Vertiv Liebert Series 610 1000kVA Installation Manual

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Vertiv Liebert Series 610 1000kVA Installation Manual | Manualzz

DISCONTINUED

PRODUCT

Liebert Series 610

UPS

Installation Manual - 1000kVA, 60Hz, Three Phase Single-Module

AC Power

For Business-Critical Continuity™

B

ATTERY

C

ABINET

P

RECAUTIONS

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).

C

ONTACTING

L

IEBERT FOR

S

UPPORT

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:___________________________________________________________

DISCONTINUED

PRODUCT

TABLE OF CONTENTS

B

ATTERY

C

ABINET

P

RECAUTIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I

NSIDE

F

RONT

C

OVER

C

ONTACTING

L

IEBERT FOR

S

UPPORT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I

NSIDE

F

RONT

C

OVER

I

MPORTANT

S

AFETY

I

NSTRUCTIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.0

I

NSTALLATION

C

ONSIDERATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.0

U

NLOADING AND

H

ANDLING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3.0

I

NSPECTIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3.1

External Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.2

Internal Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4.0

E

QUIPMENT

L

OCATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

5.0

B

ATTERY

I

NSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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

C

ONFIGURING

Y

OUR

N

EUTRAL AND

G

ROUND

C

ONNECTIONS

. . . . . . . . . . . . . . . . . . . . . . .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

W

IRING

C

ONSIDERATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

7.1

Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

7.2

Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

7.3

Battery Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

8.0

W

IRING

C

ONNECTIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

8.1

Specific Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

9.0

W

IRING

I

NSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

10.0 I

NSTALLATION

D

RAWINGS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

A

PPENDIX

A - S

ITE

P

LANNING

D

ATA

, 1000

K

VA, S

INGLE

-M

ODULE

S

YSTEMS

. . . . . . . . . . . . . . . .43

i

DISCONTINUED

PRODUCT

FIGURES

Figure 1 Preferred grounding configuration, wye-connected service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Figure 2 Alternate grounding configuration, wye-connected service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Figure 3 Preferred grounding configuration with isolated bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Figure 4 Alternate grounding configuration, non-isolated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Figure 5 Grounding configuration, corner-grounded delta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Figure 6 Grounding configuration, impedance-grounded wye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Figure 7 Preferred battery cabinet grounding configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Figure 8 Power single-line diagrams*. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Figure 9 Outline drawing, 1000kVA, front-access Single-Module UPS, 480V and 600V . . . . . . . . . . . . . . 29

Figure 10 Bussing details, 1000kVA, front-access Single-Module UPS, 480V and 600V . . . . . . . . . . . . . . . 30

Figure 11 Base mounting details, 1000kVA, Single- and Multi-Module rectifier and inverter sections . . . 31

Figure 12 Base mounting details, 1000kVA, Single- and Multi-Module control section . . . . . . . . . . . . . . . . 32

Figure 13 Shipping split detail, 1000kVA, Single- and Multi-Module UPS . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Figure 14 Control connection location diagram, Single-Module system, 1000kVA . . . . . . . . . . . . . . . . . . . . 34

Figure 15 Wiring diagrams, Single-Module System, interconnect diagram. . . . . . . . . . . . . . . . . . . . . . . . . . 35

Figure 16 Control wire list, Single-Module System, external interconnection, Part 1 . . . . . . . . . . . . . . . . . 36

Figure 17 Control wire list, Single-Module System, external interconnection, Part 2 . . . . . . . . . . . . . . . . . 37

Figure 18 Control wire list, Single-Module System, external interconnection, optional internal modem . . 38

Figure 19 Control wire list, Single- and Multi-Module System, external interconnection, optional battery temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Figure 20 Control wire list, Single-Module System, external interconnection, optional customer alarm interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Figure 21 Outline drawing, single-breaker module battery disconnect,

1400AT/1600AT/2000AT/2500AT, 600VDC circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Figure 22 Outline drawing, remote status panel, surface mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Table 1

Table 2

Table 3

Table 4

Table 5

Table 6

Table 7

TABLES

Abbreviations for circuit breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Power wiring terminals - factory supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Field-supplied lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Table 310-16, National Electrical Code (Reprint) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Site planning data—480V input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Site planning data—600V input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

ii

DISCONTINUED

PRODUCT

I

MPORTANT

S

AFETY

I

NSTRUCTIONS

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 16,700 to 17,550 lbs. (7575 to 7961kg), 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

DISCONTINUED

PRODUCT

!

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

Materials sold hereunder cannot be used in the patient vicinity (i.e., cannot be used where

UL 60601-1, cUL 60601-1 or IEC 60601-1 is required). Medical Applications such as invasive procedures and electrical life support equipment are subject to additional terms and conditions.

2

DISCONTINUED

PRODUCT

Installation Considerations

1.0 I

NSTALLATION

C

ONSIDERATIONS

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 9 through

22 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 16,700 to 17,550 lbs. (7575 to 7961kg). 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

DISCONTINUED

PRODUCT

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

DISCONTINUED

PRODUCT

Unloading and Handling

2.0 U

NLOADING AND

H

ANDLING

UPS modules are shipped in split cabinets to allow ease of handling. Because the weight distribution in the cabinets is uneven, use extreme care during handling and transport. Your installation may also include battery cabinets and a System Control Cabinet.

!

WARNING

Exercise extreme care when handling UPS cabinets to avoid equipment damage or injury to personnel. The UPS module weight ranges from 16,700 to 17,550 lbs. (7575 to 7961kg).

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

DISCONTINUED

PRODUCT

Inspections

3.0 I

NSPECTIONS

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. Verify that all items have been received.

2. If spare parts were ordered, verify arrival.

3. Open doors and remove cabinet panels to check for shipping damage to internal components.

4. Check for loose connections or unsecured components in the cabinet(s).

5. 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

DISCONTINUED

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Equipment Location

4.0 E

QUIPMENT

L

OCATION

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 Outline Drawing (

Figure 9) 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

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Battery Installation

5.0 B

ATTERY

I

NSTALLATION

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

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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.

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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 the Battery Cabinet submittal drawings if a battery cabinet is to be used. 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 your submittal drawings for instructions on wiring cabinets in parallel.

NOTE

The 1000kVA 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.

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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.

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Configuring Your Neutral and Ground Connections

6.0 C

ONFIGURING

Y

OUR

N

EUTRAL AND

G

ROUND

C

ONNECTIONS

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.

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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, Wye-

Connected Service or 6.3 - Preferred Grounding Configuration With Isolated Bypass to determine a suitable configuration.

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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.

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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.

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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.

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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

GROUNDING

ELECTRODE

PER NEC 250-24

Figure 6 Grounding configuration, impedance-grounded wye

LOCAL

GROUNDING

ELECTRODE

PER NEC 250-30

GROUNDING

ELECTRODE

PER NEC 250-24

These configurations have the same restrictions as explained in

6.2 - Alternate Grounding Config-

uration, 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.

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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

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Wiring Considerations

7.0 W

IRING

C

ONSIDERATIONS

!

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).

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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 Bussing Details drawings

(

Figures 9, 10, 21 and 22) 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 9, 21 and 22) 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.

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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

BIB

MBB

MIB

Critical load

AC output

RIB

Main input switchgear

MBFB

UPS module

Static switch disconnect

Static bypass switch

Bypass CB

Control power

Input

CB

Rectifier/ charger

Inverter

Output CB

Battery

MBD

Two-breaker maintenance bypass switchboard

Critical load

AC output

BIB

RIB

Main input switchgear

MBB

MIB

UPS module

Static switch disconnect

Static bypass switch

Bypass CB

Control power

Input

CB

Rectifier/ charger

Inverter

Output CB

MBD

Battery

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Wiring Considerations

Figure 8 Power single-line diagrams* (continued)

* 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.

Four-breaker maintenance bypass switchboard

FB

RIB BIB

MBB

MIB

Critical load

AC output

Main input switchgear

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

UPS module

Static switch disconnect

Static bypass switch

Bypass CB

Control power

Rectifier/ charger

Inverter

Output CB

MBD

Battery

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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.

Figure 14 shows 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 Battery Cabinet submittal drawings.

!

!

!

WARNING

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.

CAUTION

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.

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.

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.

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Wiring Connections

8.0 W

IRING

C

ONNECTIONS

!

!

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.

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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 switchboard, 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.

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Wiring Inspection

9.0 W

IRING

I

NSPECTION

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

1000/1100kVA

Connection Type

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 1000/1100kVA modules are designed for top or bottom entry and are located adjacent to the input circuit breaker. Rectifier input wiring is top or bottom entry, directly to busbars on top of the input circuit breaker. UPS module output wiring (and bypass input for Single-Module Systems) is top or bottom entry, directly to busbars above the circuit breakers (left side of unit). Fieldsupplied lugs are required for all input and output terminations.

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

Bolt Shaft Size

1/4

5/16

3/8

1/2

Grade 2 Standard

Lb-in N-m

53

107

192

428

6.0

12

22

22

Electrical Connections with Belleville Washers

Lb-in N-m

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

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Table 4 Field-supplied lugs

3

4

1

2

One-Hole Lugs

T & B

1

Lug Style Wire Size Bolt Size (in.) Tongue Width (in.) T & B

1

P/N

Stak-On

#1 AWG

1/0 AWG

2/0 AWG

3/0 AWG

3/8

3/8

3/8

3/8

7

8

5

6

Color-Keyed

Aluminum/

Copper

4/0 AWG

#1 AWG

1/0 AWG

2/0 AWG

3/8

3/8

3/8

3/8

9

10

11

12

3/0 AWG

#1 AWG

1/0 AWG

2/0 AWG

3/8

5/16

3/8

3/8

13

14

Color-Keyed

Copper Cable

Long Barrel

3/0 AWG

4/0 AWG

1/2

1/2

15 250 MCM 1/2

16

17

Narrow-Tongue

Copper Cable

350 MCM

500 MCM

1/2

1/2

1. Manufacturer: Thomas & Betts (T & B), 1-800-862-8324

0.76

0.88

1.00

1.10

1.20

0.75

0.88

0.97

1.06

0.67

0.75

0.81

0.94

1.03

1.09

1.09

1.20

H973

J973

K973

L973

M973

60124

60130

60136

60142

54947BE

54909BE

54910BE

54965BE

54970BE

54913BE

55165

55171

Wiring Inspection

Liebert P/N

12-714255-46

12-714255-56

12-714255-66

12-714255-76

12-714255-86

27

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Wiring Inspection

1/0

2/0

3/0

4/0

3

2

6

4

1

AWG kcmil

18

16

14*

12*

10*

8

250

300

350

400

500

600

700

750

800

900

1000

1250

1500

1750

2000

55

70

85

95

110

125

145

165

195

.......

.......

20

25

30

40

215

240

260

280

320

355

385

400

410

435

455

495

520

545

560

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 SIZE

60°C

(140°F)

TYPES

TW=

UF=

65

85

100

115

130

150

175

200

230

.......

.......

20

25

35

50

255

285

310

335

380

420

460

475

490

520

545

590

625

650

665

TEMPERATURE RATING OF CONDUCTOR. SEE TABLE 310-13.

75

(167

°

°

C

F)

TYPES

FEPW=,

RH, RHW=,

THHW=,

THW=,

THWN=,

XHHW=,

USE=, ZW=

COPPER

90

(194

°

°

C

F)

TYPES

TBS, SA,

SIS, FEP=

FEPB=, MI,

RHH= RHW-2

THHN=, THHW=,

THW-2, THWN-2,

USE-2, XHH,

XHHW=

XHHW-2, ZW-2

60

(140

°

C

)

75

(167

°

°

C

F)

90

(194

°

°

C

F)

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

ALUMINUM OR COPPER-CLAD ALUMINUM

75

95

110

130

150

170

195

225

260

14

18

25

30

40

55

.......

.......

.......

20

25

30

40

55

65

75

85

100

115

130

150

290

320

350

380

430

475

520

535

555

585

170

190

210

225

260

285

310

320

330

355

615

665

705

735

750

375

405

435

455

470

CORRECTION FACTORS

50

65

75

90

100

120

135

155

180

.......

.......

.......

20

30

40

205

230

250

270

310

340

375

385

395

425

445

485

520

545

560

60

75

85

100

115

135

150

175

205

.......

.......

.......

25

35

45

230

255

280

305

350

385

420

435

450

480

500

545

585

615

630

1/0

2/0

3/0

4/0

3

2

6

4

1

AWG kcmil

.......

.......

.......

12*

10*

8*

250

300

350

400

500

600

700

750

800

900

1000

1250

1500

1750

2000

21-25

26-30

31-35

36-40

41-45

46-50

51-55

56-60

61-70

71-80

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

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

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10.0 I

NSTALLATION

D

RAWINGS

Figure 9 Outline drawing, 1000kVA, front-access Single-Module UPS, 480V and 600V

Installation Drawings

29

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PRODUCT

Figure 10 Bussing details, 1000kVA, front-access Single-Module UPS, 480V and 600V

Installation Drawings

30

DISCONTINUED

PRODUCT

Installation Drawings

Figure 11 Base mounting details, 1000kVA, Single- and Multi-Module rectifier and inverter sections

31

DISCONTINUED

PRODUCT

Figure 12 Base mounting details, 1000kVA, Single- and Multi-Module control section

Installation Drawings

32

DISCONTINUED

PRODUCT

Figure 13 Shipping split detail, 1000kVA, Single- and Multi-Module UPS

Installation Drawings

33

DISCONTINUED

PRODUCT

Figure 14 Control connection location diagram, Single-Module system, 1000kVA

Installation Drawings

34

DISCONTINUED

PRODUCT

Figure 15 Wiring diagrams, Single-Module System, interconnect diagram

Installation Drawings

35

DISCONTINUED

PRODUCT

Figure 16 Control wire list, Single-Module System, external interconnection, Part 1

Installation Drawings

36

DISCONTINUED

PRODUCT

Figure 17 Control wire list, Single-Module System, external interconnection, Part 2

Installation Drawings

37

DISCONTINUED

PRODUCT

Installation Drawings

Figure 18 Control wire list, Single-Module System, external interconnection, optional internal modem

38

DISCONTINUED

PRODUCT

Installation Drawings

Figure 19 Control wire list, Single- and Multi-Module System, external interconnection, optional battery temperature sensor

39

DISCONTINUED

PRODUCT

Installation Drawings

Figure 20 Control wire list, Single-Module System, external interconnection, optional customer alarm interface

40

DISCONTINUED

PRODUCT

Installation Drawings

Figure 21 Outline drawing, single-breaker module battery disconnect, 1400AT/1600AT/2000AT/2500AT,

600VDC circuit breaker

41

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PRODUCT

Figure 22 Outline drawing, remote status panel, surface mount

Installation Drawings

42

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PRODUCT

AC output to

Site Planning Data, 1000kVA, Single-Module Systems

43

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PRODUCT

Approx. Weig Approx. Weig

Site Planning Data, 1000kVA, Single-Module Systems

Current at Current at

44

DISCONTINUED

PRODUCT

NOTES

Site Planning Data, 1000kVA, Single-Module Systems

45

DISCONTINUED

PRODUCT

Site Planning Data, 1000kVA, Single-Module Systems

46

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DISCONTINUED

PRODUCT

Ensuring The High Availability

Of Mission-Critical Data And Applications.

Emerson Network Power, the global leader in enabling business-critical continuity, ensures network resiliency and adaptability through a family of technologies—including Liebert power and cooling technologies—that protect and support business-critical systems.

Liebert solutions employ an adaptive architecture that responds to changes in criticality, density and capacity. Enterprises benefit from greater IT system availability, operational flexibility and reduced capital equipment and operating costs.

While every precaution has been taken to ensure the accuracy and completeness of this literature, Liebert Corporation assumes no responsibility and disclaims all liability for damages resulting from use of this information or for any errors or omissions.

© 2007 Liebert Corporation

All rights reserved throughout the world. Specifications subject to change without notice.

® Liebert is a registered trademark of Liebert Corporation.

All names referred to are trademarks or registered trademarks of their respective owners.

SL-25155_REV03_07-09

Emerson Network Power.

The global leader in enabling Business-Critical Continuity.

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Technical Support / Service

Web Site

www.liebert.com

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[email protected]

800-222-5877

Outside North America: +800 1155 4499

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Outside North America: +800 1155 4499

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800-543-2778

Outside the United States: 614-888-0246

Locations

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