AC Power For Business-Critical Continuity™ Liebert® NXL™ Maintenance Bypass Cabinet Installation Manual – 250-400kVA, 60Hz
CONTACTING LIEBERT FOR SUPPORT To contact Emerson Network Power Liebert Services for information or repair service in the United States, call 1-800-LIEBERT (1-800-543-2378). Liebert 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 Services, if available in your area.
TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1.0 SINGLE-MODULE MECHANICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.2 Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURES Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Cabinet arrangement—Liebert NXL UPS, battery cabinets, maintenance bypass cabinet. . . . . . 4 Two-Breaker Maintenance Bypass Cabinet, one-input, attached . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Two-Breaker Maintenance Bypass Cabinet, two-input, attached . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during installation of your Liebert NXL™ Maintenance Bypass Cabinet. ! WARNING Exercise extreme care when handling cabinets to avoid equipment damage or injury to personnel. The Liebert NXL Maintenance Bypass Cabinet weight ranges from 700 to 900 lb (317 to 409kg). Locate center of gravity symbols and determine unit weight before handling each cabinet.
Single-Module Mechanical Installation 1.0 SINGLE-MODULE MECHANICAL INSTALLATION 1.1 Introduction This section describes the requirements that must be taken into account when planning the positioning and cabling of the Liebert NXL Maintenance Bypass Cabinet. This chapter is a guide to general procedures and practices that should be observed by the installing engineer. The particular conditions of each site will determine the applicability of such procedures.
Single-Module Mechanical Installation 1.3.2 Storage Should the equipment not be installed immediately, it must be stored in a room for protection against excessive humidity and or heat sources (see Table 6). 1.4 Positioning The cabinet is structurally designed to handle lifting from the base. Access to the power terminals, auxiliary terminals blocks and power switches is from the front. The top and front removable panels are secured to the chassis by screws.
Single-Module Mechanical Installation 1.6 Power Cables The Maintenance Bypass Cabinet requires both power and control cabling once it has been mechanically installed. All control cables must be separate from the power cables. Run control cables in metal conduits or metal ducts that are electrically bonded to the cabinets they are connected to.
Single-Module Mechanical Installation 1.6.1 Power Cable Connection Procedure The system input, UPS bypass, UPS output and system output cables (all require lug type terminations) are connected to busbars situated behind the power isolator switches as shown in 2.0 - Installation Drawings. These are accessible when the power compartment door is opened. Equipment Ground The equipment ground busbar is located near the input and output power supply connections as shown in 2.0 - Installation Drawings.
Single-Module Mechanical Installation Once the equipment has been finally positioned and secured, connect the power cables as described in the following procedure. Refer to the appropriate cable connection drawing in 2.0 - Installation Drawings. 1. Verify that the bypass equipment is isolated from its external power source and all the power isolators are open. Check that these supplies are electrically isolated and post any necessary warning signs to prevent their inadvertent operation. 2.
Installation Drawings INSTALLATION DRAWINGS Figure 2 Two-Breaker Maintenance Bypass Cabinet, one-input, attached Two Breaker Maintenance Bypass Cabinet FBO MBB Critical Load MIB 2.
Installation Drawings Figure 3 Two-Breaker Maintenance Bypass Cabinet, two-input, attached MBB Two Breaker Maintenance Bypass Cabinet Critical Load FBO MIB I Load Bank (FBO) BFB FBO DC Bus CB1 CB2 N Main Input Switchgear MBJ UPS Module Battery System EG MIB - Maintenance Isolation Breaker BIB - Bypass Input Breaker MBB - Maintenance Bypass Breaker FBO – Furnished By Others N – Neutral EG – Equipment Ground MBJ – Main Bonding Jumper(3-wire systems only) MBD I Figure 4 - Option Interlock T
Installation Drawings Figure 5 Liebert NXL Maintenance Bypass Cabinet—250 and 300kVA main component location INPUT OUTPUT PHASE C PHASE C OUTPUT INPUT PHASE A PHASE A BREAKER REMOVED FOR CLARITY GROUND INPUT PHASE B NEUTRAL OUTPUT PHASE B BUSBAR DETAIL B A OPTIONAL SOLENOID INTERLOCK B MAINTENANCE BYPASS BREAKER (MBB) MAINTENANCE ISOLATION BREAKER (MIB) CONTROL WIRING TERMINAL BLOCK (TB1) A SECTION A-A FRONT 9
Installation Drawings Figure 6 Liebert NXL Maintenance Bypass Cabinet—400kVA main component location INPUT PHASE C INPUT PHASE A GROUND OUTPUT PHASE C OUTPUT PHASE A INPUT PHASE B NEUTRAL OUTPUT PHASE B BREAKER REMOVED FOR CLARITY BUSBAR DE TAIL B A NEUTRAL BUSBAR LOCATED IN REAR CORNER FOR ADDITIONAL LANDING SPACE OPTIONAL SOLENOID INTERLOCK B MAINTENANCE BYPASS BREAKER (MBB) MAINTENANCE ISOLATION BREAKER (MIB) CONTROL WIRING TERMINAL BLOCK (TB1) A SECTION A-A FRONT 10
Installation Drawings Figure 7 Liebert NXL Maintenance Bypass Cabinet—250 and 300kVA outline drawing 31.3 ( 795) CONDUIT LANDING AREA 24.0 ( 610) 24.8 ( 630) 4.9 ( 124) TYP 56.8 ( 1442) 3.9 ( 100) TYP 21.1 ( 535) KNOCK-OUT FOR CONTROL WIRING O 1" 3 PLCS BOTTOM VIEW (FOOTPRINT) TOP VIEW (DOOR OPEN) 76.8 ( 1951) CG CG 38.5 ( 979) 24.2 (615) 12.2 (309) 38.5 ( 979) 22.7 ( 578) 33.5 ( 850) NOTES: 1. All dimensions are in inches (mm). 2.
Installation Drawings Figure 8 Liebert NXL Maintenance Bypass Cabinet—400kVA outline drawing 37.3 (947) 24.0 ( 610) 4.9 (124) TYP Conduit Landing Area 30.8 (782) 62.8 (1595) 3.9 ( 100) TYP 21.1 (535) Knock-out for control wiring O 1.0" (25.4mm) 3 Places BOTTOM VIEW (FOOTPRINT) TOP VIEW (DOOR OPEN) 76.8 (1950) CG CG 38.5 (979) 12.2 (309) FRONT 24.2 (615) See Note 10 38.5 ( 979) 39.4 (1000) See Note 11 28.2 ( 716) SIDE VIEW NOTES: 1. All dimensions are in inches (mm). 2.
Installation Drawings Figure 9 Liebert NXL Maintenance Bypass Cabinet—250 and 300kVA terminal details 2.6 ( 65 ) 2.6 ( 65 ) 1.6 ( 40 ) NOTE: ALL DIMENSIONS ARE IN inches (mm). 2.0 ( 51 ) 1.8 ( 45 ) 4.8 ( 123 ) TYP 2.0 ( 51 ) BUS BAR DETAIL A TOP VIEW BREAKER REMOVED FOR CLARIT Y .6 O (14 ) 8 PLACES TYP 1.8 (45) CUSTOMER CONNECTION 1.
Installation Drawings Figure 10 Liebert NXL Maintenance Bypass Cabinet—400Kva terminal details 2.57 ( 65 ) 2.57 ( 65) 1.59 ( 40 ) 4.59 (117) TYP O .56 (14) 8 PLACES TYP 1.75 ( 44 ) 1.75 ( 44 ) 2.00 ( 51 ) 1.78 ( 45 ) TOP VIEW 4.84 (123 ) 2.00 ( 51) BUS TERMINATION DETAIL CUSTOMER CONNECTION AREA BUSBAR DETAIL A BREAKERS REMOVED FOR CLARITY 1.75 ( 44 ) TYP (BOTTOM ENTRY) 1.75 ( 44 ) TYP (TOP ENTRY) 3.1 ( 79 ) 1.37 X .56 SLOT TYPICAL (20 PLACES) O .
Installation Drawings Figure 11 Cable routing TOP ENTRY NOTES: 1. Cables from lower busbars must be routed and tied to the aligning holes on the the cable landing bar directly above (see figure below). Installation method is to prevent cables from lower busbars from contacting the upper busbars. 2. Cables from upper busbars can be optionally tied also, as shown in top entry view. 3. The UPS output phase cables must be run on the left side of cabinet, outside of the ground bus. BOTTOM ENTRY NOTES: 1.
Installation Drawings Figure 12 Liebert NXL Maintenance Bypass Cabinet, one-input system, point-to-point wiring to UPS S MBB MIB P Q R N H C O F A L D T G B M U E V RE AR FRONT V (+) L (-) BYPASS NEUTRAL H K G J C B F I K A C J B I P A O C B A OUTPUT NEUTRAL UPS 16 N M
Installation Drawings Table 1 Run Liebert-supplied interconnect wiring for one-input Liebert NXL Maintenance Bypass Cabinet To From Conductor A Utility AC - Phase A MBC Bypass AC - Phase A Maintenance Bypass AC - Phase A B Utility AC - Phase B MBC Bypass AC - Phase B Maintenance Bypass AC - Phase B C Utility AC - Phase C MBC Bypass AC - Phase C Maintenance Bypass AC - Phase C D Utility Neutral MBC Neutral System Input Neutral E Utility Ground MBC Ground System Ground F MBC Bypass A
Installation Drawings Figure 13 Liebert NXL Maintenance Bypass Cabinet, two-input system, point-to-point wiring to UPS S MBB MIB P Q N R O H C F A L D T G B M U E V RE AR FRONT V BYPASS NEUTRAL (+) L (-) H G C B F A C B I A B OUTPUT NEUTRAL UPS 18 P O C A K J N M
Installation Drawings Table 2 Run Liebert-supplied interconnect wiring for two-input Liebert NXL Maintenance Bypass Cabinet To From Conductor A Utility AC - Phase A MBC Bypass AC - Phase A Maintenance Bypass AC - Phase A B Utility AC - Phase B MBC Bypass AC - Phase B Maintenance Bypass AC - Phase B C Utility AC - Phase C MBC Bypass AC - Phase C Maintenance Bypass AC - Phase C D Utility Neutral MBC Neutral System Input Neutral E Utility Ground MBC Ground System Ground F MBC Bypass A
Installation Drawings Figure 14 Liebert NXL Maintenance Bypass Cabinet, three-input system, point-to-point wiring to UPS S MBB MIB P Q N R C O A P1 D T B M U E V RE AR FRONT V BYPASS NEUTRAL (+) (-) L H G C B F B I A J C A P O C B A K N M OUTPUT NEUTRAL P1 UPS 20
Installation Drawings Table 3 Run Liebert-supplied interconnect wiring for three-input Liebert NXL Maintenance Bypass Cabinet To From Conductor A Utility AC - Phase A MBC Bypass AC - Phase A Maintenance Bypass AC - Phase A B Utility AC - Phase B MBC Bypass AC - Phase B Maintenance Bypass AC - Phase B C Utility AC - Phase C MBC Bypass AC - Phase C Maintenance Bypass AC - Phase C D Utility Neutral MBC Neutral System Input Neutral E Utility Ground MBC Ground System Ground F Utility AC
Installation Drawings Figure 15 Liebert NXL Maintenance Bypass Cabinet Control wire diagram without interlock Connections at UPS External Interface Board (EIB) 1 3 02-806708 TB0821 TB0811 1 TB0813 3 1 3 1 3 TB0824 LOW VOLTAGE TERMINAL STRIP - TB1 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Table 4 TB1-13 TB1-12 TB1-11 TB1-10 TB1-9 TB1-8 TB1-7 TB1-6 TB1-5 TB1-4 TB1-3 TB1-2 TB0813 TB0811 TB0823 TB0821 EPO PB SW TB1-1 WIRE DIAGRAM WITHOUT INTERLOCK 22 Control wiring connections with
Installation Drawings Figure 16 Liebert NXL Maintenance Bypass Cabinet control wire diagram with interlock Connections at UPS External Interface Board (EIB) 1 3 TB0821 TB0811 02-806708 1 1 3 1 3 TB0813 3 TB0824 TB0820 1 LOW VOLTAGE TERMINAL STRIP - TB1 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 TB1-16 TB1-15 TB1-14 TB1-13 TB1-12 TB1-11 TB1-10 TB1-9 TB1-8 TB1-7 TB1-6 TB1-5 TB1-4 TB1-3 TB1-2 Table 5 TB0820 TB0813 TB0811 TB0824 TB0821 EPO PB SW TB1-1 WIRE DIAGRAM WITH INTERLOCK Con
Installation Drawings Figure 17 Liebert NXL Maintenance Bypass Cabinet control wire routing CONDUIT KNOCK-OUTS FOR CONTROL WIRING A INTERNAL ROUTING FOR CONTROL WIRING INTERNAL ROUNTING FOR CONTROL WIRING CONDUIT KNOCK-OUTS FOR CONTROL WIRING SECTION A-A 24 A FRONT VIEW
Installation Drawings Figure 18 Ground strap location for connected cabinets Reference of corner post of connected cabinets FRONT SIDE OF UNITS A DETAIL A Cabinet-to-Cabinet Bolting Instructions Typical Ground Strap Installation (Use for all connected units except Battery Cabinet) 25
Specifications 3.0 SPECIFICATIONS Table 6 Liebert NXL Maintenance Bypass Cabinet specifications Model Size 250 300 400 Input Parameters Input Voltage to Bypass, VAC 480V 3-phase, 3-wire or 4-wire Permissible Input Voltage Range, VAC +10% to -30% Input Frequency, Hz 60 Permissible Input Frequency Range, Hz 55 to 65 Neutral Current 1.
Specifications Table 7 Liebert NXL Maintenance Bypass Cabinet current ratings—System Input UPS Rating Voltage (VAC) System Input kVA kW Input Bypass Output Nominal Current 10 Minute Overload External Breaker Trip, Amps 250 225 480 480 480 301 376 400 300 270 480 480 480 361 451 500 400 360 480 480 480 481 601 700 Table 8 Liebert NXL Maintenance Bypass Cabinet current ratings—System Output UPS Rating Voltage, VAC System Output kVA kW Input Bypass Output Nominal
Specifications Table 11 Recommended conduit and cable sizes—Module Bypass Input Module Bypass Input UPS Rating System Input Voltage (VAC) Maint kVA kW Rectifier Bypass Byp Output Nominal Selection Alternate Selection Top Cable Entry Wire & Conduit Ph, N, G,THW / FMC Bottom Cable Entry Wire & Conduit Ph, N, G, THW / RNC Top Cable Entry Wire & Conduit Ph, N, G, THW / FMC Bottom Cable Entry Wire & Conduit Ph, N, G THW / RNC 250 225 480 480 480 480 (2) 3C 3-250kcmil, 2-250kcmil, #1/0AWG (2) 3C
Specifications Notes See the Liebert NXL UPS installation manual, SL-25420, for UPS rectifier, UPS bypass and UPS output sizes. The manual is available at the Liebert Web site: www.liebert.com These are guidelines only and are superseded by local regulations and codes of practice where applicable. • Take special care when determining the size of the neutral cable, as current circulating on the neutral cable may be greater than nominal current in the case of non-linear loads.
Specifications 30
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