GE SG 500 Series, Installation Manual

Page 1: ...stallation Guide Uninterruptible Power supply SG Series 400 500 400 500 kVA 480Vac UL S2 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 gepowerquality com g imagination at work ...

Page 2: ...ained 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 describing the equipment are intended as general reference only and are not necessarily complete in every detail The cont...

Page 3: ...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 contact g GE Consumer Industrial SA General Electric Company CH 6595 Riazzino Locarno Switzerland www gepowerquality com g GE Digital Energy Power Quality 2501 Pecan ...

Page 4: ...500 is a product that needs to be installed by a licensed and knowledgeable contractor We recommend that this manual be kept next to the UPS for future references If any problems are encountered with the procedures contained in this manual please contact your Service Center before you proceed This document shall not be copied or reproduced without the permission of GE Some of the information conta...

Page 5: ...and External Battery Breaker connection 29 3 8 5 Interface to External Bypass for single unit 30 3 8 6 Connections to External Bypass switch in case of RPA Parallel System 30 3 8 7 Set up for SG Series 400 500 intended to be operated in eBoost Operation Mode 31 3 9 RPA PARALLEL SYSTEM CONNECTION 32 3 9 1 Power wiring of parallel units 32 3 9 2 Parallel control bus connection 33 3 9 3 Control bus c...

Page 6: ...r 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 intrusion WARNING HIGH EARTH LEAKAGE CURRENT Earth connection is essential before connecting to AC input Switching OFF the unit does not isolate the UPS from ...

Page 7: ...battery terminals Do not allow a tool 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 Install the battery as shown on the drawing provided with the battery When connecting cables never allow a cable to short across a battery s te...

Page 8: ... 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 alternating sine wave current or voltage may be applied or supplied A terminal to which or from which a direct current o...

Page 9: ...00 general view with optional 5th harmonic filter and removed protection panels 1 Opening for top cable entry 2 Opening for bottom cable entry 3 Bus bars for Utility input and Load output 4 Bus bars for external Battery connection CR Connectivity Rack Q1 UPS output switch Q2 Manual Bypass switch option XA Terminals for 24Vdc Auxiliary Power Supply connection XB Terminals for EPO connection Remove ...

Page 10: ...te of the center of gravity marked on the package Take all necessary precautions to avoid damage to the cabinet while hoisting the UPS NOTE Check for sufficient floor and elevator loading capacity Fig 3 1 1 UPS cabinets moving 3 1 1 Dimensions and weight Dimensions SG Series 400 500 W x D x H 80 71 x 33 47 x 76 78 inches 2 050 x 850 x 1 950 mm SGSU_400 500_S2_UPS dimensions_GE_01US D H W Fig 3 1 1...

Page 11: ...n 3 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 verified by an authorized Service Center before putting the UPS into operation 3 3 2 Storage of battery When the delivery includ...

Page 12: ...FI 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 from the sensitive equipment A single phase power outlet 120Vac should be provided near the UPS for connection of power tools test equipment or connectivity devices This outlet ...

Page 13: ...47 80mm 3 15 2 050mm 80 71 30mm SGSU_400 500_S2_UPS view bottom_01US Please remove the plate before drilling any holes Fig 3 4 1 3 Opening on the bottom of the cabinet for input and output cables Fixing of the UPS cabinet on the floor The UPS cabinet is free standing and normally does not require to be bolted to the floor The UPS cabinet can be fixed however to the floor by bolting it with the sup...

Page 14: ...ptimal room temperature for Battery storage is 68 F 20 C to 77 F 25 C and shall never exceed the range 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 Installat...

Page 15: ...r Dealer or the nearest Service Center for appropriate solutions In order to prevent overheating of the UPS the available air intake flow rate must exceed the total air exhaust flow rate requirement of the UPS system The below table indicates the heat dissipation at full load at PF 0 9 lag and charged battery up to 3 280 ft 1 000 m altitude for cooling air 77 F 25 C to 86 F 30 C Losses Cooling air...

Page 16: ...indicator for shock and TiltWatch indicator for overthrow on the outside These devices indicate an eventual shock or overthrow during transport Whenever these devices show a possible anomaly the UPS shall not be commissioned before consulting a Service Center Fig 3 6 2 TiltWatch device NOTE Take care not to damage the UPS when moving by forklift A damaged UPS must never be installed or connected t...

Page 17: ... and are indicated with an appropriate symbol on the assembly layout drawing see Fig 3 6 1 For parallel systems the delivery also includes the bus control cables for inter connecting the UPS modules Packing material recycling GE in compliance with environment protection use only environmentally friendly material UPS packing materials must be recycled in compliance with all applicable regulations M...

Page 18: ...y Fuses are opened there is a supply failure to the Rectifier as well as to the Bypass and Manual Bypass In this case the interconnection links BR1 BR2 and BR3 on the input terminals or bus bars MUST REMAIN CONNECTED See Fig 3 8 3 3 Dual Input Configuration Rectifier Bypass option The Bypass and Rectifier inputs are to be powered from different Utility supplies F1 and F2 inputs In this case when t...

Page 19: ...sing four pole circuit breakers as protection A potential problem exists for situations with non linear loads The neutral current could be greater than the phase currents The three phase Utility power supply must be symmetrical with respect to ground due to the existence of voltage surge protection devices inside the UPS NOTE If you use ELCB breaker Earth Limiting Circuit Breaker to protect the in...

Page 20: ...nput Rectifier AC Input Bypass AC Input DC Input F1 F3 UPS rating Max F2 Nom Nom Max F4 SG Series 400 512 A 615 A 481 A 512 A 615 A 702 A SG Series 500 617 A 708 A 600 A 617 A 708 A 960 A Size of Branch Circuit Over Current Protection All Models CAUTION To reduce the risk of fire only connect UPS to a circuit provided with See below maximum amperes branch circuit over current protection in accorda...

Page 21: ... 150 170 100 120 135 2 0 145 175 195 115 135 150 3 0 165 200 225 130 155 175 4 0 195 230 260 150 180 205 250 215 255 290 170 205 230 300 240 285 320 190 230 255 350 260 310 350 210 250 280 400 280 335 380 225 270 305 500 320 380 430 260 310 350 600 355 420 475 285 340 385 700 385 460 520 310 375 420 750 400 475 535 320 385 435 800 410 490 555 330 395 450 900 435 520 585 355 425 480 1000 455 545 61...

Page 22: ...ield wiring connections can be made from the front side by removing the front right side panel protection cover panel E as indicated in Fig 3 8 1 1 be advised that installation performed from the front position will give the installer reduced visibility to the terminal lugs The input output cables must be connected in clockwise phase rotation for both Bypass and Rectifier Input Terminals if separa...

Page 23: ...ove the plate before drilling any holes Detail of the power wiring terminal for the AC input output Detail of the power wiring terminal for external battery connection 2 51mm 0 57 14 5mm 2 51mm 2 51mm 1 02 26mm Ø 0 55 14mm Ø 0 55 14mm 1 75 44 5mm 0 57 14 5mm 31 5 80mm 1 75 44 5mm 0 79 20mm 1 97 50mm 0 98 25mm 0 98 25mm A C B D Top entry cables Dual mains customer connection bars are optional Manua...

Page 24: ...n INPUT OUTPUT power wiring Bus Bars Cable terminations are to the Rectifier Input Output Bus Bars as shown above Connect wire to the Bus Bars using appropriate tools and appropriate torque Torque specification for two hole lugs on Bus Bars see Section 3 8 1 Common Input Rectifier Bypass L1 1 Rectifier Bypass Phase A L2 1 Rectifier Bypass Phase B L3 1 Rectifier Bypass Phase C N Utility Neutral PE ...

Page 25: ... 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 ground with a ground bonding jumper Fig 3 8 2 2 RPA Parallel System Cable size for the ground bonding jumper ...

Page 26: ...t Bus Bars as shown above Connect wire to the Bus Bars using appropriate tools and appropriate torque Torque specification for two hole lugs on Bus Bars see Section 3 8 1 Dual Input Configuration Rectifier Bypass option L1 1 Rectifier Phase A L1 2 Bypass Phase A L2 1 Rectifier Phase B L2 2 Bypass Phase B L3 1 Rectifier Phase C L3 2 Bypass Phase C PE Input Utility Ground N Bypass Bypass Neutral For...

Page 27: ... 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 ground with a ground bonding jumper Fig 3 8 3 2 RPA Parallel System Cable size for the ground bonding jumper ...

Page 28: ... BR2 and BR3 MUST BE REMOVED in case of dual input utility Fig 3 8 3 3 AC bus bars BR1 BR2 and BR3 For separate Bypass and Rectifier input configuration option the AC Bus Bars BR1 BR2 and BR3 MUST BE REMOVED Modifications reserved Page 28 41 OPM_SGS_ISG_M40_M50_2US_V021 doc User Manual SG Series 400 500 UL S2 ...

Page 29: ... connection between the UPS and external Battery must be done by using a shielded cable or suitable shielded steel conduit External Battery Breaker Release Fig 3 8 4 2 External battery breaker connection For connection or disconnection of the Battery an external breaker CB with UVR is required The UVR of the external breaker must be connected to terminal XA see Fig 4 1 7 1 The release signal will ...

Page 30: ... External Bypass for single unit SG Series 400 500 has to be interfaced to the External Bypass Auxiliary Contacts NO for safety reasons This will prevent contactor K7 from closing when the external bypass breaker is on The connections shown in the diagram are mandatory 3 8 6 Connections to External Bypass switch in case of RPA Parallel System In a parallel system this connection must be made betwe...

Page 31: ...ce Center for more information NOTE If an emergency generator set supplies the UPS in case of Mains Failure and the system is intended to be operated in eBoost Operation Mode eBoost operation shall be prevented during generator operation This can be accomplished by either installing a Generator ON signal refer to Section 4 1 4 or an eBoost IEMi control signal refer to Section 4 1 6 Modifications r...

Page 32: ... Center which will help you find cost effective solutions The AC input power of the Bypass must be 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 be inserted between the unit s output and the Load common bus bars However it is recommended that a disconnection or isolation sw...

Page 33: ...h of the control bus cable between two parallel unit is 40 ft 12 m Maximal overall length of bus connection between the first and the last unit should not be longer than 276 ft 84 m Verify that control wiring is run in individual separate steel conduit NOTE Under no circumstance should the control bus cable connecting JA 1 2 3 4 5 and JB 1 2 3 4 5 be connected or disconnected after the system has ...

Page 34: ...S2_RPA IM0048_03 JA2 JB2 JP2 JP1 Fig 3 9 2 3 Bus connection on intermediate units Intermediate units On the parallel bus PCB P34 Bus Interface of the intermediate units of the parallel system the Jumpers JP1 JP2 JP3 and JP4 MUST BE REMOVED NOTE In a parallel system composed of 2 or more units only the first and last units having 1 input JA and JB free have the Jumper JP1 JP2 JP3 and JP4 inserted o...

Page 35: ...units must be made on the electronic module P34 Bus Interface situated at the inside of the UPS door Next parallel unit JA SGSU_400 500_S2_RPA control bus cable_02US A JA1 JA2 JB B JA1 JA2 Fig 3 9 3 2 Front view electronic module on intermediate unit Control bus cables connection Plug the cables JA 1 2 3 4 5 and JB 1 2 3 4 5 onto the RJ connectors JA and JB located on parallel bus PCB P34 Bus Inte...

Page 36: ...es JA and JB inside the UPS cabinet In case one unit should be removed from the parallel system the bus cables JA and JB must be removed from the cabinet without disconnecting them from the metal plate where the sockets JA and JB are located For reliability reasons the cables JA 1 2 3 4 5 and JB 1 2 3 4 5 connecting the units should be run in separated protected conduits as indicated in Fig 3 9 3 ...

Page 37: ...NO def RL2 1 12 13 2 14 3 15 4 16 5 17 6 18 7 19 8 20 9 21 10 22 11 1 14 9 1 X1 J2 J3 J5 J4 2 1 JP3 Fig 4 1 1 Customer interface NO Normally Open C Common NC Normally Closed The connectors J4 and J5 can be used for additional 3 ph SNMP WEB plug in adapter or an additional Customer Interface installation only when the UPS is switched Off XA terminals for 24Vdc Auxiliary Power Supply connection XB t...

Page 38: ...rminal blocks X1 The meaning of the alarms on the free contacts in standard configuration default is the following X1 1 2 3 or J2 1 2 3 NO C NC Utility Failure X1 4 5 6 or J2 4 5 6 NO C NC Load on Inverter X1 7 8 9 or J2 7 8 9 NO C NC Stop Operations X1 12 13 14 or J2 14 15 16 NO C NC Load on Utility X1 15 16 17 or J2 17 18 19 NO C NC General Alarm X1 18 19 20 or J2 20 21 22 NO C NC Acoustic Alarm...

Page 39: ...ated by changing a dedicated parameter password required When this NO Normally Open contact closes the output Inverter Contactor K7 it is automatically opened and the Load transfer back to Inverter will be inhibited In a parallel system the input on the customer interface of each unit must be connected to a separate AUX contact of the External Maintenance Bypass Switch 4 1 6 eBoost IEMi control si...

Page 40: ...nals XB_01 4 2 3 1 Fig 4 1 8 1 Terminals XB for connection EPO SGS_400 500_Customer interface EPO_01 JP3 J2 Fig 4 1 8 2 Customer interface NOTE This procedure could imply a Load shut down NOTE In case of parallel Customer Interface the EPO contact must be connected to one Customer Interface only but the bridge on X2 and jumper JP3 on the P4 Customer Interface must be removed on all other boards In...

Page 41: ...Notes with date and short description all the operations performed on the UPS as maintenance components replacement abnormal situations etc Date Description Done by Modifications reserved Page 41 41 OPM_SGS_ISG_M40_M50_2US_V021 doc User Manual SG Series 400 500 UL S2 ...