GE Consumer & Industrial TLE Series 160, Installation Manual

Page 1: ...pply GE Consumer Industrial SA General Electric Company CH 6595 Riazzino Locarno Switzerland T 41 0 91 850 51 51 F 41 0 91 850 52 52 www gecriticalpower com imagination at work TLES_UL_160 500_S2b_UPS_GE_01 TLE Series 160 200 225 250 TLE Series 300 350 400 500 ...

Page 2: ...Up dating Revision Concern Date COPYRIGHT 2018 by GE Consumer Industrial SA All rights reserved The information contained in this publication is intended solely for the purposes indicated The present publication and any other documentation supplied with the UPS system is not to be reproduced either in part or in its entirety without the prior written consent of GE The illustrations and plans descr...

Page 3: ...he installation of the UPS Thank you for choosing GE START UP AND COMMISSIONING A GE GLOBAL SERVICES FIELD ENGINEER must perform start up and commissioning of the UPS Please Contact GE GLOBAL SERVICES at least two weeks prior to schedule start up and commissioning at 1 800 637 1738 or by E mail at pqservice ge com Distributed in the USA by Your Service Center g GE Consumer Industrial SA General El...

Page 4: ...contained in this document WARNING TLE Series 160 500 is a Category C3 UPS Product according to IEC 62040 2 This is a product for commercial and industrial application in the second environment installation restrictions or additional measures may be needed to prevent disturbances We recommend that this manual be kept next to the UPS for future references If any problems are encountered with the pr...

Page 5: ... 225 250 Power connection with Common Input Utility 35 4 8 2 TLE Series 160 200 225 250 Power connection with Dual Input Utility 37 4 8 3 TLE Series 300 400 500 Power connection with Common Input Utility 40 4 8 4 TLE Series 300 400 500 Power connection with Dual Input Utility 42 4 8 5 Use of TLE Series 160 500 in eBoost Operation Mode 45 4 8 6 Use of TLE Series 160 500 as frequency converter 46 4 ...

Page 6: ...urately during Commissioning and Maintenance of the UPS for the following Damaged components squeezed wires and cables or not correctly inserted plugs After removing the sidewalls of the UPS make sure that all earth connections when reassembling are correctly reattached This UPS is intended for use in a controlled indoor environment free of conductive contaminants and protected against animals int...

Page 7: ...ool to short between individual or separate battery terminals or to the cabinet or rack Do not lay tools or metal parts on top of the battery and do not lay them where they could fall onto the battery or into the cabinet 3 Disconnect charging source prior to connecting or disconnecting battery terminals Install the battery as shown on the drawing provided with the battery When connecting cables ne...

Page 8: ...his manual the following symbols are defined WARNING if instruction is not followed injury or serious equipment damage may occur CAUTION internal parts have dangerous voltage present Risk of electric shock PE Earth GND Ground PROTECTIVE GROUNDING TERMINAL A terminal which must be connected to earth ground prior to making any other connection to the equipment A terminal to which or from which an al...

Page 9: ...Series 160 200 225 250 General view Fig 2 1 3 Control Panel Fig 2 1 4 Connectivity Rack Fig 2 1 2 TLE Series 160 200 225 250 General view with open doors Fig 2 1 5 Q1 UPS Output switch TLES_UL_225 250_S1_UPS_GE_02 TLES_160 400_S1_Custom er interface CI_SNMP_XA_01 SNMP CI 1 2 E P O E P O J35µP XA TLES_UL_225 250_S1_UPS_GE_03 Q1 I ON 0 OFF 1 2 EPO EPO Q1 I ON 0 OFF TLES_UL_225 250_S1_Switch Q1_01 ...

Page 10: ...al Battery connection CI Customer Interface Board see Fig 2 1 4 CR Connectivity Rack J35µP Serial port RS232 for IMV protocol Q1 UPS Output switch RPA RPA board Redundant Parallel Architecture for Parallel System option SNMP 3 ph SNMP WEB plug in adapter option see Fig 2 1 4 XA Terminals for EPO Emergency Power Off connection and 24Vdc for external battery switch Remove this panel or provide means...

Page 11: ...ies 300 400 500 General view Fig 2 2 3 Control panel Fig 2 2 4 Connectivity Rack Fig 2 2 2 TLE Series 300 400 500 General view with open doors Fig 2 2 5 Q1 UPS Output switch TLES_UL_400 500_S1_UPS_GE_02 TLES_160 400_S1_Custom er interface CI_SNMP_XA_01 SNMP CI 1 2 E P O E P O J35µP XA TLES_UL_400 500_S1_UPS_GE_03a Q1 1 2 I ON 0 OFF EPO EPO TLES_UL_400 500_S1_Switch Q1_01 Q1 I ON 0 OFF ...

Page 12: ... Battery connection CI Customer Interface Board see Fig 2 2 4 CR Connectivity Rack J35µP Serial port RS232 for IMV protocol Q1 UPS Output switch RPA RPA board Redundant Parallel Architecture for Parallel System option SNMP 3 ph SNMP WEB plug in adapter option see Fig 2 2 4 XA Terminals for EPO Emergency Power Off connection and 24Vdc for external battery switch Remove this panel or provide means t...

Page 13: ...id PACKING MATERIAL RECYCLING GE in compliance with environment protection uses only environmentally friendly material UPS packing materials must be recycled in compliance with all applicable regulations RECYCLING AT THE END OF SERVICE LIFE GE in compliance with environment protection recommends to the User that the UPS equipment at the end of its service life must be recovered conforming to the l...

Page 14: ...e unpacked UPS Forklift The UPS may be lifted with a forklift in upright position Take note of the center of gravity marked on the package Crane Fig 4 1 2 Position of the carrying belts when moving the unpacked UPS WARNING Check for sufficient floor and elevator loading capacity Transport UPS only in upright position Do not stack other package on top of the UPS Crane If the UPS has to be lifted by...

Page 15: ... 1120 x 865 x 1905 mm Weight 1345 lbs 610 kg Floor loading 129 lbs sq ft 630 kg m2 Dimensions and weights TLE Series 300 400 500 Dimensions W x D x H 63 78 x 34 06 x 75 00 inches 1620 x 865 x 1905 mm Weight 2756 lbs 1280 kg Floor loading 187 lbs sq ft 914 kg m2 NOTE The weight of each single piece is marked outside the package 34 06 865mm 44 10 1120 mm 75 00 1905mm TLES_UL_225 250_S1_UPS dimension...

Page 16: ... and with a temperature range not exceeding 13 F 25 C to 131 F 55 C In case the battery is included please refer to Section 4 3 2 Some important functions of the UPS such as the customized functions are defined by parameters stored in a RAM memory A small backup Battery located on the Control Unit board supplies the RAM If the storage time of the UPS exceeds 1 year these functions should be verifi...

Page 17: ...explained in Section 9 1 4 of the User Manual read and understand them The TLE Series 160 500 UPS can radiate radio frequency energy Although some RFI Radio Frequency Interference filtering is inherent to the UPS there is no guarantee that the UPS will not influence sensitive devices such as cameras and monitors that are positioned close by If interference is expected the UPS should be moved away ...

Page 18: ...nd the bottom of the UPS for the connection of input and output cables Pay attention to the position of these openings when choosing the placement of the UPS These openings are covered with a protective plate Please remove the plate before drilling any holes Utility input Output load Battery 9 85 250 mm 44 10 1120 mm 0 99 25 mm TLES_UL_225 250_S1_UPS view top_01US FRONTAL SIDE 1 25 mm 29 53 750 mm...

Page 19: ...he floor Fig 4 4 1 6 Fixing of the UPS cabinet on the floor Fig 4 4 1 7 TLE Series 160 220 225 250 UPS cabinet floor fixing points Fig 4 4 1 8 TLE Series 300 400 500 UPS cabinet floor fixing points TLES_UL_225 500_S2_UPS fixing_01 2 13 54 mm 2 37 60 mm 44 10 1120 mm 27 56 700 mm 14 18 360mm Ø 0 5 3 1 3 5 m m TLES_UL_225 250_S1_UPS fixing_01 FRONTAL SIDE 29 53 750 mm 34 06 865 mm 2 37 60 mm TLES_UL...

Page 20: ...ange 4 F 20 C to 104 F 40 C The life of valve regulated batteries will be reduced by 50 for each additional 18 F 10 C that the battery ambient temperature is above 77 F 25 C The Battery System associated with larger UPS is usually either rack mounted or installed in multiple Battery Cabinets Installation and assembly must be made according to the local standards and Battery System manufacturer s r...

Page 21: ...w rate requirement of the UPS system Contact your GE Service Center for appropriate solutions The below table indicates the heat dissipation at full Load at PF 1 and charged Battery up to 3280 ft 1000 m altitude for cooling air 77 F 25 C to 86 F 30 C UPS model Losses Cooling air flow VFI eBoost option VFI PF 1 PF 1 PF 1 TLE Series 160 20137 BTU hr 5 9 kW 6826 BTU hr 2 0 kW 1013 CFM 1721 m3 h TLE S...

Page 22: ...r GE Service Center Fig 4 6 1 ShockWatch device Fig 4 6 2 TiltWatch device NOTE Be aware of the heavy weight of the UPS pay attention when moving the UPS cabinet Take care not to damage the UPS when moving by forklift A damaged UPS must never be installed or connected to Utility or Battery In case of any damage sustained during the transport immediately inform the shipping agent A detailed report ...

Page 23: ...Center Fig 4 6 4 TLE Series 300 400 500 Location of the Anti Humidity Corrosion devices TLE Series 300 400 500 a Humidity indicator b Desiccant bag 8 pcs c VCI foil base d PE stretch foil PROTECTIVE FOIL Fig 4 6 5 Location of the Protective Foil TLE Series 160 500 is provided with a Protective Foil on the roof and door front panels to prevent material from falling into UPS WARNING It s MANDATORY T...

Page 24: ... Common Input source or Dual Input sources if desired Common Input Utility Rectifier Bypass Fig 4 7 1 1 Common Input Utility Rectifier Bypass The same power source is to be used for both Bypass Supply and Rectifier Input input F3 Bear in mind that when the Utility fuses are opened there is a supply failure to the Rectifier as well as to the Automatic Bypass In this case the interconnection links B...

Page 25: ...nnected and grounded solidly due to the existence of voltage surge protection devices inside the UPS The connection of the Battery to the UPS must be protected with fuses or similar devices according to technical specifications and in accordance with local standards NOTE If you use ELCB breaker Earth Limiting Circuit Breaker to protect the input connections consider the high leakage current genera...

Page 26: ... chart below Minimum battery cable requirement is based on the current data below The maximum available fault current from the battery supply is 20kA The minimum breaker voltage rating is 540V The AC values below are current ratings per phase These maximum and nominal ratings should be considered when choosing the appropriate AC over current protection device NEC National Electric Code Section 210...

Page 27: ...E Series 400 700 A 600 A 600 A 500 A 700 A 600 A 1000 A 1000 A TLE Series 500 900 A 700 A 800 A 700 A 900 A 700 A 1200 A 1200 A WIRING Wire sizing according to NEC Section 210 20 A Table 310 16 Use 167 F 75 C copper or aluminum wire Wiring requirements AC INPUT RECTIFIER 3 Phase 4 wire plus Ground AC INPUT BYPASS 3 Phase 4 wire plus Ground AC OUTPUT 3 Phase 4 wire plus Ground DC INPUT 2 wire posit...

Page 28: ... 6 55 65 75 40 50 60 4 70 85 95 55 65 75 3 85 100 110 65 75 85 2 95 115 130 75 90 100 1 110 130 150 85 100 115 1 0 125 150 170 100 120 135 2 0 145 175 195 115 135 150 3 0 165 200 225 130 155 175 4 0 195 230 260 150 180 205 250 215 255 290 170 205 230 300 240 285 320 190 230 255 350 260 310 350 210 250 280 400 280 335 380 225 270 305 500 320 380 430 260 310 350 600 355 420 475 285 340 385 700 385 4...

Page 29: ...s 160 500 Single UPS with Common Input Utility for Rectifier Bypass Single UPS with Common Input Utility for Rectifier Bypass 3 wire distribution 3 phase plus ground Single UPS with Dual Input Utility for Rectifier Bypass Connect a single input Neutral to Bypass Utility inside the UPS common Neutral for Bypass and Rectifier Single UPS with Dual Input Utility for Rectifier Bypass 3 wire distributio...

Page 30: ...GE_UPS_ISG_TLE_SUL_M16_M50_2bU_V010 docx Installation Guide TLE Series 160 500 UL S2B UPS Parallel System with Common Input Utility Rectifier Bypass UPS Parallel System with Common Input Utility Rectifier Bypass 3 wire distribution 3 phase plus ground ...

Page 31: ...Guide TLE Series 160 500 UL S2B UPS Parallel System with Dual Input Utility for Rectifier Bypass Connect a single input Neutral to Bypass Utility inside the UPS common Neutral for Bypass and Rectifier UPS Parallel System with Dual Input Utility for Rectifier Bypass 3 wire distribution 3 phase plus ground ...

Page 32: ...sk of short circuit between different poles The grounding and neutral connection of the electrical system must be in accordance with local regulations In case of additional cabinets containing batteries input output transformers etc their ground terminals must be connected to the UPS main ground terminal Once the power cables have been connected re install the internal safety shields and close the...

Page 33: ...e plate C NOTE For UPS correct operation the input utility phase rotation must be clock wise CAUTION Panel A B and C should never be removed or replaced with power applied to the UPS These panels are in close proximity to 480V live buss bars Always disconnect the rectifier bypass load and battery sources from the UPS before removing or replacing these panels If not serious injury or death could oc...

Page 34: ...1US a Utility mains Battery Output load Position of the cover protection for cables input from the bottom of the UPS PE L3 1 L2 1 L1 1 N Utility Neutral Load Neutral Load 1 Rectifier Bypass Utility BR2 BR3 BR1 PE PE Input Utility PE Load Use for top entry cables L3 L2 L1 PE PE Input Utility PE Load Attention Use only as additional PE Q1 TLES_UL_400 500_S1_UPS connection_Bottom_01US a Position of t...

Page 35: ... The interconnection links BR1 BR2 and BR3 on the input bus bars MUST REMAIN CONNECTED Output Load L1 Load phase A L1 L2 Load phase B L2 L3 Load phase L3 N Neutral Ground External Battery connection Positive pole of the battery Before closing the External Battery Fuses verify for correct polarity of the battery connection Negative pole of the battery PE Battery cabinet ground NOTE To meet standard...

Page 36: ...net must contain a Neutral Bus as per the following Figure 4 8 1 2 If no Neutral Connection is available with the Bypass Input 3 wire input ground and the Load does not require a Neutral solidly connect the Output Neutral of the UPS to ground in the Output Distribution Cabinet Wire Neutral Conductors from the UPS to the output distribution cabinet common point of connection and solidly connect to ...

Page 37: ...C L3 L3 2 Bypass phase C L3 PE Ground N Neutral NOTE The interconnection links BR1 BR2 and BR3 on the input bus bars MUST BE REMOVED see Fig 4 8 2 3 Output Load L1 Load phase A L1 L2 Load phase B L2 L3 Load phase L3 N Neutral Ground External Battery connection Positive pole of the battery Before closing the External Battery Fuses verify for correct polarity of the battery connection Negative pole ...

Page 38: ...net must contain a Neutral Bus as per the following Figure 4 8 2 2 If no Neutral Connection is available with the Bypass Input 3 wire input ground and the Load does not require a Neutral solidly connect the Output Neutral of the UPS to ground in the Output Distribution Cabinet Wire Neutral Conductors from the UPS to the output distribution cabinet common point of connection and solidly connect to ...

Page 39: ...ility Fig 4 8 2 3 TLE Series 300 400 500 Interconnection links BR1 BR2 and BR3 NOTE For separate Bypass and Rectifier input configuration the interconnection links BR1 BR2 and BR3 MUST BE REMOVED see Fig 4 8 2 3 Q1 TLES_UL_225 250_S1_UPS BR1 2 3_01US a Q1 I ON 0 OFF 1 2 EPO EPO 36 BR1 3x20x1mm L 220mm 36 37 BR2 3x20x1mm L 220mm 37 38 BR3 3x20x1mm L 220mm 38 BR1 BR3 BR1 BR2 and BR3 MUST BE REMOVED ...

Page 40: ...d phase L3 N Neutral Ground External Battery connection Positive pole of the battery Before closing the External Battery Fuses verify for correct polarity of the battery connection Negative pole of the battery PE Battery cabinet ground NOTE To meet standards concerning electromagnetic compliance the connection between the UPS and external Battery must be done by using a shielded cable or suitable ...

Page 41: ...net must contain a Neutral Bus as per the following Figure 4 8 3 2 If no Neutral Connection is available with the Bypass Input 3 wire input ground and the Load does not require a Neutral solidly connect the Output Neutral of the UPS to ground in the Output Distribution Cabinet Wire Neutral Conductors from the UPS to the output distribution cabinet common point of connection and solidly connect to ...

Page 42: ...ig 4 8 4 3 Output Load L1 Load phase A L1 L2 Load phase B L2 L3 Load phase L3 N Neutral Ground External Battery connection Positive pole of the battery Before closing the External Battery Fuses verify for correct polarity of the battery connection Negative pole of the battery PE Battery cabinet ground NOTE To meet standards concerning electromagnetic compliance the connection between the UPS and e...

Page 43: ...net must contain a Neutral Bus as per the following Figure 4 8 4 2 If no Neutral Connection is available with the Bypass Input 3 wire input ground and the Load does not require a Neutral solidly connect the Output Neutral of the UPS to ground in the Output Distribution Cabinet Wire Neutral Conductors from the UPS to the output distribution cabinet common point of connection and solidly connect to ...

Page 44: ...nks BR1 BR2 and BR3 NOTE For separate Bypass and Rectifier input configuration the interconnection links BR1 BR2 and BR3 MUST BE REMOVED see Fig 4 8 4 3 PE L3 1 L1 2 L2 2 with bottom cable entry PE N Utility Neutral Load Neutral L3 2 Load 2 Bypass Utility 1 Rectifier Utility PE PE with top cable entry L3 L2 L1 Q1 TLES_UL_400 500_S1_UPS BR1 2 3_01US a L2 1 L1 1 BR1 BR2 and BR3 MUST BE REMOVED BR1 B...

Page 45: ...stic As the inverter output filter exhibits a predominantly capacitive characteristic it may provide some degree of reactive power compensation when combined with lagging power factor loads Conversely depending on the load type and level the UPS input characteristic may exhibit a leading power factor in eBoostTM Operation Mode Please contact your GE Service Center for more information NOTE If an e...

Page 46: ... 8 6 2 TLE Series 300 400 500 Interconnection links BR1 BR2 and BR3 In order to avoid improper operation only the Rectifier input should be powered L1 1 L2 1 and L3 1 Fig 4 8 2 1 4 8 4 1 therefore the interconnection links BR1 BR2 and BR3 on the input bus bars MUST BE REMOVED See pictures above and Fig 4 8 2 3 and 4 8 4 3 Special care must be taken in choosing the fuse ratings installed in the out...

Page 47: ... the same for all units of the Parallel System no phase shift allowed between units NOTE It is strongly recommended that no transformers automatic circuit breakers or fuses should be inserted between the unit s output and the Load common bus bars However it is recommended that a disconnection or isolation switch is installed in order to totally isolate a unit if needed Verify that power wiring and...

Page 48: ...es In this way communication is maintained between units in case one of the control cables should fail or be accidentally damaged or disconnected The standard length of the control bus cable between two parallel units is 40 ft 12m The maximal overall length of bus connection between the first and the last unit should not exceed 295 ft 90m Verify that control wiring run in an individual separate st...

Page 49: ...f a Parallel System the switches SW1 1 2 3 4 5 6 MUST BE IN POSITION ON see Fig 4 9 2 2 Fig 4 9 2 3 Bus connection on intermediate units Intermediate units of a RPA Parallel System On the two boards P13 P14 IM0022 Bus Interface Board of the intermediate units of a Parallel System the switches SW1 1 2 3 4 5 6 MUST BE IN POSITION OFF see Fig 4 9 2 3 J2 J1 J2 J1 B A J1A 1 J1B 1 1 2 3 SW1 4 5 6 O N TL...

Page 50: ...it Access to the control bus connection The communication bus cable connectors are placed on the two boards P13 P14 IM0022 Bus Interface Board see Fig 4 9 3 1 and 4 9 3 2 Fig 4 9 3 3 View electronic module on intermediate unit Control bus cables connection Plug the cables J1A J2A 1 2 3 4 5 and J1B J2B 1 2 3 4 5 on the connectors J1A J2A and J1B J2B placed on the two boards P13 P14 IM0022 Bus Inter...

Page 51: ...13 P14 IM0022 Bus Interface Board For reliability reasons the cables J1A J2A 1 2 3 4 5 and J1B J2B 1 2 3 4 5 connecting the units should be run in separated protected conduits as indicated in Fig 4 9 3 4 and 4 9 3 5 separated from the power cables It is important that the cable J1A J2A 1 2 3 4 5 must be the same length as cable J1B J2B 1 2 3 4 5 WARNING Connection and commissioning of an additiona...

Page 52: ...inal block for EPO Emergency Power Off command connection When opened this contact causes the immediate opening of the Contactors K6 and K7 as well as the shut down of Rectifier Inverter and Static Switch NOTE This procedure could imply a Load shut down Keep SELV cables separated from HIGH VOLTAGE cables In a Parallel System a separate NC Normally Closed contact must be connected individually to e...

Page 53: ...en the EPO Emergency Power Off has been activated the system must be restored as follows Realize the push button EPO Emergency Power Off contact on XA EPO 1 EPO 2 is closed again Perform the Inverter OFF command from the screen Commands 1 Inverter OFF see User Manual to Section 6 5 In case of a Parallel System perform the Inverter OFF command from the screen Commands 1 Inverter OFF of each unit co...

Page 54: ... Customer Interface boards for each UPS max 2 3 ph SNMP WEB Plug in Adapter boards for Parallel System ATTENTION The installation of any option board must be performed by a GE Service Technician Prior to the installation connection and cabling of any option board the UPS must be COMPLETELY POWERED DOWN and all the power sources that will be connected to the option board must be DE ENERGIZED Option...

Page 55: ... select printing of measurements alarms and parameters see User Manual to Section 6 4 SETUP PRINTER Fig 5 1 2 Serial port J35µP connection to PC with RS232 1 1 cable DB9m DB9f The serial port J35µP RS232 is enabled on all the units of the RPA Parallel System Fig 5 1 3 Connector J1 RJ45 8P8C NOTE The serial port J35µP RS232 is enabled also in case the J1 RJ45 connector of the P4 Customer Interface ...

Page 56: ...rmally Open C Common NC Normally Closed Output signals on voltage free contacts Programmable functions on input contacts On terminals X1 6 of the following 27 signals can be selected from the display entering with the appropriate password Some UPS functions can be activated with parameters when an external Normally Open NO contact is closed on X1 10 21 or X1 11 22 Selectable functions by changing ...

Page 57: ...ault is the following X1 1 2 3 NO C NC UTILITY FAILURE def Parameter RL 1 X1 4 5 6 NO C NC LOAD ON INVERTER def Parameter RL 3 X1 7 8 9 NO C NC STOP OPERATION def Parameter RL 5 X1 12 13 14 NO C NC LOAD ON UTILITY def Parameter RL 2 X1 15 16 17 NO C NC GENERAL ALARM def Parameter RL 4 X1 18 19 20 NO C NC BUZZER ACOUSTIC ALARM def Parameter RL 6 In case different alarms or operating status are requ...

Page 58: ...siderably unstable in frequency it should be suitable to install the signal GENERATOR ON on X1 11 22 See Fig 5 2 1 X1 Since the Parameter for of the reading of the Generator function is password protected contact your GE Service Center for it s activation When this contact closes it changes certain programmable functions such as Enabling or disabling of synchronization and consequently the Load tr...

Page 59: ... connected to a separate AUX contact of the External Maintenance Bypass Switch 5 2 7 X1 terminal block eBoost IEMi control signal The UPS operation in either eBoost or IEMi operating modes can be controlled via an NO Normally Open contact by installing the eBoost IEMi CONTROL signal routed to the programmable function contacts see Section 5 2 3 When this contact closes eBoost or IEMi operation mod...

Page 60: ...010 docx Installation Guide TLE Series 160 500 UL S2B 6 NOTES 6 1 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 abnormal situations etc Date Description Done by ...