Schneider Electric Galaxy VL User Guide

Galaxy VL
Maintenance Bypass Cabinet for UL
Installation
GVLMBCA200K500G
Latest updates are available on the Schneider Electric website
11/2022
www.se.com
Legal Information
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subsidiaries referred to in this guide are the property of Schneider Electric SE or its
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This guide and its content are protected under applicable copyright laws and
furnished for informational use only. No part of this guide may be reproduced or
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Schneider Electric does not grant any right or license for commercial use of the guide
or its content, except for a non-exclusive and personal license to consult it on an "as
is" basis. Schneider Electric products and equipment should be installed, operated,
serviced, and maintained only by qualified personnel.
As standards, specifications, and designs change from time to time, information
contained in this guide may be subject to change without notice.
To the extent permitted by applicable law, no responsibility or liability is assumed by
Schneider Electric and its subsidiaries for any errors or omissions in the informational
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information contained herein.
Maintenance Bypass Cabinet for UL
Table of Contents
Important Safety Instructions — SAVE THESE
INSTRUCTIONS .........................................................................................5
Safety Precautions .....................................................................................6
Additional Safety Precautions After Installation........................................7
Electrical Safety .........................................................................................8
Battery Safety ............................................................................................9
Specifications ............................................................................................ 11
Maximum Short Circuit Rating ................................................................... 11
Trip Settings............................................................................................. 11
Recommended Upstream Protection.......................................................... 11
Recommended Cable Sizes ...................................................................... 11
Recommended Bolt and Lug Sizes ............................................................12
Torque Specifications................................................................................12
Maintenance Bypass Cabinet Weights and Dimensions...............................13
Clearance ................................................................................................13
Environment.............................................................................................13
System Overview .....................................................................................14
Installation Procedure ..............................................................................15
Install the Seismic Anchoring (Option) ..................................................16
Prepare for Installation .............................................................................18
Connect the Power Cables ......................................................................24
Restrain the Cables ..................................................................................28
Interconnect the UPS with the Maintenance Bypass Cabinet ............30
Prepare the UPS for Internal Busbar Connection ................................33
Install Busbars Between the UPS and the Maintenance Bypass
Cabinet in Single Mains System .............................................................36
Install Busbars Between the UPS and the Maintenance Bypass
Cabinet in Dual Mains System ................................................................38
Install Busbars for Load Bank Breaker (Option) ...................................41
Prepare for Signal Cables in Top Cable Entry Systems ......................42
Prepare for Signal Cables in Bottom Cable Entry Systems................44
Connect the Signal Cables Between the Maintenance Bypass
Cabinet and the UPS ................................................................................47
Add Translated Safety Labels to Your Product .....................................50
Final Installation ........................................................................................51
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Important Safety Instructions — SAVE THESE
INSTRUCTIONS
Maintenance Bypass Cabinet for UL
Important Safety Instructions — SAVE THESE
INSTRUCTIONS
Read these instructions carefully and look at the equipment to become familiar
with it before trying to install, operate, service or maintain it. The following safety
messages may appear throughout this manual or on the equipment to warn of
potential hazards or to call attention to information that clarifies or simplifies a
procedure.
The addition of this symbol to a “Danger” or “Warning” safety
message indicates that an electrical hazard exists which will result in
personal injury if the instructions are not followed.
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages with this symbol
to avoid possible injury or death.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
Failure to follow these instructions will result in death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
Failure to follow these instructions can result in injury or equipment
damage.
NOTICE
NOTICE is used to address practices not related to physical injury. The safety
alert symbol shall not be used with this type of safety message.
Failure to follow these instructions can result in equipment damage.
Please Note
Electrical equipment should only be installed, operated, serviced, and maintained
by qualified personnel. No responsibility is assumed by Schneider Electric for any
consequences arising out of the use of this material.
A qualified person is one who has skills and knowledge related to the construction,
installation, and operation of electrical equipment and has received safety training
to recognize and avoid the hazards involved.
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Important Safety Instructions — SAVE THESE
INSTRUCTIONS
Maintenance Bypass Cabinet for UL
Safety Precautions
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Read all instructions in the installation manual before installing or working on
this product.
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Do not install the product until all construction work has been completed and the
installation room has been cleaned.
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
The product must be installed according to the specifications and requirements
as defined by Schneider Electric. It concerns in particular the external and
internal protections (upstream breakers, battery breakers, cabling, etc.) and
environmental requirements. No responsibility is assumed by Schneider Electric
if these requirements are not respected.
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
The UPS system must be installed according to local and national regulations.
Install the UPS according to:
•
IEC 60364 (including 60364–4–41- protection against electric shock, 60364–
4–42 - protection against thermal effect, and 60364–4–43 - protection
against overcurrent), or
•
NEC NFPA 70, or
•
Canadian Electrical Code (C22.1, Part 1)
depending on which one of the standards apply in your local area.
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
•
Install the product in a temperature controlled indoor environment free of
conductive contaminants and humidity.
•
Install the product on a non-flammable, level and solid surface (e.g.
concrete) that can support the weight of the system.
Failure to follow these instructions will result in death or serious injury.
6
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Important Safety Instructions — SAVE THESE
INSTRUCTIONS
Maintenance Bypass Cabinet for UL
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
The product is not designed for and must therefore not be installed in the
following unusual operating environments:
•
Damaging fumes
•
Explosive mixtures of dust or gases, corrosive gases, or conductive or
radiant heat from other sources
•
Moisture, abrasive dust, steam or in an excessively damp environment
•
Fungus, insects, vermin
•
Salt-laden air or contaminated cooling refrigerant
•
Pollution degree higher than 2 according to IEC 60664-1
•
Exposure to abnormal vibrations, shocks, and tilting
•
Exposure to direct sunlight, heat sources, or strong electromagnetic fields
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Do not drill or cut holes for cables or conduits with the gland plates installed and
do not drill or cut holes in close proximity to the UPS.
Failure to follow these instructions will result in death or serious injury.
WARNING
HAZARD OF ARC FLASH
Do not make mechanical changes to the product (including removal of cabinet
parts or drilling/cutting of holes) that are not described in the installation manual.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
NOTICE
RISK OF OVERHEATING
Respect the space requirements around the product and do not cover the
ventilation openings when the product is in operation.
Failure to follow these instructions can result in equipment damage.
Additional Safety Precautions After Installation
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Do not install the UPS system until all construction work has been completed
and the installation room has been cleaned. If additional construction work is
needed in the installation room after this product has been installed, turn off the
product and cover the product with the protective packaging bag the product
was delivered in.
Failure to follow these instructions will result in death or serious injury.
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Important Safety Instructions — SAVE THESE
INSTRUCTIONS
Maintenance Bypass Cabinet for UL
Electrical Safety
This manual contains important safety instructions that should be followed during
the installation and maintenance of the UPS system.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
•
Electrical equipment must be installed, operated, serviced, and maintained
only by qualified personnel.
•
Apply appropriate personal protective equipment (PPE) and follow safe
electrical work practices.
•
Disconnection devices for AC and DC must be provided by others, be readily
accessible, and the function of the disconnect device marked for its function.
•
Turn off all power supplying the UPS system before working on or inside the
equipment.
•
Before working on the UPS system, check for hazardous voltage between all
terminals including the protective earth.
•
The UPS contains an internal energy source. Hazardous voltage can be
present even when disconnected from the mains supply. Before installing or
servicing the UPS system, ensure that the units are OFF and that mains and
batteries are disconnected. Wait five minutes before opening the UPS to
allow the capacitors to discharge.
•
The UPS must be properly earthed/grounded and due to a high leakage
current, the earthing/grounding conductor must be connected first.
Failure to follow these instructions will result in death or serious injury.
The label below must be added if:
1. The UPS input is connected through external isolators that, when opened,
isolate the neutral, OR
2. The UPS input is connected via an IT power system.
The label must be placed adjacent to all upstream power disconnection devices
that isolate the neutral.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Risk of voltage backfeed. Before working on this circuit: Isolate the UPS and
check for hazardous voltage between all terminals including the protective
earth.
Failure to follow these instructions will result in death or serious injury.
8
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Important Safety Instructions — SAVE THESE
INSTRUCTIONS
Maintenance Bypass Cabinet for UL
Battery Safety
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
•
Battery circuit breakers must be installed according to the specifications and
requirements as defined by Schneider Electric.
•
Servicing of batteries must only be performed or supervised by qualified
personnel knowledgeable of batteries and the required precautions. Keep
unqualified personnel away from batteries.
•
Disconnect charging source prior to connecting or disconnecting battery
terminals.
•
Do not dispose of batteries in a fire as they can explode.
•
Do not open, alter, or mutilate batteries. Released electrolyte is harmful to
the skin and eyes. It may be toxic.
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Batteries can present a risk of electric shock and high short-circuit current. The
following precautions must be observed when working on batteries
•
Remove watches, rings, or other metal objects.
•
Use tools with insulated handles.
•
Wear protective glasses, gloves and boots.
•
Do not lay tools or metal parts on top of batteries.
•
Disconnect the charging source prior to connecting or disconnecting battery
terminals.
•
Determine if the battery is inadvertently grounded. If inadvertently grounded,
remove source from ground. Contact with any part of a grounded battery can
result in electric shock. The likelihood of such shock can be reduced if such
grounds are removed during installation and maintenance (applicable to
equipment and remote battery supplies not having a grounded supply
circuit).
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
When replacing batteries, always replace with the same type and number of
batteries or battery packs.
Failure to follow these instructions will result in death or serious injury.
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Important Safety Instructions — SAVE THESE
INSTRUCTIONS
Maintenance Bypass Cabinet for UL
CAUTION
RISK OF EQUIPMENT DAMAGE
•
Mount the batteries in the UPS system, but do not connect the batteries until
the UPS system is ready to be powered up. The time duration from battery
connection until the UPS system is powered up must not exceed 72 hours or
3 days.
•
Batteries must not be stored more than six months due to the requirement of
recharging. If the UPS system remains de-energized for a long period, we
recommend that you energize the UPS system for a period of 24 hours at
least once every month. This charges the batteries, thus avoiding
irreversible damage.
Failure to follow these instructions can result in injury or equipment
damage.
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Specifications
Maintenance Bypass Cabinet for UL
Specifications
Maximum Short Circuit Rating
The maximum short circuit rating for the maintenance bypass cabinet is 65 kA
RMS symmetrical Icc.
CAUTION
HAZARD OF CABLE MOVEMENT IN SHORT CIRCUIT CONDITIONS
In systems over 35 kAIC it is mandatory to restrain the power cables:
•
Use 10 mm nylon rope or rope with a minimum tensile strength of 1000 kg
(2204.62 lbs).
Failure to follow these instructions can result in injury or equipment
damage.
Trip Settings
NOTE: The power cables for 200-300 kW must be sized for 350 kW for SSIB/
UOB because the minimum Ir setting for PJF36120CU33A is 0.4. This is only
excepted if the power cables for SSIB/UOB are projected upstream.
UPS rating
Breaker type
UIB
SSIB/MBB/UOB
Ir
tr
Isd
tsd
Ii
Ir
tr
Isd
tsd
Ii
200 kW
PJF36120CU33A
0.4
1
1.5
Off
6
0.4
0.5
1.5
Off
6
250 kW
PJF36120CU33A
0.4
1
1.5
Off
6
0.4
0.5
1.5
Off
6
300 kW
PJF36120CU33A
0.4
1
1.5
Off
6
0.4
0.5
1.5
Off
6
350 kW
PJF36120CU33A
0.5
1
1.5
Off
6
0.4
0.5
1.5
Off
6
400 kW
PJF36120CU33A
0.5
1
1.5
Off
6
0.4
0.5
1.5
Off
6
450 kW
PJF36120CU33A
0.6
1
1.5
Off
6
0.5
0.5
1.5
Off
6
500 kW
PJF36120CU33A
0.7
1
1.5
Off
6
0.5
0.5
1.5
Off
6
Recommended Upstream Protection
Refer to the UPS installation manual for recommended upstream protection.
Recommended Cable Sizes
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
All wiring must comply with all applicable national and/or electrical codes. The
maximum allowable cable size is 500 kcmil.
Failure to follow these instructions will result in death or serious injury.
Refer to the UPS installation manual for recommended cable sizes.
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Maintenance Bypass Cabinet for UL
Specifications
Recommended Bolt and Lug Sizes
NOTICE
RISK OF EQUIPMENT DAMAGE
Use only UL approved compression cable lugs.
Failure to follow these instructions can result in equipment damage.
Copper
Cable size
Bolt size
Cable lug type (one
hole)
Cable lug type (two
hole NEMA)
Crimping tool
Die
1/0 AWG
M10x35mm
LCB1/0-12-X
LCC1/0-12-X
CT-930
CD-920-1/0 Pink P42
2/0 AWG
M10x35mm
LCB2/0-12-X
LCC2/0-12-X
CT-930
CD-920-2/0 Black
P45
3/0 AWG
M10x35mm
LCB3/0-12-X
LCC3/0-12-X
CT-930
CD-920-3/0 Orange
P50
4/0 AWG
M10x35mm
LCB4/0-12-X
LCC4/0-12-X
CT-930
CD-920-4/0 Purple
P54
250 kcmil
M10x35mm
LCB250-12-X
LCC250-12-X
CT-930
CD-920-250 Yellow
P62
300 kcmil
M10x35mm
LCB300-12-X
LCC300-12-X
CT-930
CD-920-300 Red P66
350 kcmil
M10x35mm
LCB350-12-X
LCC350-12-X
CT-930
CD-920-350 Red P71
400 kcmil
M10x35mm
LCB400-12-X
LCC400-12-6
CT-930
CD-920-400 Blue P76
450 kcmil
M10x35mm
—
LCC450-12-6
CT-930
—
500 kcmil
M10x35mm
LCB500-12-X
LCC500-12-6
CT-930
CD-920-500 Blue P87
Cable size
Bolt size
Cable lug type (one
hole)
Cable lug type (two
hole NEMA)
Crimping tool
Die
1/0 AWG
M10x35mm
LAA1/0-12-5
LAB1/0-12-X
CT-930
CD-920-1/0 Pink P42
2/0 AWG
M10x35mm
LAA2/0-12-5
LAB2/0-12-5
CT-930
CD-920-2/0 Black
P45
3/0 AWG
M10x35mm
LAA3/0-12-5
LAB3/0-12-5
CT-930
CD-920-3/0 Orange
P50
4/0 AWG
M10x35mm
LAA4/0-12-5
LAB4/0-12-5R
CT-930
CD-920-4/0 Purple
P54
250 kcmil
M10x35mm
LAA250-12-5
LAB250-12-5
CT-930
CD-920-250 Yellow
P62
300 kcmil
M10x35mm
LAA300-12-2
LAB300-12-2
CT-930
CD-920-300 Red P66
350 kcmil
M10x35mm
LAA350-12-2
LAB350-12-2R
CT-930
CD-920-350 Red P71
400 kcmil
M10x35mm
—
LAB400-12-2
CT-930
CD-920-400 Blue P76
500 kcmil
M10x35mm
LAA500-12-2
LAB500-12-2R
CT-930
CD-920-500 Blue P87
Aluminum
Torque Specifications
Bolt size
Torque
M6
5 Nm (3.69 lb-ft / 44.3 lb-in)
M8
17.5 Nm (12.91 lb-ft / 154.9 lb-in)
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Specifications
Maintenance Bypass Cabinet for UL
Bolt size
Torque
M10
30 Nm (22 lb-ft / 194.7 lb-in)
M12
50 Nm (36.87 lb-ft / 442.5 lb-in)
Maintenance Bypass Cabinet Weights and Dimensions
Commercial reference
Weight kg (lbs)
Height mm (in)
Width mm (in)
Depth mm (in)
GVLMBCA200K500G
158 (348)
1970 (77.55)
500 (19.68)
847 (33.34)
Clearance
NOTE: Clearance dimensions are published for airflow and service access
only. Consult with the local safety codes and standards for additional
requirements in your local area.
Front View of the Maintenance Bypass Cabinet and the UPS
Environment
Operating
Storage
Temperature
0 °C to 40 °C (32 °F to 104 °F )
-25 °C to 55 °C (-13 °F to 131 °F)
Relative humidity
0-95% non-condensing
0-95% non-condensing
Protection class
IP20
Color
RAL 9003, gloss level 85%
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Maintenance Bypass Cabinet for UL
Specifications
System Overview
UIB
Unit input breaker
SSIB
Static switch input breaker
MBB
Maintenance bypass breaker
UOB
Unit output breaker
Single Mains UPS System
Dual Mains UPS System
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Installation Procedure
Maintenance Bypass Cabinet for UL
Installation Procedure
1. Install the Seismic Anchoring (Option), page 16.
2. Prepare for Installation, page 18.
3. Connect the Power Cables, page 24.
4. Interconnect the UPS with the Maintenance Bypass Cabinet, page 30.
5. Prepare the UPS for Internal Busbar Connection, page 33.
6. Connect the busbars between the UPS and the maintenance bypass cabinet.
Perform one of the following procedures:
– Install Busbars Between the UPS and the Maintenance Bypass Cabinet in
Single Mains System, page 36, or
– Install Busbars Between the UPS and the Maintenance Bypass Cabinet in
Dual Mains System, page 38.
7. Install Busbars for Load Bank Breaker (Option), page 41.
8. Prepare for signal cabling. Perform one of the following procedures:
– Prepare for Signal Cables in Top Cable Entry Systems, page 42, or
– Prepare for Signal Cables in Bottom Cable Entry Systems, page 44.
9. Connect the Signal Cables Between the Maintenance Bypass Cabinet and
the UPS, page 47.
10. Follow the UPS installation manual and other auxiliary product installation
manuals to connect relevant signal cables and external communication
cables in the UPS.
11. Add Translated Safety Labels to Your Product, page 50.
12. Final Installation, page 51.
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Maintenance Bypass Cabinet for UL
Install the Seismic Anchoring (Option)
Install the Seismic Anchoring (Option)
Use the optional seismic kit GVLOPT002 for this procedure.
1. Connect the rear anchoring assemblies for the UPS and the maintenance
bypass cabinet with the interconnection plate.
Rear View
2. Mount the rear anchoring assembly to the floor. Use appropriate hardware for
the floor type – the hole diameter in the rear anchors is ø16 mm. Minimum
requirement is M12 strength grade 8.8 hardware.
Rear View
3. Remove all the screws and the interconnection plate.
Rear View
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Install the Seismic Anchoring (Option)
Maintenance Bypass Cabinet for UL
4. Remove the rear anchoring brackets.
Rear View
5. Install the rear anchoring brackets on the UPS and the maintenance bypass
cabinet with the provided bolts.
Rear View of the UPS and the Maintenance Bypass Cabinet
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Maintenance Bypass Cabinet for UL
Prepare for Installation
Prepare for Installation
1. Remove the brackets (A) and (B) from the maintenance bypass cabinet.
Install the brackets (A) on the rear of the maintenance bypass cabinet. Save
the bracket (B) for top interconnection with the UPS.
Right Side View of the Maintenance Bypass
Cabinet
18
Rear View of the Maintenance Bypass Cabinet
990-91376D-001
Prepare for Installation
Maintenance Bypass Cabinet for UL
2. Remove the right side panel from the maintenance bypass cabinet.
The Maintenance Bypass Cabinet
3. Remove the left side panel from the UPS. Install the left side panel on the
maintenance bypass cabinet.
The Maintenance Bypass Cabinet and the UPS
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Maintenance Bypass Cabinet for UL
Prepare for Installation
4. Push the maintenance bypass cabinet into final position. Align with seismic
anchoring, if present. For systems without seismic anchoring, reinstall the
rear transportation bracket on the maintenance bypass cabinet and mount it
to the floor.
Rear View with Seismic Anchoring
20
Rear View without Seismic Anchoring
990-91376D-001
Prepare for Installation
Maintenance Bypass Cabinet for UL
5. Prepare for power cables:
a. Remove the top or bottom gland plate.
b. For bottom cable entry, remove the rear caster and the caster screws
from the bottom gland plate. Discard the caster.
c. Drill or punch holes for power cables or conduits in the gland plate.
Conduits are not provided.
d. Reinstall the top or bottom gland plate.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Do not drill or punch holes with the gland plates installed and do not drill or
punch holes in close proximity to the cabinet.
Failure to follow these instructions will result in death or serious
injury.
Top Cable Entry
Bottom Cable Entry
6. Open the inner door on the UPS.
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Maintenance Bypass Cabinet for UL
Prepare for Installation
7. Remove the transparent protection covers in the UPS.
Front View of the UPS
22
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Prepare for Installation
Maintenance Bypass Cabinet for UL
8. Remove busbars from the UPS. Some of the busbars will be installed in the
maintenance bypass cabinet:
a. Remove the three busbars from the UPS. Install the three busbars in the
maintenance bypass cabinet with the nine provided M8 nuts with washer
(provided in kit). If the M8 nuts with washer are not in the provided kit,
new M8 nuts with washer must be locally sourced and used.
b. Remove the three busbars from the UPS. Only for dual mains: Install
the three busbars in the maintenance bypass cabinet with the 12
provided M8 nuts with washer (provided in kit). If the M8 nuts with
washer are not in the provided kit, new M8 nuts with washer must be
locally sourced and used.
c. Remove the three busbars from the UPS. Save for load bank breaker
(LBB) option if this is part of the system.
d. Remove the four busbars from the UPS. Discard or save for spare parts.
Front View of the UPS
990-91376D-001
Front View of the Maintenance Bypass Cabinet
23
Maintenance Bypass Cabinet for UL
Connect the Power Cables
Connect the Power Cables
CAUTION
HAZARD OF CABLE MOVEMENT IN SHORT CIRCUIT CONDITIONS
In systems over 35 kAIC it is mandatory to restrain the power cables:
•
Use 10 mm nylon rope or rope with a minimum tensile strength of 1000 kg
(2204.62 lbs).
Failure to follow these instructions can result in injury or equipment
damage.
1. Route the power cables through the top or bottom of the maintenance bypass
cabinet.
2. Connect the EGC (Equipment Grounding Conductor), input cables, bypass
cables (in dual mains systems), load cables, and DC cables. Assemble the
cable lugs to the busbars as shown.
Single Mains
24
Dual Mains
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Connect the Power Cables
Maintenance Bypass Cabinet for UL
Cable Lug to Busbar Assembly
A. Spring washer – provided in kit.
B. Flat washer (not provided).
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Maintenance Bypass Cabinet for UL
Connect the Power Cables
3. Mandatory in systems over 35 kAIC: Tie the power cables together at 250
mm (9.84 in) from the power cable terminals and at each 250 mm (9.84 in)
interval. Wrap the rope around the power cables five times before tying a knot
at each interval – see Restrain the Cables, page 28 for guidance.
Side View – Top Cable Entry
Side View – Bottom Cable Entry
4. Check the fastening of the cable lugs.
CAUTION
RISK OF EQUIPMENT DAMAGE
Check the fastening of the cable lugs. If the cable lugs move due to pulling
on cables, the bolt can become loose.
Failure to follow these instructions can result in injury or equipment
damage.
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Connect the Power Cables
Maintenance Bypass Cabinet for UL
5. Reinstall the right side panel on the maintenance bypass cabinet.
6. Reposition the protection covers on the right side panel. Reuse the M6
screws.
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Maintenance Bypass Cabinet for UL
Restrain the Cables
Restrain the Cables
Use 3/8 in nylon rope to restrain the cables.
1. Wrap the rope around the cables (a). Wrap the cables four times leaving 1 m
(3 ft) of excess rope at the first end (b). Pull rope (c) taut.
* Unsupported cable length.
2. Wrap rope (a) several times until the space between the first two sets of
cables is completely filled. Weave final rope loop underneath the previous
loop (b). Bring rope (c) through the other open area and pull the rope taut.
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990-91376D-001
Restrain the Cables
Maintenance Bypass Cabinet for UL
3. Wrap rope (a) several times until the space between the second and the third
set of cables is completely filled. Wave the final rope loop (b) underneath the
previous loop as shown. Pull the rope taut.
4. Tie rope End 1 and End 2 together as shown. The rope must be taut. Cut off
excess rope and tape ends to prevent fraying.
5. Repeat the procedure where needed.
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29
Maintenance Bypass Cabinet for UL
Interconnect the UPS with the Maintenance Bypass Cabinet
Interconnect the UPS with the Maintenance Bypass
Cabinet
1. Push the UPS into position next to the maintenance bypass cabinet. Align
with seismic anchoring, if present.
2. Lower the front and rear leveling feet on the maintenance bypass cabinet and
on the UPS with a wrench until they connect with the floor. The casters must
not have contact with the floor. Use a bubble-leveler to check that the cabinet
is level.
NOTICE
RISK OF EQUIPMENT DAMAGE
Do not move the cabinet after the leveling feet have been lowered.
Failure to follow these instructions can result in equipment damage.
3. Interconnect the maintenance bypass cabinet and the UPS in the front with
screws as shown
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990-91376D-001
Interconnect the UPS with the Maintenance Bypass Cabinet
Maintenance Bypass Cabinet for UL
4. Install the top bracket. The top bracket was removed from the side of the
maintenance bypass cabinet earlier.
5. Open the inner door in the UPS.
990-91376D-001
31
Maintenance Bypass Cabinet for UL
Interconnect the UPS with the Maintenance Bypass Cabinet
6. Remove the two special screws from the UPS and use for rear
interconnection between the maintenance bypass cabinet and the UPS as
shown.
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990-91376D-001
Prepare the UPS for Internal Busbar Connection
Maintenance Bypass Cabinet for UL
Prepare the UPS for Internal Busbar Connection
1. Only for HRG earthing system: Remove and discard the two preconnected
cables that connect the E terminal on the bonding contactor to the ground
busbar.
990-91376D-001
33
Maintenance Bypass Cabinet for UL
Prepare the UPS for Internal Busbar Connection
2. Reposition the ground busbar in the UPS:
a. Disconnect the EMC cable, the EMC cable holder and the bonding
cables from the ground busbar. Note the connection of the cables on the
ground busbar.
b. Remove and discard the copper busbar.
c. Move the ground busbar to the new position.
d. Hold onto the EMC cable holder and pull gently on the end of the EMC
cable to extend the length. Reconnect the EMC cable to the ground
busbar.
e. Reconnect the bonding cables to the ground busbar
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Prepare the UPS for Internal Busbar Connection
Maintenance Bypass Cabinet for UL
3. Only for HRG earthing system: Connect an external impedance between
the E terminal on the bonding contactor and the ground busbar according to
NEC 2014 article 250.36.
4. Bend the M zone flaps upwards on the plastic box. This is necessary to make
room for the internal busbars between the maintenance bypass cabinet and
the UPS.
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35
Install Busbars Between the UPS and the Maintenance
Bypass Cabinet in Single Mains System
Maintenance Bypass Cabinet for UL
Install Busbars Between the UPS and the
Maintenance Bypass Cabinet in Single Mains
System
The busbars and insulator parts are provided in a kit with the maintenance bypass
cabinet. The part numbers shown on the illustrations are printed on the parts. Use
the provided M8x30 screws and torque to 17.5 Nm (12.91 lb-ft / 154.9 lb-in).
1. Install the neutral busbars, the DC busbars, the insulator part, and the ground
busbar.
Front View of the UPS
2. Install the input busbars and the insulator part.
Front View of the UPS
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990-91376D-001
Install Busbars Between the UPS and the Maintenance
Bypass Cabinet in Single Mains System
Maintenance Bypass Cabinet for UL
3. Install the output busbars and the insulator parts.
Front View of the UPS
990-91376D-001
37
Install Busbars Between the UPS and the Maintenance
Bypass Cabinet in Dual Mains System
Maintenance Bypass Cabinet for UL
Install Busbars Between the UPS and the
Maintenance Bypass Cabinet in Dual Mains System
The busbars and insulator parts are provided in a kit with the maintenance bypass
cabinet. The part numbers shown on the illustrations are printed on the parts. Use
the provided M8x30 screws and torque to 17.5 Nm (12.91 lb-ft / 154.9 lb-in).
1. Remove the three single mains busbars.
NOTE: Save the three single mains busbars. They are needed for testing
during start-up of the UPS.
Front View of the UPS
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990-91376D-001
Install Busbars Between the UPS and the Maintenance
Bypass Cabinet in Dual Mains System
Maintenance Bypass Cabinet for UL
2. Install the input busbars, the neutral busbar, the DC busbars, the insulator
part, and the ground busbar.
Front View of the UPS
3. Install the bypass busbars and the insulator part.
Front View of the UPS
990-91376D-001
39
Install Busbars Between the UPS and the Maintenance
Bypass Cabinet in Dual Mains System
Maintenance Bypass Cabinet for UL
4. Install the output busbars and the insulator parts.
Front View of the UPS
40
990-91376D-001
Install Busbars for Load Bank Breaker (Option)
Maintenance Bypass Cabinet for UL
Install Busbars for Load Bank Breaker (Option)
NOTE: The busbars for the load bank breaker were removed from the UPS
during preparation for installation.
1. Install busbars for load bank breaker (LBB) in the UPS. Note the direction of
the busbars.
Front View of the UPS
2. The load bank breaker cables can be routed through the top of the UPS for a
permanent installation or through the open inner door for a temporary
installation. See the UPS manual for information on how to create top cable
entry in the UPS.
990-91376D-001
41
Maintenance Bypass Cabinet for UL
Prepare for Signal Cables in Top Cable Entry Systems
Prepare for Signal Cables in Top Cable Entry
Systems
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Do not drill or punch holes with the gland plates installed and do not drill or
punch holes in close proximity to the cabinet.
Failure to follow these instructions will result in death or serious injury.
1. Prepare the UPS for signal cables:
a. Remove the cover.
b. Remove the gland plates and brush plates from the top of the UPS.
Front View of the UPS
c. For installation without conduits: Reinstall the brush plates.
d. For installation with conduits: Drill a hole in the gland plates for
conduits, install conduits, and reinstall the gland plates.
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990-91376D-001
Prepare for Signal Cables in Top Cable Entry Systems
Maintenance Bypass Cabinet for UL
2. Route the signal cables as shown to separate the Class 2/SELV cables from
the non-Class 2/non-SELV cables. A divider inside the cable channel
separates the cables.
Front View of the UPS
990-91376D-001
43
Maintenance Bypass Cabinet for UL
Prepare for Signal Cables in Bottom Cable Entry Systems
Prepare for Signal Cables in Bottom Cable Entry
Systems
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Do not drill or punch holes with the gland plates installed and do not drill or
punch holes in close proximity to the cabinet.
Failure to follow these instructions will result in death or serious injury.
1. Remove the covers.
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990-91376D-001
Prepare for Signal Cables in Bottom Cable Entry Systems
Maintenance Bypass Cabinet for UL
2. Prepare for signal cables:
a. Remove the gland plates.
b. Drill/punch holes for signal cables or conduits in the gland plate. Install
conduits (not provided), if applicable.
c. Reinstall the gland plates.
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45
Maintenance Bypass Cabinet for UL
Prepare for Signal Cables in Bottom Cable Entry Systems
3. Route the signal cables from the UPS, into the maintenance bypass cabinet,
and out through the bottom of the maintenance bypass cabinet.
4. Reinstall the covers.
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990-91376D-001
Connect the Signal Cables Between the Maintenance Bypass
Cabinet and the UPS
Maintenance Bypass Cabinet for UL
Connect the Signal Cables Between the
Maintenance Bypass Cabinet and the UPS
1. Connect the provided Class 2/SELV signal cable 0W50021 and the provided
non-Class 2/non-SELV signal cable 0W50023 between the maintenance
bypass cabinet and the UPS as shown.
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47
Maintenance Bypass Cabinet for UL
Connect the Signal Cables Between the Maintenance Bypass
Cabinet and the UPS
Single Mains System
48
990-91376D-001
Connect the Signal Cables Between the Maintenance Bypass
Cabinet and the UPS
Maintenance Bypass Cabinet for UL
Dual Mains System
990-91376D-001
49
Maintenance Bypass Cabinet for UL
Add Translated Safety Labels to Your Product
Add Translated Safety Labels to Your Product
The safety labels on your product are in English and French. Sheets with
translated safety labels are provided with your product.
1. Find the sheets with translated safety labels provided with your product.
2. Check which 885-XXX numbers are on the sheet with translated safety
labels.
3. Locate the safety labels on your product that match the translated safety
labels on the sheet – look for the 885-XXX numbers.
4. Add the replacement safety label in your preferred language to your product
on top of the existing French safety label.
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990-91376D-001
Final Installation
Maintenance Bypass Cabinet for UL
Final Installation
1. Only for dual mains: Add the labels for SSIB, the indicator lights, and the
diagram label on the maintenance bypass cabinet. The labels are provided
with this manual.
Single Mains
Dual Mains
2. Add label 885-91965 (provided with the UPS) on the maintenance bypass
cabinet.
3. Only for seismic anchoring: Install the seismic front anchoring bracket on
the maintenance bypass cabinet and on the UPS. Mount the seismic front
brackets to the floor. Use appropriate hardware for the floor type – the hole
diameter in the seismic front bracket is ø14 mm. The minimum requirement is
M12 strength grade 8.8 hardware.
4. Close the front door on the maintenance bypass cabinet
990-91376D-001
51
Schneider Electric
35 rue Joseph Monier
92500 Rueil Malmaison
France
+ 33 (0) 1 41 29 70 00
*990-91376D-001*
As standards, specifications, and design change from time to time,
please ask for confirmation of the information given in this publication.
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990-91376D-001

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