Choosing The Right Battery Box

Transcript

CHOOSING THE RIGHT BATTERY BOX FOR POWER+ AND MEGA POWER+ SYSTEMS This document describes Gamatronic's recommendations for: • Choosing the most suitable battery according to UPS capacity and required back-up time. • Choosing the solution kits. • Certified electrical topology and battery connection. • Recommended procedure for replacing battery blocks and battery fuses. TABLE OF CONTENTS Circuit breaker (CB) and wire kits for battery backup-time solution ..................... 2 Technical description of the kits ........................................................................... 2 Choosing the batteries, battery box kits and CB kits ............................................. 3 Choosing the battery according to desired backup time ....................................... 4 FOR MEGA UPS SYSTEMS ............................................................................................. 5 FOR POWER+ UPS SYSTEMS.......................................................................................... 7 Appendix A - Battery cabinets .............................................................................. 9 Appendix B - Replacing battery blocks or battery box fuses ............................... 11 Appendix C – A sample of available battery cabinets ......................................... 12 1 Rel. 1.13 Battery box and circuit breaker (CB) kits for battery backup-time solution Gamatronic offers all the components required to achieve a safe dc system with minimal maintenance requirements. The battery backup time solution includes the following components: 1. 2. 3. 4. Batteries; Battery cabinets suitable for the chosen battery capacity (Ah); Battery cabinet wires and fuses kit suitable to battery capacity and UPS capacity; CB kit fits the maximal power capacity of the UPS system. Technical description of the kits 1. Battery cabinet: Robust solution, compact, easy to assemble. 2. Includes battery box, wires and fuses kit: a. Each 8 batteries (96 V) can be disconnected for safety. b. The connectors are based on Anderson (APP) connectors. c. Each set of 32 battery blocks (30 for Mega V2) has its own protection fuses. d. The fuses are fast blow fuses for handling short circuit current and designed for at least 500 Vdc. 3. C.B. kit fits the maximal power capacity of the UPS system: a. Each set of 32 battery blocks (30 for Mega V2) (432 Vdc for Power+, 405 Vdc for Mega V2) is connected to the UPS through a CB. b. The CB is designed to at least 500 Vdc. c. In addition to the CB, there are fast blow fuses handling short circuit current. 4. Wiring inside and outside battery box: There are two standards of recommended wires between the battery and the C.B Kit: a. PVC, 70 ºC stranded wires (mm2) – recommended for low current ratings. b. UL 1015 105 ºC stranded wires (AWG) – recommended for high current ratings. Figure 1 shows the dc switch boxes. Figure 2 shows the recommended connection topology. 2 Rel. 1.13 Figure 1: Connecting the batteries through the CB kit Choosing the batteries, battery box kits and CB kits The following section describes the process for choosing the battery solution: 1. Look for the most suitable battery capacity according to the backup time you desire, using Table 1 for Mega or Table 4 for Power+. 2. Choose the appropriate battery box kit and CB kit using Table 2 for Mega or Table 5 for Power+. 3. Choose one of the CB kits using Table 3 for Mega or Table 4 for Power+. 3 Rel. 1.13 Choosing the battery according to desired backup time Tables 1 and 4 help you choose the appropriate battery capacity (in ampere hours [Ah]) for any Mega and Power+ UPS systems. The tables assume the use of one or two sets of battery blocks (64 x 12 V for P+, 60 x 12 V for Mega), which are the standard configurations for the Mega and Power+ UPS systems. Instruction for using the tables: In the first horizontal line select the output capacity of your UPS (in kW or kVA), and in the column below the chosen number choose the required backup time. The Ah rating of the battery blocks that will provide that backup time is on the same row, in the table's first column line on the left for 1 or 2 battery sets. Remarks: 1. Wire kits for batteries with capacity higher than 90 Ah are available up on request. 2. Wires kits are designed for Gamatronic's standard battery cabinets. . 4 Rel. 1.13 FOR MEGA UPS SYSTEMS Table 1 helps you choose the right ampere/hour rating and number of battery sets, based on desired backup time. Example: Mega capacity of 125 kW and battery rating of 65 Ah provides a backup time of 6 minutes when 1 battery set is used and 17 minutes when 2 battery sets are used. Table 1: MEGA backup time (minutes) for one or two Battery sets Battery rating 9 Ah-1 set 9 Ah-2 sets 12 Ah-1 set 12 Ah-2 sets 20 Ah-1 set 20 Ah-2 sets 26 Ah-1 set 26 Ah-2 sets 40 Ah-1 set UPS Mega Power+ capacity (kVA) 25 50 100 125 150 8 24 13 38 6 17 9 27 4 13 7 21 175 200 225 250 6 5 4 5** 3 5 11 16 40 Ah-2 sets 4* 12 6 17 11 32 65 Ah-1 set 65 Ah-2 sets 90 Ah-1 set 90 Ah-2 sets Max. dc input current Fast-blow fuses 1-6 75 40 40 81 63 6 18 12 36 20 58 121 100 162 125 202 160 243 200 17 283 250 14 324 250 12 15** 315 350 364 * The information in the table above is based on typical values from battery manufacturers' YUASA NP Battery data sheets (20 hr.rate, 1.6 V per cell at 25 °C); the exact values can vary from one manufacturer to another. ** Back up time for Mega 250kW UPS is based on Deka batteries 31HR4000 model. 405 Notes for Mega SA model: • Mega SA Battery Boxes are designed to be installed nearby the Mega SA UPS system. It can not be installed outside the UPS room. • Mega SA model battery wires kits includes the CB. There’s no need to add outside CB kit. • Mega SA model battery wires kits does not include Fuse 5, 6 (see figure 1). 5 Rel. 1.13 FOR MEGA UPS SYSTEMS To find the right battery box in Table 2, use your UPS output capacity and the battery capacity in Ah that you got from Table 1. The battery box kit includes: battery box, battery box inside wiring, battery box fuses, and cables between the battery box and the CB kit. Table 3 shows you the appropriate battery CB kit based on your Mega’s output capacity. Table 2: Mega Battery Box Kits UPS Output Power Battery No. off Capacity (KW) capacity (AH) battery sets Description Gama. SN 25 9 1 M+ BAT-60X9AH-25KVA-SA-810V-EMP 29B009060-PMESA 25 12 1 M+ BAT-60X12AH-25K-SA-810V-EMP 29B012060-PMESA 25 20 1 M+ BAT-60X20AH-25K-SA-810V-EMP 29B020060-PMESA 25 26 1 M+ BAT-60X26AH-25K-SA-810V-EMP 29B026060-PMESA 50 20 1 M+ BAT-60X20AH-50K-810V-EMP 29B020060-PME 50 26 1 M+ BAT-60X26AH-50K-810V-EMP 29B026060-PME 50-75 40 1 M+ BAT-60X40AH-50-75K-810V-EMP 29B040060-PME 75-125 65 1 M+ BAT-60X65AH-75-125K-810V-EMP 29B065060-PME 75-125 65 2 M+ BAT-120X65AH-75-125K-810V-EMP 29B065120-PME 75-100 90 1 M+ BAT-60X90AH-75-100K-810V-EMP 29B090060-PME 75-100 90 2 M+ BAT-120X90AH-75-100K-810V-EMP 29B090120-PME 125 90 1 M+ BAT-60X90AH-125K-810V-EMP 29B090060-PME1 125 90 2 M+ BAT-120X90AH-125K-810V-EMP 29B090120-PME1 150 90 1 M+ BAT-60X90AH-150K-810V-EMP 29B090060-PME2 150 90 2 M+ BAT-120X90AH-150K-810V-EMP 29B090120-PME2 175 90 1 M+ BAT-60X90AH-175K-810V-EMP 29B090060-PME3 175 90 2 M+ BAT-120X90AH-175K-810V-EMP 29B090120-PME3 200 90 1 M+ BAT-60X90AH-200K-810V-EMP 29B090060-PME4 200 90 2 M+ BAT-120X90AH-200K-810V-EMP 29B090120-PME4 225 90 1 M+ BAT-60X90AH-225K-810V-EMP 29B090060-PME5 225 90 2 M+ BAT-120X90AH-225K-810V-EMP 29B090120-PME5 250 90 1 M+ BAT-60X90AH-250K-810V-EMP 29B090060-PME6 250 90 2 M+ BAT-120X90AH-250K-810V-EMP 29B090120-PME6 Note 1: The kits with “1” in the “Number of battery sets” column provide no redundancy. Note 2: If you require full redundancy, choose the kit with “1” in “Number of battery sets” and order 2 kits. Note 3: The kits with “2” in the “Number of battery sets” column do not provide full redundancy. Each battery set supports half the UPS capacity, providing redundancy for half the maximum system load. 25 - 50 29BP002 Table 3: Battery CB kits for Mega systems (excluding SA model) MEGA CAPACITY (KW) 75 100 125 150 175 200 29BP003 29BP004 29BP005 29BP006 29BP007 29BP008 6 225 29BP009 250 29BP010 Rel. 1.13 FOR POWER+ UPS SYSTEMS Table 4 helps you choose the right ampere/hour rating and number of battery sets, based on desired backup time. Example: P+ capacity of 100 kVA and battery rating of 65 Ah has battery backup time of 12 minutes for 1 battery set and battery backup time of 34 minutes for 2 sets. Battery rating Table 4: P+ Battery backup time for one or two sets UPS Power+ capacity (kVA) 10 20 30 40 50 60 70 80 90 100 5 Ah-1 set 8 3 5 Ah-2 sets 24 8 7 Ah-1 set 13 5 7 Ah-2 sets 37 13 9 Ah-1 set 20 7 3 9 Ah-2 sets 56 20 11 12 Ah-1 set 30 11 6 12 Ah-2 sets 85 30 16 20 Ah-1 set 65 23 12 8 6 4 20 Ah-2 sets 182 65 36 23 16 12 26 Ah-1 set 96 34 19 12 9 6 5 4 26 Ah-2 sets 269 96 53 34 25 19 15 12 40 Ah-1 set 36 23 16 12 10 8 7 6 40 Ah-2 sets 100 65 47 36 28 23 19 16 65 Ah-1 set 48 34 26 21 17 14 12 65 Ah-2 sets 134 96 73 58 48 40 34 90 Ah-1 set 56 42 34 28 23 20 90 Ah-2 sets 156 119 95 78 65 56 Max. dc input 12 24 36 48 60 72 84 96 108 120 current Fast-blow 15 25 40 50 50 63 80 80 100 100 fuses 1-6 * The information in the table above is based on typical values from battery manufacturers' YUASA NP Battery data sheets (20 hr.rate, 1.6 V per cell at 25 °C); the exact values can vary from one manufacturer to another. Important notes for P+ SA and P+ 19'' models: • • • • • P+ SA 20-40kVA UPS model includes the C.B kit as part of the UPS system. There's no need to add outside C.B kit. The C.B kits for UPS P+ 20-40kVA (see table 6) are relevant only for classic or FS models. P+ SA 20-40kVA UPS model Battery Wires kits does not include Fuse 5, 6 (see figure 1). It includes inside fuses for each module. P+ SA 10kVA UPS model Battery Boxes are designed to be installed nearby the P+ SA UPS system (it can not be installed outside the UPS room). Battery box for P+ SA 10 UPS model includes fuses only. P+ 10-20kVA 19'' UPS model is designed to be installed nearby the Battery box in the same rack of the UPS system. Battery box for P+ 10-20kVA 19'' UPS model includes fuses only. 7 Rel. 1.13 FOR POWER+ UPS SYSTEMS To find the right battery box in Table 5, use your UPS output capacity and the battery capacity in Ah that you got from Table 4. The battery box kit includes: battery box, battery box inside wiring, battery box fuses, and cables between the battery box and the CB kit. Table 6 shows you the CB kit to order, based on your Power+ system’s output capacity. Table 5: Battery box kit for Power+ UPS systems UPS output power capacity (kVA) 10 SA 10-20,19'' 10-20 10-20 10-20 10-20 10-20 10-20 10-20 10-20 10-50 10-50 10-50 10-50 30-50 30-50 40-50 40-50 60 60 60-80 60-80 60-80 60-80 60-80 60-80 90-100 80-100 90-100 90-100 Battery capacity (Ah) 5 5 7 7 9 7 9 12 12 20 20 20 26 26 40 40 65/90 65/90 20 20 26 26 40 40 65/90 65/90 40 40 65/90 65/90 No. of Battery sets 1 1 1 1 1 2 2 1 2 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 Description P+ SA BAT.BOX 64X5AH EMPTY P+ BAT.BOX 19" 64X5AH EMPTY P+ BAT-64X7AH-10-20K-SA-864V-EMP P+ BAT-64X7AH-10-20K-SA-864V-EMP P+ BAT-64X9AH-10-20K-SA-864V-EMP P+BAT-128X7AH-10-20K-SA-864V-EMP P+BAT-128X9AH-10-20K-SA-864V-EMP P+BAT-64X12AH-10-20K-SA-864V-EMP P+BAT-128X12AH-10-20K-SA-864-EMP P+ BAT-128X20AH-10-20K-864V-EMP P+ BAT-64X20AH-10-50KVA-864V-EMP P+ BAT-128X20AH-10-50KVA-864V-EMP P+ BAT-64X26AH-10-50KVA-864V-EMP P+ BAT-128X26AH-10-50K-864V-EMP P+ BAT-64X40AH-30-50KVA-864V-EMP P+ BAT-128X40AH-30-50K-864V-EMP P+BAT-64X65/90AH-40-50K-864V-EMP P+BAT-128X65/90AH-40-50K-864-EMP P+ BAT-64X20AH-60KVA-864V-EMP P+ BAT-128X20AH-60KVA-864V-EMP P+ BAT-64X26AH-60-80KVA-864V-EMP P+ BAT-128X26AH-60-80K-864V-EMP P+ BAT-64X40AH-60-80KVA-864V-EMP P+ BAT-128X40AH-60-80K-864V-EMP P+BAT-64X65/90AH-60-80K-864V-EMP P+BAT-128X65/90AH-60-80K-864-EMP P+ BAT-64X40AH-90-100K-864V-EMP P+ BAT-128X40AH-80-100K-864V-EMP P+BAT-64X65/90AH-90-100K-864-EMP P+BAT-128X65/90AH-90-100-864-EMP Gama. SN 29B005064-PPESA 29B005064-PP19E 29B007064-PPESA 29B007064-PPESA 29B009064-PPESA 29B007128-PPESA 29B009128-PPESA 29B012064-PPESA 29B012128-PPESA 29B020128-PPE1 29B020064-PPE3 29B020128-PPE3 29B026064-PPE3 29B026128-PPE1 29B040064-PPE4 29B040128-PPE1 29B090064-PPE3 29B090128-PPE1 29B020064-PPE4 29B020128-PPE2 29B026064-PPE4 29B026128-PPE2 29B040064-PPE5 29B040128-PPE2 29B090064-PPE4 29B090128-PPE2 29B040064-PPE6 29B040128-PPE3 29B090064-PPE5 29B090128-PPE3 Note 1: The kits with “1” in the “Number of battery sets” column provide no redundancy. Note 2: If you require full redundancy, choose the kit with “1” for “Number of battery sets” and order 2 kits. Note 3: The kits with “2” in the “Number of battery sets” column do not provide full redundancy. Each battery set supports half the UPS capacity, providing redundancy for half the maximum system load. 10 - 20 29BP156 Table 6: CB kits for Power+ systems (excluding SA model) POWER+ CAPACITY (KW) 30 40 50 60 70 80 29BP157 29BP158 29BP163 29BP159 29BP160 29BP161 8 90 29BP162 100 29BP162 Rel. 1.13 Appendix A - Battery cabinets Gamatronic recommends the following battery connection topology. Topologies use fuses and circuit breakers. WARNING! • REPLACEMENT OF FUSES AND BATTERY BLOCKS SHALL BE PERFORMED ONLY BY A TRAINED SERVICE TECHNICIAN! • REPLACEMENT OF FUSES AND BATTERY BLOCKS MUST NOT BE DONE UNDER LOAD! CONNECTION TOPOLOGY 1. The battery bank of the Power+ UPS contains 64 x 12 V battery blocks. The 64 battery blocks are grouped into two sets of 32 (384 Vdc each set). Each set of 32 battery blocks is connected to the UPS separately. The battery bank of the Mega UPS contains 60 x 12 V battery blocks. The 60 battery blocks are grouped into two sets of 30 (360 Vdc each set. Each set of 30 battery blocks is connected to the UPS separately. 2. Within each set, every four battery blocks are connected to one another with direct links and each set of four battery blocks is connected with snap-fast connectors to another set of four. 3. Each set of 30 or 32 battery blocks is connected to the UPS through its own connection box, which includes two fuses. 4. On the UPS side there are also two connection boxes, one for each set of 30 or 32 batteries. Each of these two connection boxes contains a fuse and circuit breakers. 5. All the fuses are fast blow fuses. 6. This arrangement is shown in Figure 2. 7. The boxes with two fuses and two disconnection elements should be installed on the battery cabinets. The other two dc switch boxes are assembled as close as possible to the UPS. 8. The circuit breaker should be rated at least 440 Vdc. Other connection topologies are availible for on request. 9 Rel. 1.13 Figure 2: Recommended battery connection topology (within the battery box). Two parallel sets of 60 (for Mega) or 64 (for Power+) battery blocks each. 10 Rel. 1.13 Appendix B - Replacing battery blocks or battery box fuses 1. Switch OFF one or both of the battery cabinet dc switches, in order to disconnect from the UPS the set(s) of batteries with which you intend to work. IF YOUR SYSTEM DOES NOT HAVE DC SWITCHES, THE UPS MUST BE SWITCHED OFF BEFORE YOU CONTINUE. 2. Disconnect the fuses for the battery box on which you intend to work. 3. In the battery cabinet(s), disconnect the Anderson-type fast-snap connectors between each set of four battery blocks (refer to Figure 2). 3. Replace the fuse and/or any battery blocks that need to be replaced. 4. Reconnect all the fast-snap connectors in the cabinet(s). 5. If the connection is based on fuse holders, return the fuses to the holders and close the fuse link. The battery cabinet switch can now be switched ON. 11 Rel. 1.13 Appendix C – A sample of available battery cabinets 5AH Internal cabinet for P+ 19" Dimensions (HxWxD): 6Ux19"x700 Battery dimensions: 105.5x89.5x69.5 1 rack, 64 batteries ≈37 kg 5AH External cabinet for P+ SA 64x5Ah Dimensions (HxWxD): 500x270x670 Battery dimensions: 105.5x89.5x69.5 1 rack, 64 batteries ≈20 kg 7AH External cabinet for P+ (GE) 32x7Ah Dimensions (HxWxD): 430x270x670 Battery dimensions: 105.5x89.5x69.5 1 rack, 32 batteries ≈16 kg 12 Rel. 1.13 7 / 9AH External cabinet for 64x9Ah Dimensions (HxWxD): 720x255x720 Battery dimensions: 7-9 AH Each rack weight : ≈29 kg 1 rack, 64 batteries 12AH External Battery cabinet for 64x12Ah Dimensions (HxWxD): 720x252x1000 Battery dimensions: 12 AH Each rack weight : ≈42 kg 1 rack, 64 batteries 13 Rel. 1.13 20AH External Battery cabinet 64x20Ah Dimensions (HxWxD): 870 x 535 x 880 Battery dimensions: 166x180x77 Each rack weight : ≈67 kg 2 rack, 32 batt. each 26AH 32x26AH External Battery cabinet - 02 Dimensions (HxWxD): 1700x970x300 Battery dimensions: 166x180x77 Each rack weight : ≈35.5kg 2 racks, 32 batteries each 40AH External Battery cabinet for 64x40Ah Dimensions (HxWxD): 850x540x965 Battery dimensions: 190x234x169 Each rack weight : 505 kg 2 rack, 32 batteries each 14 Rel. 1.13 65AH External Battery cabinet for 64x65Ah Dimensions (HxWxD): Battery dimensions: 1230x800x420 187x342x167 Each rack weight : 27.5kg 4 racks, 16 batteries each 90AH External Battery cabinet for 64x90Ah Dimensions (HxWxD): Battery dimensions: 1230x800x420 230x357x170 Each rack weight : 27.5kg 4 racks, 16 batteries each If additional assistance is required, please contact Gamatronic's Customer Support Department at "[email protected]". 15 Rel. 1.13