POWER PROTECTION Series 600T™ UPS Multi-Module Three Phase 500 kVA to 750 kVA, 60 Hz Installation Manual
The following WARNING applies to all battery cabinets supplied with UPS systems: WARNING HAZARD INTERNAL BATTERY STRAPPING MUST BE VERIFIED BY MANUFACTURER PRIOR TO MOVING A BATTERY CABINET. 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.
Table of Contents 1.0 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.0 INSTALLATION CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.1 Types of System Control Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3.0 UNLOADING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . .
List of Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 Figure 45 Figure 46 Figure 47 UPS Multi-Module Unit Block Diagra
Figure 48 Figure 49 Figure 50 Figure 51 Figure 52 Figure 53 Figure 54 Figure 55 Figure 56 Figure 57 Figure 58 iv Option Wiring, Battery Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Option Wiring, SNMP Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Interconnections, Module 1/SCC, Cable Groups 21 and 22 . . . . . . . . . . . . . . . . . . .
IMPORTANT SAFETY INSTRUCTIONS Save These Instructions. This manual contains important instructions that should be followed during installation of your Series 600T UPS and batteries. ! WARNING EXERCISE EXTREME CARE WHEN HANDLING UPS CABINETS TO AVOID EQUIPMENT DAMAGE OR INJURY TO PERSONNEL. THE UPS MODULE WEIGHT RANGES UP TO 12,000 POUNDS (5,455 KG), INCLUDING INPUT TRANSFORMER. THE BATTERY CABINETS WEIGH BETWEEN 3000 POUNDS (1364 KG) AND 4900 POUNDS (2227 KG).
! WARNING LOCATE CENTER OF GRAVITY SYMBOLS AND DETERMINE UNIT WEIGHT BEFORE HANDLING CABINET. If you require assistance for any reason, call the toll-free Liebert Global Services number; 1-800543-2378.
1.0 SAFETY PRECAUTIONS Read this manual thoroughly, paying special attention to the sections that apply to you, before working with the UPS. Retain this manual for use by installing personnel. 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 from puddles of water, excess moisture, or debris.
2.0 INSTALLATION CONSIDERATIONS Install your Series 600T 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 1-800-543-2378 to arrange for system start-up.
Figure 1 UPS Multi-Module Unit Block Diagram Installation Considerations 5
Figure 2 System Control Cabinets SCCT Dimensions Amp WxD Weight Ratings (Inches) (lbs.) 200-1200 37x37 1000 1600 62x48 1525 2000-2500 62x48 2850 3000 62x48 3100 4000 138x60 5850 2.1 Types of System Control Cabinets 1. SCCT is a stand-alone cabinet containing system control logic for up to six UPS modules, static bypass switch, manually operated disconnects for the static bypass switch, and two motor-operated system breakers.
3.0 UNLOADING AND HANDLING The UPS module is shipped in one cabinet to allow easy handling at the site. Because the weight distribution in the cabinet is uneven, use extreme care during handling and transport. Your installation may also include Battery Cabinets and a System Control Cabinet. ! WARNING EXERCISE EXTREME CARE WHEN HANDLING UPS CABINETS TO AVOID EQUIPMENT DAMAGE OR INJURY TO PERSONNEL. THE UPS MODULE WEIGHS UP TO 12,000 POUNDS. BATTERY CABINETS WEIGH BETWEEN 3100 AND 4900 POUNDS.
4.0 INSPECTIONS 4.1 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 1-800-543-2378 to inform them of the damage claim and the condition of the equipment. 2.
5.0 EQUIPMENT LOCATION 1. Handle cabinet(s) in accordance with the Section 1.0 Safety Precautions and 3.0 Unloading & Handling. 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.
6.0 BATTERY INSTALLATION 6.1 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. 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.
Battery Safety Precautions in French Per CSA Requirements Instructions Importantes Concernant La Sécurité Conserver Ces Instructions ! ADVERTISSEMENT DES PIECES SOUS ALIMENTATION SERONT LAISSEES SANS PROTECTION DURANT CES PROCEDURES D’ENTRETIEN. UN PERSONNEL QUALIFIE EST REQUIS POUR EFFECTUER CES TRAVAUX. LES FUSIBLES A C.C. DE LA BATTERIE D’ACCUMULATEURS OPERENT EN TOUT TEMPS A LA TENSION NOMINALE. LA PRESENCE D’UN FUSIBLE A C.C. BRULE INDIQUE UN PROBLEME SERIEUX.
Les accumulateurs plomb-acide présentent un risque d’incendie parce qu’ils génèrent des gaz à l’hydrogène. Les procédures suivantes devront être respectées. 1. NE PAS FUMER lorsque près des accumulateurs. 2. NE PAS produire de flammes ou d’étincelles près des accumulateurs. 3. Décharger toute électricité statique présente sur votre corps avant de toucher un accumulateur en touchant d’abord une surface métallique mise à la terre.
6.2 Matching Battery Cabinets Two sizes of optional battery cabinets are available. Refer to Figure 16 to Figure 18. 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 3000 to 4900 pounds.
7.0 CONFIGURING YOUR NEUTRAL AND GROUND CONNECTIONS Improper grounding is the largest single cause of UPS installation and start-up problems. This is not an easy subject, since grounding techniques vary significantly from site to site, depending on several factors. The questions you should ask are: • What is the configuration of the input power source? Most of the recommended schemes for UPS grounding require grounded-wye service.
7.1 Preferred Grounding Configuration, 480 or 600 VAC Input and Output, Isolated Power Distribution Units, Wye-Connected Service Figure 3 Preferred Grounding Configuration, 480 or 600 VAC Input and Output The most-common configuration of Series 600T UPS Multi-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.
7.2 Grounding Configuration, 480 or 600 VAC Input and Output, Delta Source Figure 4 Grounding Configuration with Ungrounded Delta Source Input As previously mentioned, Series 600T UPS systems require a bypass input netrual for sensing and monitoring. With a wye-connected input source, the installer should always connect the building service neutral to the System Control Cabinet (SCC) output neutral to achieve this.
7.3 Preferred Grounding Configuration with Power-Tie Switchgear Figure 5 Preferred Grounding Configuration, Power-Tie Systems Multi-Module Systems can be used with Power-Tie switchgear to provide dual critical load busses. The Power-Tie switchgear permits transferring critical loads from one critical bus to the other so that one UPS system and associated breakers can be de-energized for maintenance.
7.4 Grounding Configurations, Battery Systems Figure 6 Battery Cabinet Grounding Configuration Large, open-rack battery systems are normally either locally grounded or left ungrounded, depending on local code requirements. Battery cabinet systems, on the other hand, should be grounded to the UPS module ground bus. The figure above illustrates how a simple one-cabinet system would be grounded. For systems with multiple cabinets, the same configuration would apply.
8.0 WIRING CONSIDERATIONS ! WARNING ALL POWER CONNECTIONS MUST BE COMPLETED BY A LICENSED ELECTRICIAN THAT IS 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.
8.1 Power Wiring 1. Power wiring must be run in individual, separate conduits or cable trays. Refer to the Outline and Terminal Details drawings (Figure 8 to Figure 15 and Figure 29 to Figure 32) for locations of the various power connections within the UPS and SCC. 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.
8.2 Control Wiring Control wiring must be stranded and tinned 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. Refer to the Control Connection Locations and Control Wire Lists, Figure 33 through Figure 52. Notice that there are nine cable groups in a typical system: • Cable group 1 carries signals for the Module Battery Disconnect.
8.3 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. Liebert Battery Cabinets include power and control cables to join multiple cabinets together into a system.
Figure 7 Typical Multi-Module Configurations RIB UPS RIB #3 UPS CB1 RIB #2 UPS CB1 BFB #1 CB1 SBS BIB R R I I I I I I CB2 R CB2 SBB MBB System Controls CB2 SKRU Output MIB SCCT To Critical Load MBD MBD MBD Battery Battery (can accomodate up to 6 UPS modules) Battery RIB UPS SCCT RIB #3 UPS CB1 RIB #2 CB1 UPS BFB #1 CB1 SBS R R R I I I CB2 CB2 CB2 BIB SBB MBB System Controls SKRU Output MIB SCCB To Critical Load MBD MBD MBD SCCB Battery Ba
Figure 7 Typical Multi-Module Configurations (continued) RIB UPS RIB #3 UPS CB1 BIB RIB UPS #2 CB1 MBB #1 CB1 SBS R R R I I I CB2 CB2 SBB System Controls CB2 Output MIB SCCI To Critical Load MBD MBD MBD SCCI / SCCC Battery Battery Battery (can accomodate up to 6 UPS modules) RIB UPS RIB #2 CB1 UPS BFB #1 CB1 SBS R R I I CB2 CB2 BIB SBB MBB System Controls SKRU Output MIB SCCP To Critical Load MBD MBD SCCP Battery 24 Wiring Considerations Battery (c
9.0 WIRING CONNECTIONS ! DANGER 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.
5. The UPS System Output Neutral is connected to one common point and solidly grounded per requirements of the National Electrical Code. The ground connection inside the UPS SCC cabinet may be required by the power wiring configuration at your site. ! CAUTION UPS bypass and system output neutral must be connected to only one common point in the UPS system. This neutral line must be grounded at the source. 6.
10.0 WIRING INSPECTION 1. Verify all power connections are tight. 2. Verify all control wire terminations are tight. 3. Verify all power wires and connections have proper spacing between exposed surfaces, phaseto-phase and phase-to-ground. 4. Verify that all control wires are run in individual, separate, steel conduit.
Table 3 Table 310-16 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° (86°F) Size Temperature Rating of Conductor. See Table 310-13.
11.
Figure 9 30 Outline Drawing, 500 kVA Multi-Module UPS, 12-Pulse Rectifier Installation Drawings
Figure 10 Outline Drawing, 625-750 kVA Multi-Module UPS, 6-Pulse Rectifier Installation Drawings 31
Figure 11 Outline Drawing, 625-750 kVA Multi-Module UPS, 12-Pulse Rectifier 32 Installation Drawings
Figure 12 Outline Drawing, System Control Cabinet (SCCT), 200-1200 Amps Installation Drawings 33
Figure 13 Outline Drawing, System Control Cabinet (SCCT), 1600-2500 Amps 34 Installation Drawings
Figure 14 Outline Drawing, System Control Cabinet (SCCT), 3000 Amps Installation Drawings 35
Figure 15 Outline Drawing, System Control Cabinet (SCCT) 4000 Amps 36 Installation Drawings
Figure 16 Battery Power Pack, Size A Installation Drawings 37
Figure 17 Battery Power Pack, Size B 38 Installation Drawings
Figure 18 Battery Power Pack, Three-Pack System Installation Drawings 39
Figure 19 Base Mounting Patterns, 500 kVA Module, 12-Pulse Rectifier 40 Installation Drawings
Figure 20 Base Mounting Patterns, 625-750 kVA Module, 6-Pulse Installation Drawings 41
Figure 21 Base Mounting Patterns, 625-750 kVA Module, 12-Pulse Rectifier 42 Installation Drawings
Figure 22 Base Mounting Patterns, System Control Cabinets (SCCT) 200-1200 Amps Installation Drawings 43
Figure 23 Base Mounting Patterns, System Control Cabinet (SCCT), 1600-2500 Amps 44 Installation Drawings
Figure 24 Base Mounting Patterns (SCCT), 3000 Amps Installation Drawings 45
Figure 25 Base Mounting Patterns (SCCT), 4000 Amps 46 Installation Drawings
Figure 26 Shipping Split Detail, 500 kVA Multi-Module UPS, 12-Pulse Rectifier Installation Drawings 47
Figure 27 Shipping Split Detail, 625-750 kVA Multi-Module UPS, 6-Pulse Rectifier 48 Installation Drawings
Figure 28 Shipping Split Detail, 625-750 kVA Multi-Module UPS, 12-Pulse Rectifier Installation Drawings 49
Figure 29 Terminal Details, 500 kVA Module, 6-Pulse Rectifier 50 Installation Drawings
Figure 30 Terminal Details, 500 kVA Module, 12-Pulse Rectifier Installation Drawings 51
Figure 31 Terminal Details, 625 & 750 kVA Modules, 6-Pulse and 12-Pulse 52 Installation Drawings
Figure 32 Terminal Details, 750 kVA/675 kW Std.
Figure 33 Control Wiring, External Interconnections, Standard UPS Module 54 Installation Drawings
Figure 34 Control Connection Location, 500 kVA Modules Installation Drawings 55
Figure 35 Control Connection Location Diagram, 625 & 750 kVA Modules 56 Installation Drawings
Figure 36 Control Connection Location Diagram, SCCC & SCCI Installation Drawings 57
Figure 37 Control Connection Location Diagram, SCCT 58 Installation Drawings
Figure 38 Control Wire List, External Interconnections, Standard UPS Module Installation Drawings 59
Figure 39 Control Wire List, External Interconnections, System Control Cabinet, Part 1 of 3 60 Installation Drawings
Figure 40 Control Wire List, External Interconnections, Standard System Control Cabinet, Part 2 of 3 Installation Drawings 61
Figure 41 Control Wire List, External Interconnections, Standard System Control Cabinet, Part 3 of 3 62 Installation Drawings
Figure 42 Control Wire List, External Interconnections, Alarm Status Contacts Installation Drawings 63
Figure 43 Option Wiring, Maintenance Bypass Interlock 64 Installation Drawings
Figure 44 Option Wiring, Remote Status Panel Interface Installation Drawings 65
Figure 45 Option Wiring, Internal Modem 66 Installation Drawings
Figure 46 Option Wiring, Customer Alarm Interface, SCC with Momentary-Duty Static Switch Installation Drawings 67
Figure 47 Option Wiring, Customer Alarm Interface, SCC with Continuous-Duty Static Switch 68 Installation Drawings
Figure 48 Option Wiring, Battery Temperature Sensor Installation Drawings 69
Figure 49 Option Wiring, SNMP Interface 70 Installation Drawings
Figure 50 External Interconnections, Module 1/SCC, Cable Groups 21 and 22 Installation Drawings 71
Figure 51 External Interconnections, Module 2/SCC, Cable Groups 21 and 22 72 Installation Drawings
Figure 52 Wiring Configurations, UPS Video Display Terminal Installation Drawings 73
Figure 53 Module Battery Disconnect, 600-1200 Amps, without Input Isolation Transformer 74 Installation Drawings
Figure 54 Module Battery Disconnect, 300-1200 Amps, with Input Isolation Transformer Installation Drawings 75
Figure 55 Remote Status Panel, Surface Mount 76 Installation Drawings
Figure 56 Circuit Breaker Schedule, Multi-Module UPS, 300-750 kVA Installation Drawings 77
Figure 57 Circuit Breaker Schedule, Merlin-Gerin Breakers, SCCT, 200-4000 Amps 78 Installation Drawings
Figure 58 Circuit Breaker Schedule, General Electric Breakers, SCCT, 200-4000 Amps Installation Drawings 79
12.0 APPENDIX A - SITE PLANNING DATA 500-750kVA Multi-Module Systems 12.1 Notes 1. Nominal rectifier AC input current (considered continuous) is based on full rated output load. Maximum current includes nominal input current and maximum battery recharge current (considered noncontinuous). Continuous and noncontinuous current limit are defined in NEC 100. Maximum input current is controlled by current limit setting which is adjustable. Values shown are for maximum setting of 125%.
Table 4 Series 600T Multi-Module Systems, 500-750 kVA - 480 Volt Input Rectifier AC Input Current UPS Rating AC Output Voltage 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 — Inverter Required Maximum or Battery Battery Maximum Bypass DisconCurrent Heat DisAC Output nect at End of sipation Current Rating Discharge BTU/hr.
Table 5 UPS Rating Series 600T Multi-Module Systems, 500-750 kVA - 600 Volt Input Rectifier AC Input Current Inverter Required Maximum Maximum or Battery Battery Heat DisBypass DisconCurrent AC Output nect at End of sipation Current Rating Discharge BTU/hr.
13.0 APPENDIX B - FIELD SUPPLIED LUGS Table 6 One-Hole Lugs 1 Wire Size Bolt Size (Inches) Tongue Width (Inches) T & B1 P/N Liebert P/N 1/0 AWG 3/8 0.88 J973 12-714255-56 2 2/0 AWG 3/8 1.00 K973 12-714255-66 3 3/0 AWG 3/8 1.10 L973 12-714255-76 4 4/0 AWG 3/8 1.20 M973 12-714255-86 1/0 AWG 3/8 0.93 60130 — 2/0 AWG 3/8 0.97 60136 — T&B Lug Style 1 5 6 Stak-On Color-Keyed Aluminum/ Copper 7 3/0 AWG 3/8 1.06 60142 — 1/0 AWG 3/8 0.
84 Appendix B - Field Supplied Lugs
Series 600T™ UPS Multi-Module Three Phase 500 kVA to 750kVA; 60 Hz Technical Support U.S.A. Outside the U.S.A. U.K. 1-800-222-5877 614-841-6755 +44 (0) 1793 553355 France +33 1 4 87 51 52 Germany +49 89 99 19 220 Italy Netherlands E-mail Web site Worldwide FAX tech support +39 2 98250 1 +00 31 475 503333 upstech@liebert.com http://www.liebert.
