS module. Fieldsupplied cabling must be provided to connect stand-alone battery cabinets to the UPS module.
Connections from the final battery cabinet to the UPS are provided in the field.
!
WARNING
Do not make any connections between battery tiers in the battery cabinet. These connections
will be made by the Liebert Global Services representative during start-up.
5. For remote battery: DC power cables (and ground) from battery to Module Battery Disconnect,
and then to UPS Module DC bus. Observe polarity. DC power cables should be installed in
conduit with conductors in matched pairs (positive and negative).
6. Module Battery Disconnect control wiring to UPS module (and between battery cabinets, if
applicable).
7. Control wiring to the optional Remote Monitor Panel, if used. Selected alarm messages are also
available for customer use through a set of contacts on an optional separate terminal board.
Wiring must be run in individual separate steel conduit.
8. Emergency Power Off control wiring must be run in separate steel conduit.
9. Communications wiring for optional site monitoring or modem must be run in separate steel
conduit.
10. Power and control connections required for the Maintenance Bypass.
11. Any additional special wiring required at your site.
25
Wiring Inspection
9.0
WIRING INSPECTION
1. Verify all power connections are tightened per the torque specifications in Table 3.
2. Verify all control wire terminations are tight.
3. Verify all power wires and connections have proper spacing between exposed surfaces, phase-tophase and phase-to-ground.
4. Verify that all control wires are run in steel conduit, separate from all power wiring.
Table 2
Power wiring terminals - factory supplied
UPS Module Rating
Connection Type
500-750kVA
Busbars for connecting hardware (with 3/8” holes on 1.75” centers) are provided for bypass
input, critical load output and DC wiring terminations. DC busbars for 625-750kVA modules
are designed for top entry and are located adjacent to the input circuit breaker. Rectifier
input wiring is top-entry, directly to lugs on top of the input circuit breaker. Field-supplied
lugs are required.
EXCEPTION: 500kVA UPS modules with the 6-pulse rectifier and no input isolation
transformer have rectifier input busbars exactly like those described above for bypass and
critical load termination.
Use 75°C copper wire. Select wire size based on the ampacities in Table 5 of this manual, a reprint of
Table 310-16 and associated notes of the National Electrical Code (NFPA 70).
Use commercially available solderless lugs for the wire size required for your application. Refer to
Table 3. Connect wire to the lug using tools and procedures specified by the lug manufacturer.
Table 3
Torque specifications
NUT AND BOLT COMBINATIONS
Grade 2 Standard
Electrical Connections
with Belleville Washers
Bolt Shaft Size
Lb-in
N-m
Lb-in
N-m
1/4
5/16
3/8
1/2
53
107
192
428
6.0
12
22
22
46
60
95
256
5.2
6.8
11
29
CIRCUIT BREAKERS WITH COMPRESSION LUGS (FOR POWER WIRING)
Wire Size or Range
Lb-in
N-m
#6 - #4
#3 - #1
1/0 - 2/0
3/0 - 200 MCM
250 - 400 MCM
500 - 700 MCM
100
125
150
200
250
300
11
14
17
23
28
34
CIRCUIT BREAKERS WITH COMPRESSION LUGS (FOR POWER WIRING)
Current Rating
Lb-in
N-m
400 - 1200 Amps
300.00
34.00
TERMINAL BLOCK COMPRESSION LUGS (FOR CONTROL WIRING)
AWG Wire Size or Range
Lb-in
N-m
#22 -#14
3.5 to 5.3
0.4 to 0.6
NOTE: Use the values in this table unless the equipment is labeled with a different torque value.
26
Wiring Inspection
Table 4
Field-supplied lugs
One-Hole Lugs
1
Wire Size
Bolt Size (in.)
Tongue Width (in.)
T & B1 P/N
Liebert P/N
1
#1 AWG
3/8
0.76
H973
12-714255-46
2
1/0 AWG
3/8
0.88
J973
12-714255-56
2/0 AWG
3/8
1.00
K973
12-714255-66
4
3/0 AWG
3/8
1.10
L973
12-714255-76
5
4/0 AWG
3/8
1.20
M973
12-714255-86
#1 AWG
3/8
0.75
60124
—
1/0 AWG
3/8
0.88
60130
—
T & B Lug Style
3
Stak-On
6
7
8
Color-Keyed
Aluminum/
Copper
2/0 AWG
3/8
0.97
60136
—
9
3/0 AWG
3/8
1.06
60142
—
10
#1 AWG
5/16
0.67
54947BE
—
1/0 AWG
3/8
0.75
54909BE
—
2/0 AWG
3/8
0.81
54910BE
—
3/0 AWG
1/2
0.94
54965BE
—
14
4/0 AWG
1/2
1.03
54970BE
—
15
250 MCM
1/2
1.09
54913BE
—
11
12
13
16
17
Color-Keyed
Copper Cable
Long Barrel
Narrow-Tongue
Copper Cable
350 MCM
1/2
1.09
55165
—
500 MCM
1/2
1.20
55171
—
1. Manufacturer: Thomas & Betts (T & B), 1-800-862-8324
27
Wiring Inspection
Table 5
Table 310-16, National Electrical Code (Reprint)
Allowable Ampacities of Insulated Conductors Rated 0-2000 Volts, 60° to 90°C (140° to 194°F) 1
Not More Than Three Conductors in Raceway or Cable or Earth (Directly Buried), Based on Ambient Temperature of 30°C (86°F)
SIZE
TEMPERATURE RATING OF CONDUCTOR. SEE TABLE 310-13.
SIZE
60°C
(140°F)
75°C
(167°F)
90°C
(194°F)
60°C
(140°F)
75°C
(167°F)
90°C
(194°F)
TYPES
TW=
UF=
TYPES
FEPW=,
RH, RHW=,
THHW=,
THW=,
THWN=,
XHHW=,
USE=, ZW=
TYPES
TBS, SA,
SIS, FEP=
FEPB=, MI,
RHH= RHW-2
THHN=, THHW=,
THW-2, THWN-2,
USE-2, XHH,
XHHW=
XHHW-2, ZW-2
TYPES
TW=
UF=
TYPES
RH=, RHW=,
THHW=,
THW=,
THWN=,
XHHW=,
USE=
TYPES
TBS,
SA, SIS,
THHN=,
THHW=,
THW-2, THWN-2,
RHH==, RHW-2,
USE-2,
XHH, XHHW=,
XHHW-2, ZW-2
AWG
kcmil
COPPER
ALUMINUM OR COPPER-CLAD ALUMINUM
AWG
kcmil
18
16
14*
12*
10*
8
.......
.......
20
25
30
40
.......
.......
20
25
35
50
14
18
25
30
40
55
.......
.......
.......
20
25
30
.......
.......
.......
20
30
40
.......
.......
.......
25
35
45
.......
.......
.......
12*
10*
8*
6
4
3
2
1
55
70
85
95
110
65
85
100
115
130
75
95
110
130
150
40
55
65
75
85
50
65
75
90
100
60
75
85
100
115
6
4
3
2
1
1/0
2/0
3/0
4/0
125
145
165
195
150
175
200
230
170
195
225
260
100
115
130
150
120
135
155
180
135
150
175
205
1/0
2/0
3/0
4/0
250
300
350
400
500
215
240
260
280
320
255
285
310
335
380
290
320
350
380
430
170
190
210
225
260
205
230
250
270
310
230
255
280
305
350
250
300
350
400
500
600
700
750
800
900
355
385
400
410
435
420
460
475
490
520
475
520
535
555
585
285
310
320
330
355
340
375
385
395
425
385
420
435
450
480
600
700
750
800
900
1000
1250
1500
1750
2000
455
495
520
545
560
545
590
625
650
665
615
665
705
735
750
375
405
435
455
470
445
485
520
545
560
500
545
585
615
630
1000
1250
1500
1750
2000
CORRECTION FACTORS
Ambient
Temp °C
21-25
26-30
31-35
36-40
41-45
46-50
51-55
56-60
61-70
71-80
*
For ambient temperatures other than 30°C (86°F), multiply the allowable ampacities
shown above by the appropriate factor shown below.
1.08
1.00
.91
.82
.71
.58
.41
.......
.......
.......
1.05
1.00
.94
.88
.82
.75
.67
.58
.33
.......
1.04
1.00
.96
.91
.87
.82
.76
.71
.58
.41
1.08
1.00
.91
.82
.71
.58
.41
.......
.......
.......
1.05
1.00
.94
.88
.82
.75
.67
.58
.33
.......
1.04
1.00
.96
.91
.87
.82
.76
.71
.58
.41
Ambient
Temp °F
70-77
78-86
87-95
96-104
105-113
114-122
123-131
132-140
141-158
159-176
Unless otherwise specifically permitted in Section 240-3 of this Code, the overcurrent protection for conductor types marked with an
asterisk (*) shall not exceed 15 amperes for No. 14, 20 amperes for No. 12, and 30 amperes for No. 10 copper; or 15 amperes for No. 12
and 25 amperes for No. 10 aluminum and copper-clad aluminum after any correction factors for ambient temperature and number of
conductors have been applied.
®
1. Reprinted with permission from NEC 1999, NFPA 70, the National Electrical Code , Copyright 1998,
National Fire Protection Association, Quincy, MA 02269. This reprinted material is not the complete and
official position of the National Fire Protection Association, on the referenced subject which is
represented only by the standard in its entirety.
28
Installation Drawings
10.0 INSTALLATION DRAWINGS
88-797658-64
Rev. 12
Figure 10 Outline drawing, 500kVA, Single-Module UPS, 6-pulse rectifier, 480V input - 480/277V output
29
Installation Drawings
88-797658-74
Rev. 09
Figure 11 Terminal details, 500kVA, Single-Module UPS, 6-pulse rectifier, 480V input - 480/277V output
30
Installation Drawings
88-797658-95
Rev. 03
Figure 12 Outline drawing, 500kVA, Single-Module UPS, 6-pulse rectifier, 600V input - 600/346V output
31
Installation Drawings
88-797657-93
Rev. 04
Figure 13 Terminal details, 500kVA, Single-Module UPS, 6-pulse rectifier, 600V input - 600/346V output
32
Installation Drawings
88-797657-64
Rev. 07
Figure 14 Outline drawing, 500kVA, Single-Module UPS, 12-pulse rectifier
33
Installation Drawings
88-797657-91
Rev. 08
Figure 15 Terminal details, 500kVA, Single-Module UPS, 12-pulse rectifier
34
Installation Drawings
88-797668-64
Rev. 06
Figure 16 Outline drawing, 625-750kVA, Single-Module UPS, 6-pulse rectifier
35
Installation Drawings
88-797668-91
Rev. 08
Figure 17 Terminal details, 625-750kVA, Single-Module UPS, 6-pulse rectifier
36
Installation Drawings
88-797665-64
Rev. 07
Figure 18 Outline drawing, 625-750kVA, Single-Module UPS, 12-pulse rectifier
37
Installation Drawings
88-797677-64
Rev. 04
Figure 19 Terminal details, 625-750kVA, Single-Module UPS, 12-pulse rectifier
38
Installation Drawings
88-797656-65
Rev. 06
Figure 20 Outline drawing, 500kVA, Single-Module UPS, 12-pulse rectifier with bottom entry wireway
39
Installation Drawings
88-797656-85
Rev. 05
Figure 21 Terminal details, 500kVA, Single-Module UPS, 12-pulse rectifier with bottom entry wireway
40
Installation Drawings
88-797668-65
Rev. 06
Figure 22 Outline drawing, 625-750kVA, Single-Module UPS, 6-pulse rectifier with bottom entry wireway
41
Installation Drawings
88-797668-85
Rev. 07
Figure 23 Terminal details, 625-750kVA, Single-Module UPS, 6-pulse rectifier with bottom entry wireway
42
Installation Drawings
88-797664-67
Rev. 06
Figure 24 Outline drawing, 625-750kVA, Single-Module UPS, 12-pulse rectifier with bottom entry wireway
43
Installation Drawings
88-797664-87
Rev. 07
Figure 25 Terminal details, 625-750kVA, Single-Module UPS, 12-pulse rectifier with bottom entry wireway
44
Installation Drawings
88-797677-85
Rev. 05
Figure 26 Terminal details, 750kVA/675kW, Single-Module UPS, 12-pulse rectifier with bottom entry wireway
45
Installation Drawings
88-797613-16
Rev. 06
Figure 27 Base mounting patterns, 500kVA module, 6-pulse rectifier
46
Installation Drawings
88-797613-22
Rev. 04
Figure 28 Base mounting patterns, 500kVA module, 12-pulse rectifier
47
Installation Drawings
88-797613-28
Rev. 04
Figure 29 Base mounting patterns, 500kVA module, 12-pulse rectifier with bottom entry wireway
48
Installation Drawings
88-797613-20
Rev. 04
Figure 30 Base mounting patterns, 625-750kVA module, 6-pulse rectifier
49
Installation Drawings
88-797613-29
Rev. 04
Figure 31 Base mounting patterns, 625-750kVA module, 6-pulse rectifier with bottom entry wireway
50
Installation Drawings
88-797613-19
Rev. 04
Figure 32 Base mounting patterns, 625-750kVA module, 12-pulse rectifier
51
Installation Drawings
88-797613-27
Rev. 05
Figure 33 Base mounting patterns, 625-750kVA module, 12-pulse rectifier with bottom entry wireway
52
Installation Drawings
88-797612-01
Rev. 04
Figure 34 Shipping split detail, 500kVA, 12-pulse rectifier
53
Installation Drawings
88-797612-08
Rev. 04
Figure 35 Shipping split detail, 500kVA, 12-pulse rectifier with bottom entry wireway
54
Installation Drawings
88-797612-04
Rev. 04
Figure 36 Shipping split detail, 625-750kVA, 6-pulse rectifier
55
Installation Drawings
88-797612-09
Rev. 05
Figure 37 Shipping split detail, 625-750kVA, 6-pulse rectifier with bottom entry wireway
56
Installation Drawings
88-797612-03
Rev. 05
Figure 38 Shipping split detail, 625-750kVA, 12-pulse rectifier
57
Installation Drawings
88-797612-07
Rev. 05
Figure 39 Shipping split detail, 625-750kVA, 12-pulse rectifier with bottom entry wireway
58
Installation Drawings
88-797616-03
Rev. 08
Figure 40 Battery power pack system
59
Installation Drawings
88-797616-01
Rev. 10
Figure 41 Battery power pack, Size A
60
Installation Drawings
88-797607-63
Rev. 04
Figure 42 Line-up detail, 300-500kVA, Single- or Multi-Module System with battery cabinets
61
Installation Drawings
96-797619-59A
Rev. 03
Figure 43 Control connection location diagram, Single-Module System, 300-500kVA
62
Installation Drawings
96-797619-67A
Rev. 03
Figure 44 Control connection location diagram, Single-Module System, 625-750kVA
63
Installation Drawings
96-797619-47A
Rev. 04
Figure 45 Control wiring, external interconnect diagram, Single-Module System, 300-750kVA
64
Installation Drawings
96-797619-49A
Rev. 07
Figure 46 Control wiring, external interconnect diagram, Single-Module System with maintenance bypass
cabinet, 300-750kVA
65
Installation Drawings
96-797619-48
Rev. 05
Figure 47 Control wire list, external interconnections, standard wiring, Single-Module System, 300-750kVA
66
Installation Drawings
96-797619-50
Rev. 05
Figure 48 Control wire list, external interconnections, standard wiring, Single-Module System with
maintenance bypass cabinet, 300-750kVA
67
Installation Drawings
98-797608-04
Rev. 05
Figure 49 Module control wiring, alarm status contacts option
68
Installation Drawings
98-797608-07A
Rev. 02
Figure 50 COM PWA, remote terminal (RS232) option, SiteScan option, internal modem option
69
Installation Drawings
98-797608-09
Rev. 03
Figure 51 Control wiring, customer alarm interface option
70
Installation Drawings
98-797608-11A
Rev. 02
Figure 52 Control wiring, SNMP interface option
71
Installation Drawings
98-797608-06
Rev. 03
Figure 53 Control wiring, remote status panel interface option
72
Installation Drawings
98-797608-10
Rev. 04
Figure 54 Control wiring, battery temperature sensor interface
73
Installation Drawings
98-797608-05
Rev. 04
Figure 55 Control wiring, maintenance bypass interlock option
74
Installation Drawings
98-797608-14
Rev. 03
Figure 56 Control wiring, maintenance bypass cabinet option
75
Installation Drawings
88-797616-09
Rev. 08
Figure 57 Outline drawing, single-breaker module battery disconnect, 300, 450, 600, 800, 1000, 1200A
76
Installation Drawings
88-797616-13
Rev. 05
Figure 58 Outline drawing, single-breaker module battery disconnect, 1400AT/1600AT/2000AT/2500AT
600VDC circuit breaker
77
Installation Drawings
88-797616-07
Rev. 08
Figure 59 Outline drawing, dual-breaker module battery disconnect, 600, 800, 1000, 1200A
78
Installation Drawings
88-791617-01
Rev. 05
Figure 60 Outline drawing, remote status panel, surface mount
79
Installation Drawings
80
APPENDIX A - SITE PLANNING DATA, SERIES 610, 500-750KVA, SINGLE-MODULE SYSTEMS
1.
2.
3.
4.
5.
6.
Nominal rectifier AC input current (considered continuous) is based on full
rated output load. Maximum current includes nominal input current and
maximum battery recharge current (considered noncontinuous). Continuous
and noncontinuous current limits are defined in NEC 100. Maximum input
current is controlled by current limit setting which is adjustable 100 to 125%
of nominal input current—except 750kVA/675kW, for which the maximum is
adjustable 100 to 115% of nominal. Standard factory setting is 115%.
Nominal AC output current (considered continuous) is based on full rated
output load. Maximum current includes nominal output current and
overload current for 10 minutes.
Bypass AC input current (considered continuous) is based on full rated
output load.
Feeder protection (by others in external equipment) for rectifier AC input
and bypass AC input is recommended to be provided by separate overcurrent
protection devices.
UPS output load cables must be run in separate conduit from input cables.
Power cable from module DC bus to battery should be sized for a total
maximum 2.0 volt line drop (power cable drop plus return cable drop as
measured at the module) at maximum discharge current.
7.
Grounding conductors to be sized per NEC 250-95. Neutral conductors to be
sized for full capacity—per NEC 310-16, Note 10—for systems with 4-wire
loads and half capacity for systems with 3-wire loads.
8.
Rectifier AC Input: 3-phase, 3-wire, plus ground
AC Output to Load: 3-phase, 3- or 4-wire, plus ground
Bypass AC Input: 3-phase, 4-wire, plus ground (3-wire in some circumstances)
Module DC Input from Battery: 2-wire (positive and negative), plus ground
9.
All wiring is to be in accordance with National and Local Electrical Codes.
10. Minimum overhead clearance is 2 ft. (0.6m) above the UPS.
11. Top or bottom cable entry through removable access plates. Cut plate to suit
conduit size.
12. Control wiring and power cables must be run in separate conduits. Control
wiring must be stranded tinned conductors.
13. 7% maximum reflected input harmonic current and 0.92 lagging input power
factor at full load with optional input filter.
4% maximum reflected input harmonic current and 0.92 lagging input power
factor at full load with optional 12-pulse rectifier and optional input filter.
Site Planning Data, Series 610, 500-750kVA, Single-Module Systems
81
Notes for Tables 6 - 7
Table 6
Site planning data—600V input
UPS
Rating
AC Output
Voltage
Options
Input
Input
Filter Xformer
Rectifier AC
Input Current
Inverter or Bypass
AC Output Current
Max. Battery
Current
at End of
Discharge (A)
Max. Heat
Dissipation
Full Load
BTU/h (kWH)
Dimensions
Approx. Weight
Unpacked
Floor Loading
Concentrated Loading
WxDxH:
in. (mm)
lb. (kg)
lb./ft. 2 (kg/m 2)
72x39x78
(1829x991x1981)
6175 (2801)
317 (1548)
6375 (2892)
327 (1597)
8775 (3980)
338 (1650)
8975 (4071)
345 (1684)
Max
Nom
Max
Required
Battery
Disconnect
Rating (A)
484
605
481
601
1000
1079
94,900 (27.8)
449
561
481
601
1000
1079
99,600 (29.2)
490
612
481
601
1000
1079
118,700 (34.8)
YES
454
567
481
601
1000
1079
123,570 (36.2)
NO
545
681
481
601
1200
1214
106,750 (31.3)
NO
505
631
481
601
1200
1214
112,050 (32.8)
kW
VAC
500
400
600
NO
NO
500
400
600
YES
NO
500
400
600
NO
YES
500
400
600
YES
500
450
600
NO
500
450
600
YES
500
450
600
NO
YES
551
688
481
601
1200
1214
133,550 (39.1)
500
450
600
YES
YES
510
638
481
601
1200
1214
139,010 (40.7)
625
500
600
NO
NO
602
753
601
752
1400
1349
108,950 (31.9)
625
500
600
YES
NO
559
699
601
752
1400
1349
118,650 (34.7)
625
500
600
NO
YES
609
761
601
752
1400
1349
128,450 (37.6)
625
500
600
YES
YES
564
705
601
752
1400
1349
134,400 (39.4)
750
600
600
NO
NO
723
903
722
902
1600
1619
130,700 (38.3)
750
600
600
YES
NO
671
839
722
902
1600
1619
142,350 (41.7)
750
600
600
NO
YES
730
913
722
902
1600
1619
154,150 (45.1)
750
600
600
YES
YES
677
846
722
902
1600
1619
161,250 (47.2)
750
675
600
NO
YES
822
945
722
902
1600
1822
173,400 (50.8)
750
675
600
YES
YES
762
876
722
902
1600
1822
13
—
6
6,8,9,11,12
See Notes (p. 81):
Nom
1,4,5,7,8,9,11,12
2,3,5,7,8,9,11,12
96x39x78
(2438x991x1981)
72x39x78
(1829x991x1981)
6195 (2810)
318 (1553)
6395 (2901)
328 (1601)
96x39x78
(2438x991x1981)
9095 (4125)
365 (1782)
9295 (4216)
358 (1748)
7900 (3583)
270 (1318)
8120 (3683)
278 (1357)
108x39x78
(2743x991x1981)
120x39x78
(3048x991x1981)
108x39x78
(2743x991x1981)
10580 (4799)
326 (1592)
10800 (4899)
332 (1621)
8500 (3856)
291 (1421)
8720 (3955)
298 (1455)
120x39x78
(3048x991x1981)
11580 (5253)
356 (1738)
11800 (5352)
363 (1772)
120x39x78
(3048x991x1981)
11880 (5389)
366 (1787)
181,400 (53.1)
12100 (5488)
372 (1816)
—
—
—
—
Site Planning Data, Series 610, 500-750kVA, Single-Module Systems
82
kVA
Table 7
Site planning data—480V input
UPS
Rating
AC Output
Voltage
Options
Input
Input
Filter Xformer
Rectifier AC
Input Current
Inverter or Bypass
AC Output Current
Max. Battery
Current
at End of
Discharge (A)
Max. Heat
Dissipation
Full Load
BTU/h (kWH)
Dimensions
Approx. Weight
Unpacked
Floor Loading
Concentrated Loading
WxDxH:
in. (mm)
lb. (kg)
lb./ft. 2 (kg/m 2)
72x39x78
(1829x991x1981)
5775 (2619)
296 (1445)
5975 (2710)
306 (1494)
8775 (3980)
338 (1650)
8975 (4071)
345 (1684)
Nom
Max
Nom
Max
Required
Battery
Disconnect
Rating (A)
NO
602
753
601
752
1000
1079
87,150 (25.5)
NO
558
698
601
752
1000
1079
91,790 (26.9)
NO
YES
612
765
601
752
1000
1079
110,700 (32.4)
kVA
kW
VAC
500
400
480
NO
500
400
480
YES
500
400
480
400
480
YES
YES
567
709
601
752
1000
1079
115,550 (33.8)
500
450
480
NO
NO
677
847
601
752
1200
1214
98,050 (28.7)
500
450
480
YES
NO
628
785
601
752
1200
1214
103,250 (30.2)
500
450
480
NO
YES
688
861
601
752
1200
1214
124,550 (36.5)
500
450
480
YES
YES
638
798
601
752
1200
1214
129,950 (38.1)
625
500
480
NO
NO
749
936
752
940
1400
1349
99,300 (29.1)
625
500
480
YES
NO
694
867
752
940
1400
1349
105,050 (30.8)
625
500
480
NO
YES
757
946
752
940
1400
1349
118,650 (34.7)
625
500
480
YES
YES
701
877
752
940
1400
1349
124,500 (36.5)
750
600
480
NO
NO
898
1123
902
1128
1600
1619
119,200 (34.9)
750
600
480
YES
NO
833
1041
902
1128
1600
1619
126,100 (36.9)
750
600
480
NO
YES
908
1135
902
1128
1600
1619
142,350 (41.7)
750
600
480
YES
YES
842
1052
902
1128
1600
1619
149,400 (43.7)
750
675
480
NO
YES
1022
1175
902
1128
1600
1822
160,150 (46.9)
750
675
480
YES
YES
947
1089
902
1128
1600
1822
13
—
6
6,8,9,11,12
See Notes (p. 81):
1,4,5,7,8,9,11,12
2,3,5,7,8,9,11,12
72x39x78
(1829x991x1981)
5795 (2629)
297 (1450)
5995 (2719)
307 (1499)
96x39x78
(2438x991x1981)
9095 (4125)
350 (1709)
9295 (4216)
358 (1748)
7500 (3402)
256 (1250)
7720 (3502)
264 (1289)
108x39x78
(2743x991x1981)
120x39x78
(3048x991x1981)
108x39x78
(2743x991x1981)
10580 (4799)
326 (1592)
10800 (4899)
332 (1621)
8100 (3674)
277 (1352)
8320 (3774)
284 (1387)
120x39x78
(3048x991x1981)
11580 (5253)
356 (1738)
11800 (5352)
363 (1772)
120x39x78
(3048x991x1981)
11880 (5389)
366 (1787)
168,100 (49.2)
12100 (5488)
372 (1816)
—
—
—
—
Site Planning Data, Series 610, 500-750kVA, Single-Module Systems
83
500
96x39x78
(2438x991x1981)
Site Planning Data, Series 610, 500-750kVA, Single-Module Systems
84
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800-543-2378
powertech@emersonnetworkpower.com
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800-543-2778
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