g SGS_225-300_UPS_GE_01 GE SG Series 225 and 300 kVA INSTALLATION GUIDE UNI NTERRUPTI BLE POWE R S UPP LY Digital Energy TM SG Series 225 and 300 kVA Series 0 g 2500 Discovery Blvd.
g GE Model: SG Series 225 and 300 kVA / Series 0 Date of issue: 11/05/2003 File name: OPM_SGS_ISG_M22_M30_0US_V011 Revision: 1.1 Author: Identification No.: Up-dating Revision Concern Date 1.1 “3-wire kit” for RPA Parallel System 11/05/2003 COPYRIGHT © 2003 by GE Industrial Systems All rights reserved. The information contained in this publication is intended solely for the purposes indicated.
g GE Dear Customer, We thank you for selecting our products and are pleased to count you amongst our very valued customers at GE. We trust that the use of the SG Series Uninterruptible Power Supply system, developed and produced to the highest standards of quality, will give you complete satisfaction. Please carefully read the Installation Guide. It contains all the necessary information about the installation of the UPS.
g GE Preface Congratulations on your choice of a SG Series Uninterruptible Power Supply (UPS). It will help eliminate load disturbances due to unexpected power problem. This manual describes how to prepare the installation site, and it provides weight and dimensions and procedures for moving, installing and connecting the UPS.
g GE Table of contents Page 1 IMPORTANT SAFETY INSTRUCTIONS .................................................................6 2 LAYOUT ...................................................................................................................9 LAYOUT SG SERIES 225 AND 300 KVA ............................................................................9 2.1 3 INSTALLATION......................................................................................................10 3.1 3.1.1 3.
g GE 1 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for models SG Series 225 and 300 kVA that should be followed during installation and maintenance of the UPS and battery. GENERAL - Move the UPS in an upright position in its original package to the final destination room. To lift the cabinets, use a forklift or lifting belts with spreader bars. Check for sufficient floor and elevator loading capacity.
g GE Safety instructions when working with battery EXTERNAL BATTERY MUST BE INSTALLED AND CONNECTED TO THE UPS BY QUALIFIED SERVICE PERSONNEL. INSTALLATION PERSONNEL MUST READ THIS ENTIRE SECTION AND REFER TO THE BATTERY MANUFACTURERS INSTALLATION MANUAL BEFORE HANDLING THE UPS AND BATTERY. UPS intended to be used with a remote battery supply – All models: “Please refer to the battery manufacturer’s installation manual for battery installation and maintenance instructions”.
g GE Safety symbols and warnings Safety warnings The text of this manual contains some warnings to avoid risk to the persons and to avoid damages to the UPS system and the supplied critical loads. The non-observance of the warnings reminding hazardous situations could result in human injury and equipment damages. Please pay attention to the meaning of the following warnings and symbols.
g GE 2 SGS_225-300_UPS_03 LAYOUT SG Series 225 AND 300 KVA SGS_225-300_UPS_GE_02 2.1 LAYOUT Q1 Q2 1 2 3 4 1 2 3 4 Fig. 2.1-2 SG Series general view with open doors Fig. 2.
g GE 3 3.1 INSTALLATION TRANSPORT Forklift Transport UPS only in upright position! The UPS is packaged on a pallet suitable for handling with a forklift. Pay attention to the center of gravity. The UPS must be moved in upright position. Do not tilt cabinets more than +/- 10° during handling. Crane Move the UPS in it’s original package to the final destination site. Do not stack other packages on top: This could damage the UPS.
g 3.2 GE DELIVERY When delivered, inspect the package integrity and the physical conditions of the cabinets carefully. In case of any damage sustained during transport, immediately inform the carrier and contact your local Service Center. A detailed report of the damage is necessary for any insurance claim. A DAMAGED UPS MUST NEVER BE INSTALLED OR CONNECTED TO UTILITY OR BATTERY! 3.3 3.3.
g 3.4 3.4.1 GE PLACE OF INSTALLATION UPS location A qualified electrical contractor must carry out the installation and cabling of the UPS. If optional cabinets and accessories are included with the UPS, please refer to those accompanying manuals for installation and operating instructions. It is important to have a clean, dust-free environment provided with proper ventilation and airconditioning to keep the ambient temperature within the specified operating range.
g GE Openings for input and output cable connections Battery S UP 00_ 25-3 S_2 SG S 1U p_0 w to vie Utility input Output Load 6" 21.6mm 550 64.96" 1,650mm 6.30" 160mm 1.58" 40mm SG Series openings are provided on the top and the bottom of the UPS for the connection of input and output cables. 0" 31.5mm 800 6" 2.7 m 70m Fig. 3.4.
g In case of parallel system, try to place the UPS modules in sequence of their numbers (marked on the packing). If the units are positioned “side by side”, the side panels must be mounted on all units. 3.4.2 SGS_225-300_RPA disposition_GE_01US GE UPS 3-4-5-6-7-8 UPS 2 UPS 1 Fig. 3.4.1-5 RPA system disposition Battery location Batteries require a well-ventilated room with controlled temperature to obtain reliable operation.
g 3.5 GE VENTILATION AND COOLING Fig. 3.5-1 Installation on plain floor Fig. 3.5-2 Installation on raised floor The heat produced by the UPS is transferred to the environment by its ventilation. Air inlets for UPS ventilation are located on the front of the UPS, while air outlets are on top of the cabinet. A suitable ventilation or cooling system must be installed to extract the heat from the UPS room. Do not put anything on the top of the cabinet.
g 3.6 GE UNPACKING The UPS and Battery Cabinets may be shipped packaged in carton boxes or in wooden crates (if requested). Move the cabinets as close as possible to the final location before removing from the pallet. If delivered in a wooden crate, remove the cabinet from the pallet with care, because of the heavy weight of the equipment. Take care not to damage the UPS when moving by forklift. For parallel systems, the delivery also includes the bus control cables for inter-connecting the UPS modules.
g 3.7 GE ELECTRICAL WIRING UPS installation and connection must be performed by qualified service personnel only. It is the responsibility of the installation technician to ensure that all local and national electric codes are adhered to. 3.7.1 Utility input connection Ensure that the AC and DC external isolators are OFF and locked out to prevent their inadvertent operation. Do not apply power to the equipment prior to the commissioning by a qualified service engineer.
g 3.7.2 GE Input/output over current protection and wire sizing The cabling of the UPS system has to be sized according to the UPS power rating. Sizing of circuit breakers, fuses and cables for Input Utility, Output Load and Battery must meet the requirements of local and national electrical codes.
g 3.7.3 • • • • GE Battery over current protection and wire sizing Please read the safety precautions at the front of this guide carefully, and thoroughly review the Battery manufacturers installation and maintenance manual before connecting the batteries to the UPS. If the UPS system has been purchased with an accompanying Battery Cabinet, that cabinet should have an integral Battery Circuit Breaker.
g GE NEC SECTION 210-20 (a) Table 310-16. Allowable Ampacities of Insulated Conductors Rated O Through 2000 Volts, 60°C Trough 90°C (140°F Trough 194°F) Not More than Three Current-Carrying Conductors in Raceway, Cable, or Earth (Directly Buried), Based on Ambient Temperature of 30°C (86°F).
g 3.8 GE WIRING CONNECTION WARNING! UPS installation and connection must be performed by qualified service personnel only. 3.8.1 Power connections Input/output and DC connections are provided with compression lugs. Please refer to chart for torque specifications. Carefully read the following recommendations before proceeding: • Ensure that the AC and DC external isolators are OFF and locked to prevent their inadvertent operation.
g GE CAUTION ! Panel “E” should never be removed or replaced with power applied to the UPS. This panel is in close proximity to 480V live buss bars. Always disconnect the rectifier, bypass, load and battery sources from the UPS before removing or replacing this panel. If not serious injury or death could occur! How to access the compression lugs for the cable connections. B SGS_225-300_UPS connection_01US Top entry cables A F Q1 Q2 1 2 3 1 4 2 3 4 Bottom entry cables E C D Fig. 3.8.
g Power connection with common input utility PE Input rectifier PE Load SGS_225-300_UPS connection common_GE_01US 3.8.2 GE AD LO L1 L2 L3 N L1-1 L2-1 L3-1 N 1 UT NP I - R IE IF T C RE PE Load Position of the PE compression lugs in case the cable input is from the bottom of the UPS PE Input rectifier Fig. 3.8.
g GE This UPS is only designed to operate in a wye-configured electrical system with a solidly grounded neutral. In case of 3-wire utility input the following solutions are possible: 1- Connection of a “3-wire kit” between Utility Input and Neutral of the output transformer. Attention: With this configuration, load can only be connected phase-phase. Absolutely no load connection permitted to the Neutral of the output transformer.
g Power connection separate input utility PE Input rectifier PE Load SGS_225-300_UPS connection separate_GE_01US 3.8.3 GE LO L1 AD L2 L3 N L1-1 L3-1 N 1 -I UT NP RE IE IF CT R L3-2 L2-2 PE Load Position of the PE compression lugs in case the cable input is from the bottom of the UPS L1-2 PE Input rectifier 2 - INPUT BYPASS L2-1 Fig. 3.8.
g GE This UPS is only designed to operate in a wye-configured electrical system with a solidly grounded neutral. In case of 3-wire utility input the following solutions are possible: 1- Connection of a “3-wire kit” between Utility Input and Neutral of the output transformer. Attention: With this configuration, load can only be connected phasephase. Absolutely no load connection permitted to the Neutral of the output transformer.
g GE Battery connection SGS_225-300_UPS connection battery_01US 3.8.4 BATTERY _ PE + Q1 Q2 1 2 3 4 1 2 3 4 Fig. 3.8.4-1 Power connections Battery Battery + Positive pole of the Battery – Negative pole of the Battery Do not insert the Battery Fuses before the commissioning. Battery Cable Terminations are to the Positive and Negative Terminals as shown above. Connect wire to the Lugs using appropriate tools and appropriate torque.
g 3.8.5 GE Setup for SG Series when functioning as frequency converter When the SG Series is utilized for different output frequency compared to the input frequency, the Automatic Bypass and Manual Bypass functions are disabled, therefore the Load cannot be transferred to Utility in case of overload, short circuit, or inverter failure.
g 3.9 GE POWER WIRING OF PARALLEL UNITS To guarantee good Load sharing between the units of a parallel system, we recommend it is recommended that the cable length from the input distribution board (5) to the output distribution board (10) are the same length for each unit (a+b = c+d = e+f = g+h = i+l = m+n = o+p = q+r). Tolerance: +/-10%. The AC input power of the Bypass must be the same for all units of the parallel system - no phase shift allowed between units.
g GE 3.10 PARALLEL CONTROL BUS CONNECTION In cases of parallel operation, the communication between the units takes place through the control bus cables. Each parallel unit is equipped with an additional board “P13 – RPA Board IM0006“ where the connectors J52 (A) and J62 (B) are located.
g GE SGT5000_100-150_RPA-IM0048_02 JB1 JP1 JP2 JB IM 0048 JP2 JP1 JP4 JP3 JA JP4 JP3 JA1 Fig. 3.10-2 Bus connection on terminal units Terminal units On the parallel bus PCB “P34 – Bus Interface IM0048”, of the first and last units (terminal) of the parallel system the Jumpers JP1, JP2, JP3 and JP4 must be inserted. SGT5000_100-150_RPA-IM0048_03 JB1 JP1 JP2 JB2 JB IM 0048 JP2 JP1 JP4 JP3 JA1 JP4 JP3 JA2 JA Fig. 3.
g GE 3.11 CONTROL BUS CABLE LOCATION SGS_225-300_RPA control bus cable_01 Warning! This installation must be verified by trained personnel before the initial start-up (ensure that the UPS installation is completely powered down). Access to the control bus connection. Q1 The control bus connection between parallel units must be made on the front of the electronic module fitted behind the front doors.
SGS_225-300_RPA control bus cable_02US g GE JB1 JB JA1 JA JB1 JB2 JA1 JA2 Q1 JB JA Q2 1 2 3 4 1 JB1 2 3 4 Q1 Q2 1 2 3 4 1 2 3 4 U PS 1 JA1 Next pa ra unit 3, 4 llel , 5, 6, 7, 8 JB2 U PS 2 JA2 Fig. 3.11-3 Control Bus cable routing and connection Control bus cables routing Place and fix the cables JA-1/2/3/4/5/6/7 and JB-1/2/3/4/5/6/7 inside the UPS cabinets in the position illustrated in the drawing.
g GE 4 4.
g 4.1.1 GE Serial Port J3 Serial port J3 - RS-232 (sub D, female 9 pin) that allows: • Total remote management of the system using new generation software JUMP (Java Universal Management Platform) for system protection and management of systems using GE Industrial Systems UPS’s. JUMP system is written in JAVA and supports virtually all platforms having JAVA runtime environment version 1.1 or higher. The serial port J3 - RS-232 is enabled on all the units of the parallel system.
g 4.1.3 GE Programmable input free contacts Some programmable UPS functions (indicated in section 4.1), can be activated by closing an external contact, if connected, on: X1 / 10, 21 or X1 / 11, 22 or 4.1.
g 4.1.7 GE EPO (Emergency Power Off) Input contact SGS_22 5-300_Cu stomer int erface EP O_01 1 2 3 1 4 JP3 An external Emergency switch (Normally Closed voltage-free contact) can be connected on terminals XB / 1 - 4 or connector J2 / 12 - 25 of the P4 - Interface Customer. 2 J2 3 XB 4 Remove the cable shortcircuiting terminals XB 2 - 3) when using this external switch. Fig. 4.1.
g GE 5 5.1 NOTES NOTES FORM It is recommended to note in this section Notes, with date and short description all the operations performed on the UPS, as: Maintenance, components replacement, anormal situations, etc. Date OPM_SGS_ISG_M22_M30_0US_V011.