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S&C PureWave UPS™ System 250 kW and 500 kW, 208 Volt—600 Volt Instructions for Operation IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This publication contains important instructions for operation of PureWave UPS System Catalog Numbers 910250 and 910500. TABLE OF CONTENTS Section Page INTRODUCTION Qualified Persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Read this Instruction Sheet . . . . . . . . . . . . . . . . . . . . . .3 Retain this Instruction Sheet . . . . . . . . . . . . . . . . . . . . .3 Proper Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Document Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . .6 SAFETY INFORMATION Understanding Safety-Alert Messages . . . . . . . . . . . . .7 Following Safety Instructions . . . . . . . . . . . . . . . . . . . .7 Replacement Instructions and Labels . . . . . . . . . . . . . .7 Section Page Hazard Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 High Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Sulfuric Acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Acid Volume/Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Hydrogen Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Decomposition of Materials During Fire . . . . . . . . . . .9 Operator Training Requirements . . . . . . . . . . . . . . . . .10 Training Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Safety Equipment, Precautions, and Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Personal Protective Equipment (PPE) . . . . . . . . . . . .12 S&C ELECTRIC COMPANY Specialists in Electric Power Switching and Protection Instruction Sheet 653-502 June 4, 2007 ©2007 Supersedes Instruction Sheet 653-502 dated 7-18-05 TABLE OF CONTENTS Section Page Section SAFETY INFORMATION—(continued) System Emergency Bypass Isolation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Data Storage and Retrieval . . . . . . . . . . . . . . . . . . . . . .29 Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Generator Interface (Optional) . . . . . . . . . . . . . . . . . .31 Recommended Emergency Response Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Individual Safety Precautions . . . . . . . . . . . . . . . . . . .13 Disconnect Means . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Insulated Hand Tools . . . . . . . . . . . . . . . . . . . . . . . . . .14 Emergency Wash Stations . . . . . . . . . . . . . . . . . . . . . .14 Maintenance Inspections to Ensure Safety . . . . . . . .14 Emergency Procedures and Equipment . . . . . . . . . . .14 Fire Protection Systems . . . . . . . . . . . . . . . . . . . . . . . .14 Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Releases of Hazardous Material . . . . . . . . . . . . . . . . .15 Maintenance Review Schedule . . . . . . . . . . . . . . . . . .15 Smoke, Fire, and Hydrogen Detection . . . . . . . . . . . .16 Hydrogen Detection (Optional) . . . . . . . . . . . . . . . . . .17 REMOTE MONITORING HARDWARE AND SOFTWARE Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Remote Communication . . . . . . . . . . . . . . . . . . . . . . . .32 Remote Access Computer . . . . . . . . . . . . . . . . . . . . . .32 Remote Monitoring Software . . . . . . . . . . . . . . . . . . . .32 Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Utility Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Power-Electronic Switch (PES). . . . . . . . . . . . . . . . . .33 Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Battery Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Power Flow Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 System Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Remote Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 System Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 CONTROLS AND INDICATORS Operating Controls and Indicators . . . . . . . . . . . . . . .18 Enabled/Disabled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Controls for Service Personnel . . . . . . . . . . . . . . . . . 19 Enabled/Disabled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Test Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Fire Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Liquid-Crystal Display . . . . . . . . . . . . . . . . . . . . . . . . . .20 States and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Monitoring Computer (Optional) . . . . . . . . . . . . . . . .23 Auxiliary Contacts (Optional) . . . . . . . . . . . . . . . . . . .23 Remote Disable (Optional). . . . . . . . . . . . . . . . . . . . . .23 SPECIFICATIONS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 MAINTENANCE Maintenance Checklists . . . . . . . . . . . . . . . . . . . . . . . .41 PureWave UPS System Quarterly Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 PureWave UPS System Annual Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 OPERATING MODES AND PROCEDURES System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Theory of System Operation . . . . . . . . . . . . . . . . . . . .24 Start-Up Operating Mode . . . . . . . . . . . . . . . . . . . . . . .25 Entering the System Enclosure . . . . . . . . . . . . . . . . . .26 PureWave UPS Maintenance Bypass Procedure . . . .28 Returning the PureWave UPS to the UPS Ready State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 653-502 Page DRAWINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 2 INTRODUCTION Qualified Persons NOTICE The equipment covered by this publication must be installed, operated, and maintained by qualified persons who are knowledgeable in the installation, operation, and maintenance of overhead electric power distribution equipment along with associated hazards. A qualified person is one who is trained and competent in: • The skills and techniques necessary to distinguish exposed live parts from non-live parts of electrical equipment. • The skills and techniques necessary to determine the proper approach distances corresponding to the voltage to which the qualified person will be exposed. • The proper use of the special precautionary techniques, personal protective equipment, insulating and shielding materials, and insulated tools for working on or near exposed energized parts of electrical equipment. These instructions are intended only for such qualified persons. They are not intended to be a substitute for adequate training and experience in safety procedures for this type of equipment. Read this Instruction Sheet Thoroughly and carefully read this instruction sheet before installing or operating your S&C PureWave UPS System. Familiarize yourself with “SAFETY INFORMATION” on page 7. Retain this Instruction Sheet This instruction sheet is a permanent part of your S&C PureWave UPS System. Designate a location where you can easily retrieve and refer to this publication. Proper Application NOTICE The equipment in this publication must be selected for a specific application. The application must be within the ratings furnished for the equipment. Ratings for this equipment are listed on a ratings label at the front of the system. The PureWave UPS System is a battery storage system capable of delivering voltage to critical loads and serving the power quality needs of the utility and its customers. The PureWave UPS System is an immediate response, high capacity, standby power system, which operates as both a voltage source and a current source. Catalog Number 910250 is capable of delivering up to 313 kVA (at 480 V) and model Catalog Number 910500 is capable of delivering up to 625 kVA (at 480 V) of clean power to protect sensitive electrical and electronic equipment from the adverse affects of voltage sags or swells, momentary power interruptions, and frequency deviations occurring on the utility’s power grid. The PureWave UPS System acts as a voltage source when replacing the utility to protect the critical load from power disturbances and when reconnecting to the utility. The PureWave UPS System acts as a current source when transferring from the PureWave UPS System to the generator to ensure a smooth transfer of power. Document Purpose This instruction sheet provides all of the information necessary to safely and effectively perform all customer available operation and maintenance procedures associated with the PureWave UPS System, referred to as a PureWave UPS System in this document. It includes information about the system, specifications, safety and security, emergency shutdown, operations, faults and troubleshooting, and maintenance. 3 653-502 INTRODUCTION NOTICE Procedures such as installation and start-up must be conducted in the presence of an AUTHORIZED FACTORY SERVICE REPRESENTATIVE. If an authorized representative is not present, any damage incurred to the PureWave UPS System will be the responsibility of the customer. NOTICE S&C reserves the right to VOID all warranty agreements if proper procedures are not followed. Warranty The warranty and/or obligations described in S&C’s standard conditions of sale, as set forth in Price Sheet 150, plus the special warranty provisions set forth below, are exclusive. The remedies provided in the former for breach of these warranties shall constitute immediate purchaser’s or end user’s exclusive remedy and a fulfillment of all seller’s liability. In no event shall seller’s liability to immediate purchaser or end user exceed the price of the specific product which gives rise to immediate purchaser’s or end user’s claim. All other warranties whether express or implied or arising by operation of law, course of dealing, usage of trade or otherwise, are excluded. The only warranties are those stated in Price Sheet 150, and THERE ARE NO EXPRESS OR IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. ANY EXPRESS WARRANTY OR OTHER OBLIGATION PROVIDED IN PRICE SHEET 150 IS GRANTED ONLY TO THE IMMEDIATE PURCHASER AND END USER, AS DEFINED THEREIN. OTHER THAN AN END USER, NO REMOTE PURCHASER MAY RELY ON ANY AFFIRMATION OF FACT OR PROMISE THAT RELATES TO THE GOODS DESCRIBED HEREIN, ANY DESCRIPTION THAT RELATES TO THE GOODS, OR ANY REMEDIAL PROMISE INCLUDED IN PRICE SHEET 150. SPECIAL WARRANTY PROVISIONS: The standard warranty contained in seller’s standard conditions of sale, as set forth in Price 150, applies to S&C PureWave UPS Systems except that the first paragraph of said warranty is replaced by the following: (1) General: Seller warrants to purchaser for a period of 24 months after startup of the system, or 30 months after the date of shipment, whichever occurs first, that the equipment delivered will be of the kind and quality specified in the contract description and will be free of defects of workmanship and material. Should any failure to conform to this warranty appear under proper and normal use within 24 months after startup of the system, or 30 months after the date of shipment, which ever occurs first, the seller agrees, upon prompt notification thereof and confirmation that the equipment has been stored, installed, operated, and maintained in accordance with recommendations of the seller and standard industry practice, to correct the nonconformity by repairing any damaged or defective parts of the equipment. Replacement parts provided by seller under the warranty for the original equipment will be covered by the original-equipment warranty for its duration. Replacement parts purchased separately will be covered by the warranty contained in seller’s standard conditions of sale, as set forth in Price Sheet 150. Seller further warrants that the batteries in each battery module will perform within their rating for either of the following” (a) 60 months after startup of the system or 66 months after date of shipment, provided that, during any storage periods, battery charge is maintained in accordance with the operation and maintenance manual requirements , or (b) A total discharge from each battery module of no less than 625 megajoules, whichever occurs first. 653-502 4 INTRODUCTION NOTICE Failure to comply with the “PRECAUTIONS” and specific “WARNINGS” identified in the manual violates safety standards of design, manufacture, and intended use of the equipment. S&C assumes no liability for failure to comply with these requirements. System Overview The PureWave UPS System functions as a voltage source for power quality applications to mitigate the effects of voltage disturbances such as voltage sags or swells and momentary power interruptions. The PureWave UPS System will provide up to 60 seconds of power at full load to critical loads when the supply voltage drops below 90% of nominal or exceeds 110% of nominal or when the supply frequency drops below 1.5 Hz of nominal or exceeds 1 Hz of nomimal. The PureWave UPS System can be interfaced with a standby generator to provide power protection against voltage disturbances greater than 60 seconds. Catalog Number 910250 PureWave UPS System is illustrated in Figure 1. Catalog Number 910500 is illustrated in Figure 2. Figure 1. PureWave UPS System, Catalog Number 910250. Figure 2. PureWave UPS System, Catalog Number 910500. 5 653-502 INTRODUCTION Description of Operation Under normal conditions, power is supplied from the utility grid to the customer’s critical bus through the input circuit breaker, power electronic switch, and output isolation circuit breaker. See Figure 3. The system’s utility disturbance monitor (UDM) continuously monitors the supply voltage for disturbance activity. When a disturbance occurs, the PureWave UPS System turns on the system’s high power inverter(s). The stored energy in the system’s batteries is converted to ac and supplied through a voltage-matching isolation transformer while the power electronic switch is commanded off (open) to isolate the customer’s critical loads from the faulted utility. Output power matches the customer load for 60 seconds at full load during the utility voltage disturbance or momentary power interruption. The entire transfer sequence occurs typically within 1 to 4 milliseconds (less than ¼ cycle), and will be transparent to the customer’s loads. Most power disturbances clear in less than 2 seconds—well within the capability of the PureWave UPS System. An electrically operated bypass circuit breaker permits continued service to the customer from the utility in the event that the PureWave UPS System is out of service for maintenance. &ROMå5TILITY -ONITORING #OMPUTER 23 )NPUT BREAKER 3YSTEM #ON ONTROL PES )SOLATION 4RANSFORMER "YPASS BREAKER $#!# )NVERTER "ATTERY "ATTERY #HARGER /UTPUT BREAKER !# #APS Figure 3. PureWave UPS System one-line diagram. 653-502 #RITICALå,OAD 6 SAFETY INFORMATION Understanding Safety-Alert Messages There are several types of safety-alert messages which may appear throughout this instruction sheet as well as on labels and tags attached to the PureWave UPS System. Familiarize yourself with these types of messages and the importance of the various signal words, as explained below. Ç DANGER “DANGER” identifies the most serious and immediate hazards which will likely result in serious personal injury or death if instructions, including recommended precautions, are not followed. Ç WARNING “WARNING” identifies hazards or unsafe practices which can result in serious personal injury or death if instructions, including recommended precautions, are not followed. Ç CAUTION “CAUTION” identifies hazards or unsafe practices which can result in minor personal injury or product or property damage if instructions, including recommended precautions, are not followed. NOTICE “NOTICE” identifies important procedures or requirements that, if not followed, can result in product or property damage if instructions are not followed. Following Safety Instructions If you do not understand any portion of this instruction sheet and need assistance, contact your nearest S&C Sales Office or S&C Authorized Distributor. Their telephone numbers are listed on S&C’s website www.sandc.com. Or call S&C Headquarters at (773) 338-1000; in Canada, call S&C Electric Canada Ltd. at (416) 249-9171. NOTICE Thoroughly and carefully read this instruction sheet before operating your S&C PureWave UPS System. Replacement Instructions and Labels If you need additional copies of this instruction sheet, contact your nearest S&C Sales Office, S&C Authorized Distributor; S&C Headquarters, or S&C Electric Canada Ltd. It is important that any missing, damaged, or faded labels on the equipment be replaced immediately. Replacement labels are available by contacting your nearest S&C Sales Office, S&C Authorized Distributor, S&C Headquarters, or S&C Electric Canada Ltd. 7 653-502 SAFETY INFORMATION Hazard Identification The following is a list of potential hazards associated with the PureWave UPS System: • High-voltage ac and dc electricity, • Corrosive liquid (battery electrolyte; i.e., sulfuric acid) and sulfuric acid vapors from cracked or leaky batteries, • Fire and explosion hazard from hydrogen gas generated during the battery charging cycle, and • Hazardous fumes or vapors resulting from decomposition of system components or materials due to combustion (fire). High Voltages Potentially lethal voltages are present inside the PureWave UPS System. High-voltage dc is present even without utility power connected. Hazardous voltages should also be expected in all interconnecting components and lines. To maintain safety, the user should use padlocks on each of the battery module bay doors and the PCS compartment door (the front doors). The door and the use of the padlock provide protection to inadvertent contact with high-voltage circuits. Sulfuric Acid Lead acid batteries contain electrolyte. Electrolyte consists of a solution of 36% sulfuric acid and 64% water by weight. Sulfuric acid (H2SO4aqueous) is a colorless, odorless liquid, which can form a mist during battery charging or emergency releases caused by explosion or fire. Exposure to sulfuric acid mist or vapors severely irritates the eyes, respiratory tract, and skin. Repeated exposure to high concentrations through inhalation of mist may also cause erosion of the teeth. Splashes in the eyes or on the skin will cause severe burns. Sulfuric acid will concentrate if not removed from contaminated clothing or skin; the concentrated acid has a severe dehydrating action and destroys tissue. Figure 4. Lead-acid battery. Contact of sulfuric acid with some metals may form corrosive sulfur dioxide fumes and flammable hydrogen gas. Toxic gases, vapors, and fumes such as sulfur dioxide, carbon monoxide, and sulfuric acid fume may be released during decomposition. Water applied directly to sulfuric acid causes evolution of heat and splattering. Reference the battery material safety data sheet shipped with the system for further information. 653-502 8 SAFETY INFORMATION Acid Volume/Capacity The combined volume of sulfuric acid contained in the 48 batteries of each battery module is approximately 78 gallons (293 liters). Each of the five vertically stacked trays within the battery module provides acid containment. The trays are designed to contain electrolyte that may be released by the rupture of batteries. See Figure 5. Figure 5. Battery module conﬁguration. Hydrogen Gas Precautions—Under charging conditions, hydrogen (H2), a colorless, odorless, and tasteless gas which is non-toxic under normal conditions may be released. It may however, cause asphyxiation in confined spaces by displacing oxygen and is a severe fire and explosion hazard when exposed to heat, flame, or oxidizers. The explosive range for hydrogen is very wide with the lower explosive limit (L.E.L.) at 4.1 percent by volume and the upper explosive limit (U.E.L.) at 74.2 percent. Hydrogen Gas Ventilation—Hydrogen gas generated during charging cycles is collected from each individual battery through a length of chemical resistant tubing. The hydrogen gas is removed from the system through natural ventilation. Ç DANGER Open flame or heat above 300°F can ignite any hydrogen being vented from the system enclosure. Keep such flame and heat a distance of at least five feet from the enclosure. Decomposition of Materials During Fire Under normal operating conditions the structural components of the system can be considered safe. In the case of fire, however, these structural components can degrade. Degradation of the enclosure structure, the module, acoustical foam panel lining, and battery cases during fire will generate carbon monoxide gas, acid vapors, and mist, and possibly hydrogen cyanide gas and vapors. In the case of fire, the systems alarm sensors will detect the smoke or change in temperature of the containers internal environment. Once the system has detected the likelihood of a fire the system will shut down. Additional information on smoke and fire detection can be found under “Smoke, Fire, and Hydrogen Detection” on page 18. 9 653-502 SAFETY INFORMATION Operator Training Requirements All personnel exposed to the risks associated with the PureWave UPS System must be properly trained in order to minimize the risk of injury to personnel and equipment. Personnel should be assessed for retraining on a regular basis and will receive retraining when procedures or systems change, when routine inspections or observations indicate workers are not following safe work practices, and when operators have not performed a task within one year. Training Programs Areas of Training—As a minimum, all personnel exposed to the potential hazards associated with the PureWave UPS System should be trained in the following: • Right-to-know • Lockout/tagout • PureWave UPS System operation • Fire extinguisher training • Personal protective equipment (PPE) • High-energy awareness training. Standards and Regulations—Personnel working on or in the vicinity of the system should know, follow, and be trained according to the safe working practices outlined in the following regulations and standards as a minimum. • Electric Power Generation Transmission and Distribution (29 CFR 1910.269) • Electrical-Safety-Related Work Practices (29 CFR 1910.331 through 1910.335) • Standard for Electrical Safety Requirements for Employee Workplaces (NFPA 70E) • Recommended Practice for Maintenance, Testing, and Replacement of Vented Lead-Acid Batteries for Stationary Applications (ANSI/IEEE 450-1995). Battery Safety 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, replace with the same number of Deka 7T31 batteries. Ç CAUTION DO NOT dispose of batteries in a fire. They may explode. Ç CAUTION Lead-acid batteries can present a risk of fire because they generate hydrogen gas. The following procedures should be followed: 1. DO NOT SMOKE when near batteries. 2. DO NOT cause flame or spark in battery area. Discharge static electricity from body before touching batteries by first touching a grounded metal surface. 653-502 10 SAFETY INFORMATION Ç CAUTION Do not open or mutilate the batteries. Released electrolyte is harmful to the skin and eyes. It may be toxic. Ç CAUTION A battery can present a risk of electrical shock and high short-circuit current. The following precautions should be observed when working on batteries: 1. Remove watches, rings, or other metal objects. 2. Use tools with insulated handles. 3. Wear rubber gloves and boots. 4. Do not lay tools or metal parts on top of batteries. 5. Disconnect charging source prior to connecting or disconnecting battery terminals. 6. Determine if the battery is inadvertently grounded. If it is grounded, remove the source of the ground. Contact with any part of a grounded battery can result in electrical shock. The likelihood of such shock will be reduced if such grounds are removed during installation and maintenance. Ç CAUTION The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. It is electrically conductive and corrosive. The following procedures should be observed: 1. Wear full eye protection and protective clothing. 2. If electrolyte contacts the skin, wash it off immediately with water. 3. If electrolyte contacts the eyes, flush thoroughly and immediately with water. Seek medical attention. 4. Spilled electrolyte should be washed down with a suitable acid neutralizing agent. A common practice is to use a solution of approximately one pound (500 grams) bicarbonate of soda to approximately one gallon (4 liters) of water. The bicarbonate of soda solution should be added until the evidence of reaction (foaming) has ceased. The resulting liquid should be flushed with water and the area dried. 11 653-502 SAFETY INFORMATION Safety Equipment, Precautions, and Practices The PureWave UPS System instruction sheet must be available to all operators and other employees. If doors to the electrical controllers or panels to the system enclosure must be opened, refer to the instruction sheet for procedures for guarding against electric shock. Lockout and tagout procedures should be developed and implemented (in accordance with 29 CFR 1910.147). All enclosure doors should be padlocked when authorized personnel are not present to prevent injury to persons unaware of the risks associated with the system. Personal Protective Equipment (PPE) All personal protective equipment must conform to the regulations established by 29 CFR 1910 Subpart I. The following list of personal protective equipment is the minimum equipment that must be made available to personnel performing maintenance. The equipment must be maintained according to manufacturer’s instructions and properly used inside the PureWave UPS System area. • Safety glasses with side shields and splash protection. • Head protection appropriate for environments with electrical hazards. • Insulated rubber gloves. Class of insulation is dependent on the specific application given the voltages present. • Insulated rubber sleeves. Class of insulation is dependent on the specific application given the voltages present. It is the responsibility of the user/owner to identify any further needs for personal protective equipment based on the specific needs of the site. Recommended Emergency Response Equipment Keeping the following equipment maintained and ready for use at the site is recommended for response to emergency situations. • Emergency eye wash and quick-drench shower located nearby the PureWave UPS System area (maintained according to manufacturer’s recommendations and state, local, and federal regulations pertaining to such equipment). • Three portable fire extinguishers approved for use in electrical fires and fires involving sulfuric acid or lead acid batteries. • Appropriate chemical protective equipment and approved air-purifying respirators (full-face APR with combination acid gas, organic vapor, and HEPA cartridges— magenta/yellow) available for clean-up of a low-risk spill of sulfuric acid; • Sulfuric acid spill control and clean-up materials—absorbent pillows, lime, crushed limestone, sodium bicarbonate, or soda ash. • High-voltage-rated emergency rescue poles. 653-502 12 SAFETY INFORMATION Individual Safety Precautions The following minimum list of personal safety precautions are to be emphasized in the training program. • Only qualified employees may work on or near exposed electrical contacts or components with differences in potential in excess of 50 volts. • Wear 100% natural fiber clothing or flame resistant apparel. • Do not wear conductive articles (e.g. rings, watches, etc.). • Use properly insulated hand tools. • Keep heat, sparks, or flame away from the hydrogen ventilation system. • Ensure unobstructed egress from the work area. • Review material safety data sheet for sulfuric acid (Ref. 29 CFR 1910.1200). • Receive training in the proper use of emergency fire extinguishers (Ref. 29 CFR 1910.157). • Receive training in the selection and use of personal protective equipment which may be required for operations and maintenance or emergency response (Ref. 29 CFR 1910 Subpart I). • Receive training in hazardous waste management. • Use the proper personal protective equipment. Personnel should be trained when and how to use the personal protective equipment required for the situation (i.e. insulated rubber gloves, safety glasses with side shields, face shields, hard hats, etc.). • Right-to-know training, including lead acid batteries. • Use the buddy system. Do not work alone in potentially hazardous situations. Disconnect Means The UPS system may be placed in bypass via the bypass switchgear located behind the side door. An external ac disconnect means shall be provide by others. 13 653-502 SAFETY INFORMATION Insulated Hand Tools Insulated hand tools are required when working on or around any energized equipment. Use only properly rated tools for the energy present. Tool inventories should be kept to ensure that all tools that enter the system enclosure are removed prior to energizing the system. Emergency Wash Stations The PureWave UPS System houses lead-acid maintenance free batteries. Check with local municipality planning and development agency for emergency eye wash and emergency shower requirements. Inspect and maintain this equipment according to manufacturer’s recommendations and local, state, and federal regulations. Maintenance Inspections to Ensure Safety All maintenance is to be performed by S&C trained, certified, and authorized personnel. Maintenance inspections are necessary to ensure the safe and proper operation of the PureWave UPS System. Failure to follow the recommended maintenance program outlined in the maintenance section may result in personal injury or damage to equipment. Inspections must be performed prior to energizing the equipment and at regular intervals by personnel trained, certified, and authorized to perform such work by S&C. Quarterly and Annual Inspections After the PureWave UPS System is started and the unit is on line, inspection and maintenance should be scheduled on a regular basis to ensure the proper operation of the system. See the “Maintenance” section for checklists of inspection and maintenance items. Emergency Procedures and Equipment The owner should develop policies and procedures for handling emergency situations. It is the responsibility of the owner to develop site-specific emergency action plans for response to such situations. Fire Protection Systems The system senses fire or the potential for fire in three different ways. An optional hydrogen detector monitors the level of hydrogen in the enclosure and will disable the system if the amount exceeds 0.8% by volume. An optional smoke detector monitors the system for smoke and will disable the system when smoke is detected. Two thermocouples inside the system enclosure sense internal temperature and will shut the system down if the temperature exceeds 64°C. See “Smoke, Fire, and Hydrogen Detection” on the next page for more information. 653-502 14 SAFETY INFORMATION Fire Extinguishers Fire extinguishers to handle electrical fires and fires involving sulfuric acid or batteries should be kept on hand and maintained for initial fire emergency response. Reference the battery material safety data sheet shipped with the system, for further information regarding the composition of the unit. Proper training, placement, and maintenance are essential to ensuring the functionality and proper use of fire extinguishers. Releases of Hazardous Material No attempt should be made to respond to the release of hazardous materials by unqualified personnel. Prior to responding to the release of any hazardous material personnel should: • Be trained in the clean up of that material, • Be trained in the use and limitations of the proper personal, protective equipment for the clean up of that material, • Have completed right-to-know training. Reference the battery material safety data sheet shipped with the system for more information on clean up and disposal of hazardous materials. Maintenance Review Schedule Since a significant volume of sulfuric acid is contained within the batteries, correct operation of the PureWave UPS System and related safety equipment is critical to preventing fire or uncontrolled releases. Records of inspections and system performance should be reviewed on a regular basis to ensure proper operation. Record Keeping A current copy of this instruction sheet should be kept at the entrance (access) to the unit. Other copies should be kept available for personnel to review as needed. Records of the initial inspection, checks, and/or testing, along with the required quarterly inspections should be maintained by the owner. Availability of Documents All relevant material safety data sheets should be made available for all employees working on or near the PureWave UPS System. 15 653-502 SAFETY INFORMATION Smoke, Fire, and Hydrogen Detection Smoke Detection (Optional)—If the optional smoke detector is supplied, it will be mounted on the back of the PCS panel. When smoke is detected, the master control automatically disables the PureWave UPS System by switching to the bypass state and shutting down the chargers in order to find the safest possible mode. The control sounds an audible alarm inside the system enclosure and displays “SMOKE IN CONTAINER” on the LCD display on the outside of the system enclosure. The optional monitoring computer will log the event, and an alarm contact will activate. NOTICE Actuation of the smoke detector disables the PureWave UPS System by commanding the system to the bypass state. Fire Detection—Fire inside the system enclosure is sensed by the presence of excessive temperature at one of the thermocouples which monitor the air temperature inside the PureWave UPS System. When a temperature of 40°C is detected inside the system, the master control displays a “CONTAINER OVER TEMP” warning on the LCD display. The system will remain functional, and an alarm contact will activate. In the event that the internal temperature of the system container exceeds 64°C, the control automatically disables the PureWave UPS System by switching to the bypass state, sounds an audible alarm inside the system enclosure, and displays a “FIRE HOT TEMPERATURE” alarm on the LCD display. The monitoring computer will log the event, and an alarm contact will activate. 653-502 16 SAFETY INFORMATION Hydrogen Detection (Optional) An optional combustible gas detector in the PureWave UPS System senses the presence of free hydrogen. Hydrogen created by the charging of batteries is evacuated from the system by a natural hydrogen evacuation system. Should the exhaust ventilation system malfunction and hydrogen collect inside the system enclosure, the combustible-gas detector will detect the accumulation of hydrogen and shutdown the system. Hydrogen in concentrations of more than 0.8% by volume inside the system enclosure will activate the sensor and automatically disable the PureWave UPS System by switching to the bypass state. The control computer will sound an audible alarm inside the system enclosure and a “HYDROGEN IN CONTAINER” alarm will be displayed on the LCD display. The monitoring computer will log the event and an alarm contact will activate. If a report-by-exception alarm system is in use (such as ADT), the alarm monitoring service will then notify the appropriate personnel. 17 653-502 CONTROLS AND INDICATORS Operating Controls and Indicators Several operating controls are located inside the side door of the system enclosure as shown in Figure 6. However, unless otherwise specified, these controls should only be operated by authorized personnel. Indicators for system status are present not only on the LCD, but also remotely through the monitoring computer. Figure 6. PureWave UPS System enabled/disabled selector switch and reset push button. Enabled/Disabled The enabled/disabled selector switch permits an operator to select whether the system is “enabled” or “disabled.” With the selector switch in the “enabled” position, the system is enabled. With the selector switch in the “disabled” position, the system is disabled. When the selector switch is in the “disabled” position, the PureWave UPS System will go to the bypass isolate state, connecting the utility to the load through the bypass breaker. The bypass breaker will be closed and the input isolation breaker and output isolation breaker will be opened. Reset A yellow push button reset switch is located immediately below the enabled/disabled switch. The reset button allows the operator to manually reset system alarms. When the system is in bypass and the reset button is pushed, the master control will reset all latched alarms. 653-502 18 CONTROLS AND INDICATORS Controls for Service Personnel In addition to the operating controls located inside the side door, several operating controls are located behind the front-right door which are shown in Figure 7. Two of these controls are redundant to the controls located behind the side door and do not need to be accessed by the owner. These controls are intended to be used by S&C authorized service personnel only. Figure 7. PureWave UPS manual operating controls. Enabled/Disabled A red mushroom enabled/disabled push button switch performs the same functionality as the enabled/disabled selector switch located behind the side door which is described above. This push button switch serves as an emergency-stop push button for service personnel. Reset The yellow push button reset switch performs the same function as the reset switch located behind the side door which is described above. Test Connection Immediately to the right of the yellow “RESET” button is a CPC connection with a removable cap. See Figure 7. This feature is for service personnel only. No attempt to use this connection point should be made unless one is trained and authorized to do so. Fire Detection The optional hydrogen and smoke sensors are mounted on the back side of the control swing panel as shown in Figure 8. The hydrogen sensor has a yellow LED located in the center of the sensor’s calibration plug. The smoke sensor has a red LED to indicate power and an audible horn that sounds when smoke is sensed. Figure 8. Hydrogen and smoke sensors. 19 653-502 CONTROLS AND INDICATORS Liquid-Crystal Display Figure 9 shows the liquid-crystal display which provides information on the PureWave UPS System status. Information is shown on two lines of characters. Figure 9. PureWave UPS System liquid-crystal display. States and Alarms UPS STATES There are six primary states of the PureWave UPS and five transition states. The transition states are temporary states that occur when the UPS is going from one state to another. The liquid-crystal display on the outside of the UPS displays the state that the UPS is currently in. Primary States Description UPS Ready The UPS is ready to protect the load in the event of a disturbance. UPS Run The UPS is running to protect the load from a utility disturbance. The inverters are on and the PES is open. Standby Inhibit The UPS has been inhibited from running however the load is being fed through the PES. The bypass breaker remains open. The UPS is placed in this state automatically as a result of an inhibit alarm (see below). Mechanical Bypass The bypass breaker has been closed, however the input and output breakers remain closed. This UPS is placed in this state automatically as a result of bypass alarms (see below). Bypass Isolate The bypass breaker is closed and the input and output breakers are open. The UPS is placed in this state automatically as a result of a bypass isolate alarm (see below). This state is also achieved by an operator disabling the UPS with the enabled/disabled selector switch, the operation disable push button switch or the optional remote disable switch. This state is utilized for servicing the UPS. Test in Bypass The Test in Bypass state is used during the startup of the UPS or during service. The Test in Bypass state permits the UPS to perform runs while the plant load is being fed from the utility through the bypass breaker. In this state, the bypass breaker is closed and the output breaker is open. Transition States Description Reset Mode The Reset state is used to reset UPS alarms. Force Off PES The Force Off PES state is used to command the PES off. The PES remains off for the duration of the UPS run, keeping the load isolated from the utility. Close Mech Bypass The Close Mechanical Bypass state is a transition state that occurs as the UPS is going to the Mechanical Bypass state. During the Close Mechanical Bypass state, the UPS controls are commanding the bypass breaker closed and conﬁrming that the bypass breaker is closed before transitioning to the Mechanical Bypass state. Soft Transfer The UPS enters the Soft Transfer state at the end of a UPS run. In this state the load is being transferred to the utility or generator gradually to prevent a voltage or frequency drop that could potentially affect the load. Load Decel The Load Deceleration state occurs if the UPS cannot support the load (either due to discharge of the batteries or from a UPS malfunction) and if the load is not in phase with the utility. The purpose of this state is to prevent spinning loads (motors) from being connected to an out-of-phase source voltage. The loads will be permitted to decelerate before being re-energized. 653-502 20 CONTROLS AND INDICATORS The PureWave UPS control system contains an extensive self diagnosis system. If any abnormal condition occurs, or if the UPS cannot protect the load from a disturbance, the PureWave UPS will activate an alarm. The alarms can be categorized by alarm type. Each alarm type is defined by what state the UPS goes to as a result of the alarm. The bottom line of the LCD which is located on the outside of the UPS displays any active alarm conditions. Below is a list of alarms categorized by alarm type. The alarm names are written in the manner in which they are displayed on the LCD display. WARNING ALARMS A warning alarm indicates a condition that requires attention; however, the UPS remains in the UPS Ready state protecting the load from a power disturbance. Alarm Description Container Over Temp Indicates that the temperature inside the UPS enclosure is over 40°C. Container Under Temp Indicates that the temperature inside the UPS enclosure is below 15°C. Broken Thermocouple Indicates a broken thermocouple inside the UPS enclosure. PES Over Temp Warn Indicates that the PES is at 90°C or higher. The temperature of the PES is not at dangerous levels; however, the condition should be investigated. This could be caused by restricted air ﬂow due to a dirty or obstructed air ﬁlter or a malfunctioned blower. H2 Sensor Alarm Indicates that the hydrogen detector (optional) is not operating properly. Utility Over Voltage Indicates that the UPS is sensing a utility over-voltage. (Greater than 110% of nominal voltage). Utility Undr Voltage Indicates that the UPS is sensing a utility under-voltage. (Less than 90% of nominal voltage). Utility Over Freq Indicates that the UPS is sensing a utility over-frequency. (Greater than 1 Hz above nominal). Utility Under Freq Indicates that the UPS is sensing a utility under-frequency. (Less than 1.5 Hz below nominal) Test In Bypass Req Indicates that the UPS has been placed in the Test in Bypass state. CB Over Current Module #x Fault Input CB Alarm Indicates that one of the bypass or isolation circuit breakers tripped due to an overcurrent. Indicates that a power module has a condition that renders it unavailable to operate. Indicates that the input circuit breaker is open when it should be closed, or closed when it should be open. Output CB Alarm Indicates that the output circuit breaker is open when it should be closed, or closed when it should be open. Parallel Bd Comm Err Indicates that the parallel board is not communicating properly. Time Not Set Indicates that the time is not set in the master control board. Transformer Ovr Temp Indicates that the transformer compartment is at or above 88°C. This could be caused by restricted air ﬂow due to a dirty or obstructed air ﬁlter or a malfunctioned blower. INHIBIT ALARMS An inhibit alarm indicates a condition that requires attention and places the UPS in the Standby Inhibit state. The UPS is not available to protect the load from a power disturbance. Alarm Lost Synch With Util Load Over Current Load Over Power Battery Discharged Reverse Phase Rotate Description Indicates that the UPS is not synchronized with the utility. Indicates that the load current has exceeded 115% of the current rating of the UPS. Indicates that the load power has exceeded 115% of the power rating of the UPS. Indicates that the batteries are discharged. Indicates that the phase rotation of the utility and/or load conductors is not correct. 21 653-502 CONTROLS AND INDICATORS BYPASS ALARMS A bypass alarm indicates a condition that requires attention and places the UPS in the Mechanical Bypass state. The UPS is not available to protect the load from a power disturbance. Alarm Description PES Over Temperature Indicates that the PES is at 100°C or higher. The temperature of the PES is approaching levels that could be harmful to the PES. This could be caused by restricted air ﬂow due to a dirty or obstructed air ﬁlter or a malfunctioned blower. Bypass CB Alarm Indicates that the input circuit breaker is open when it should be closed, or closed when it should be open. UPS Output Fault Indicates that the UPS reached current limit for one second during a run. This may indicate a fault down stream from the UPS. This is a latched fault that requires a manual reset by an operator. The distribution system and loads should be evaluated before returning the UPS to the UPS Ready state. BYPASS ISOLATE ALARMS A bypass isolate alarm indicates a condition that requires attention and places the UPS in the Bypass Isolate state. The UPS is not available to protect the load from a power disturbance. Alarm Description Remote Isolate Indicates that the UPS has a request to go to the Bypass Isolate state via the optional remote disable input contact. This alarm requires a manual reset before returning to the UPS Ready state. Operation Disabled Indicates that the UPS operation has been disabled by pushing the red mushroom enabled/disabled push button switch. Smoke in Container Indicates that the optional smoke detector detected smoke. Hydrogen in Containr Indicates that the optional hydrogen detector detected a level of hydrogen in the container greater than 0.8%. Fire Hot Temperature Indicates that the temperature inside the enclosure has reached 65°C. DC Cap Bank Alarm Indicates that there may be a fault on the dc circuit within a PCM (Power Conversion Module). AUTO RESET BYPASS ALARMS An auto reset bypass alarm indicates a condition that requires attention and places the UPS in the Bypass state. The UPS automatically resets the alarm two times (after five minute intervals). If the alarm reoccurs within 30 minutes of the second reset, the UPS will remain in the Bypass state and will not attempt to reset the alarm. The UPS is not available to protect the load from a power disturbance. Alarm Description Shorted PES Alarm Each phase (SCR) of the PES is tested for a shorted condition every twelve seconds. The tests are performed sequentially so that one of the phases is being tested every four seconds. If the test indicates a shorted SCR a Shorted PES alarm will be annunciated. Open PES Alarm Indicates that the PES was open when it was expected to be closed. This could also indicate an open input or output breaker or a cleared PT fuse. MESSAGES The two-line LCD display which is located on the outside of the UPS displays messages regarding the state of the UPS and active alarm conditions. In addition to the alarms, the bottom line of the LCD displays the following general messages: Message Description S&C PUREWAVE UPS Indicates the type of PureWave product. FWVER PQ001VvvvvRrrr Indicates the version of ﬁrmware running in the UPS. CNFG CcccRrrrr Indicates the conﬁguration revision of the ﬁrmware running in the UPS. Test Run Request This message indicates that the UPS has received a manual run request. 653-502 22 CONTROLS AND INDICATORS Monitoring Computer (Optional) The monitoring computer logs system events. The monitoring computer can be accessed via a modem or Ethernet connection. An Ethernet connection and phone connection are located behind the front right door on the left side of the compartment near the base. See Figure 10. Figure 10. Ethernet connection and phone line connection. Auxiliary Contacts (Optional) The following optional contacts are available. The contacts operate as follows if provided. Low Battery: The low-battery contact will annunciate during a UPS run after 50% of its run-time has been utilized. The contact will annunciate at 30 seconds during a run. Overcurrent: The overcurrent contact will annunciate an alarm when the load current exceeds 115% of the current rating of the PureWave UPS System is capable of providing. UPS Running: The UPS Running contact will annunciate when the UPS is in the run state. Remote Disable (Optional) If supplied, a normally open input contact must be provided by the customer to the UPS. Upon closure of the input contact the UPS will go to the bypass state and an output contact will close to indicate that the system has been remotely disabled. 23 653-502 OPERATING MODES AND PROCEDURES System Overview The fully automatic PureWave UPS System does not require user interaction to perform its specified functions. An optional monitoring system via a modem or Ethernet connection and a remote computer allows the viewer to see the status of the PureWave UPS System. A real time display shows the path of power through the system from the source to the load. For more information on the optional monitoring computer, see the monitoring hardware and software section on page 32 of this instruction sheet. The battery module and inverter module are housed within the system enclosure. The system switches from standby to full operation typically in less than 4 milliseconds. This eliminates the potential effects to the end user from momentary power interruptions, voltage sags, and voltage swells. System Operation This section includes discussion on the theory of operation, the PureWave UPS System operating modes, manual bypass procedure, and emergency shutdown procedure. Nonproprietary system design specifications beyond those identified below may be obtained by contacting S&C Power Quality Products Division. Theory of System Operation The PureWave UPS System is an immediate-response, energy storage and delivery device for high-capacity utility power customers. The PureWave UPS System connects a critical load to either the utility source or, in the event of a power quality disturbance, the PureWave UPS System. A PureWave UPS System one-line diagram is shown in Figure 11. &ROMå5TILITY -ONITORING #OMPUTER 23 )NPUT BREAKER 3YSTEM #ON ONTROL PES )SOLATION 4RANSFORMER "YPASS BREAKER $#!# )NVERTER "ATTERY "ATTERY #HARGER /UTPUT BREAKER !# #APS Figure 11. PureWave UPS System one-line diagram. #RITICALå,OAD 653-502 24 OPERATING MODES AND PROCEDURES When the utility source voltage is within tolerance and the PureWave UPS System is operational, power is supplied to the critical load from the utility source through the utility input circuit breaker, the power electronic switch, and output isolation switch. The PureWave UPS System will be in the standby-ready state, and may be charging via power from the utility source through the isolation transformer. If a utility voltage disturbance is detected (due to sags, swells, outages, etc.), the power electronic switch (PES) opens and the PureWave UPS System supplies power to the load. The PureWave UPS System is capable of sensing and switching within approximately ¼ cycle, undetected by the customer’s critical loads. Once running, the PureWave UPS System will continue to supply power to the customer’s critical loads until one of the following conditions occur: a) the utility comes back into tolerance, b) the PureWave UPS System’s available energy is used up, or c) a standby generator comes on-line. In the event that a system alarm is detected in the PureWave UPS System, the system may remain in the UPS Ready State or it may inhibit itself from operating by going into another state. The UPS states and alarms are described on pages 20 through 22. The PureWave UPS System’s stored energy resides in the battery modules. The battery module contains five stacked trays of batteries. The bottom four trays contain ten heavyduty, maintenance-free, lead-acid batteries, and the top tray contains eight batteries—a total of 48 batteries per battery module. Use of high-quality maintenance-free batteries ensures that the PureWave UPS System will be able to deliver power to the customer’s critical loads when needed. Start-Up Operating Mode Following initial start-up, the PureWave UPS System operates automatically and does not require manipulation of any controls to function properly. NOTICE In the event of an emergency shutdown, the system must be restarted by S&C service personnel, or trained personnel in consultation with S&C. 25 653-502 OPERATING MODES AND PROCEDURES Entering the System Enclosure Ç WARNING Do not enter the system enclosure unless trained, certified, and authorized to do so by S&C. Potentially lethal voltages are present inside the system enclosure. High-voltage dc is present even without utility power connected. The side door provides access to the bypass switchgear, enabled/disabled switch, reset push button switch, and customer connections. See Figure 13 on page 27. The front right door provides access to the optional monitoring computer (no display, keyboard or mouse are included), control system, power electronic switch, and ac filter capacitor. In addition, an emergency disable switch (red mushroom switch), reset push button, and CPC connector are located behind the front right door. The left door of the battery bay provides access to the battery module, the right door of the battery bay provides access to the inverter. See Figure 14 on page 27. To open a door, remove the padlock from the security cover located over the center bolt. There are three bolts (top, center, and bottom) securing the door closed. Loosen the three bolts so they detach from the enclosure (the bolt will not completely detach from the door). The door will now open. Once the door is opened approximately 90 degrees or 135 degrees, engage the lock-bar at the bottom of the door to prevent the door from being accidentally closed. See Figure 12. To close a door, disengage the lock-bar by lifting the lock-bar and returning it to its storage location. Swing the door closed. Tighten the three bolts to secure the door and install the padlock. High-voltage dc is always present because of the nature of batteries and proper safeguards should always be used. Proper insulating equipment should always be used to protect personnel from electric shock. Figure 12. Door latch. 653-502 26 OPERATING MODES AND PROCEDURES Always use extreme caution when accessing the internal components of the system enclosure, high ac and dc voltages are present inside the enclosure. Voltages up to 600 Vdc and 690 Vac should be expected under normal operating conditions. Physical entry into the PureWave UPS System should never be attempted while in the enabled state or when the modules are on-line. Technicians may access the PureWave UPS System control panel and the monitoring computer through the front right door of the system. Again, voltages of up to 600 Vdc and 690 Vac should be expected under normal operating conditions inside the enclosure. Input breaker Enable/disable selector switch and reset push button Bypass breaker Output breaker Safety guard Figure 13. Inside the system side door. Figure 14. Inside the system battery bay. 27 653-502 OPERATING MODES AND PROCEDURES PureWave UPS Maintenance Bypass Procedure NOTICE The customer’s critical load will be connected to the utility via the bypass circuit breaker after following this maintenance bypass procedure. Ç WARNING Ensure that the safety guards located behind the side door, which protect personnel against contact with energized parts, are in place before performing these procedures. Potentially lethal voltages are present behind the guards. If the guards are not in place, secure the side door closed and contact S&C at 1-773-338-1000. 1. Disable the UPS system by placing the enabled/disabled selector switch, located behind the side door (see Figure 15), in the “DISABLED” position. Note: When selector switch is moved to the “DISABLED” position, the bypass breaker will automatically close and after a short time delay the output breaker and input breaker will open. 2. Verify that the UPS system’s input and output circuit breakers are open, and that the bypass circuit breaker is closed. If the bypass circuit breaker did not close and the input and output circuit breakers did not open, follow the system emergency Bypass Isolation Procedure on page 29. Returning PureWave UPS to the UPS Ready State The following procedure provides the means for returning the PureWave UPS System to the UPS-ready state from the bypass state. 1. Verify that the PureWave UPS System’s input and output circuit breakers are open, and the bypass circuit breaker is closed. 2. Re-enable the PureWave UPS System by placing the enabled/disabled selector switch in the ”ENABLED” position. See Figure 15. 3. Manually close the PureWave UPS System’s output circuit breaker. Then manually close the input circuit breaker. 4. Reset the PureWave UPS System by depressing the yellow reset push button switch located on the front of the PCS panel. See Figure 15. Figure 15. PureWave UPS System enabled/disabled selector switch and reset switch. 653-502 28 OPERATING MODES AND PROCEDURES System Emergency Bypass Isolation Procedure In the event that the bypass breaker does not close and the input and output breakers do not open after the maintenance bypass procedure has been implemented, the UPS can be placed in bypass manually via the following procedure: 1. Ensure that the enabled/disabled selector switch is in the “disabled” position. 2. Manually close the bypass breaker. The PureWave UPS System may be manually isolated from the utility and load via the following procedure: 3. Manually open the input and output circuit breakers. 4. If needed, contact S&C immediately at 1-773-338-1000. Data Storage and Retrieval If an optional monitoring computer was supplied, S&C’s Power Systems Services Division may periodically retrieve system data for performance evaluation or diagnostic purposes. This service can be provided on a daily basis for a fee. Contact your local S&C Sales Office regarding remote monitoring service. 29 653-502 OPERATING MODES AND PROCEDURES Battery Charging Two battery charging modes ensure that the batteries are kept in proper working condition. Once a charge cycle of any type begins, the only normal operating mode that can interrupt it is a run event. The batteries can also be manually charged if they are being stored prior to installation. Automatic Charge: The PureWave UPS System uses an automatic charging method to ensure that the system is ready to handle any power disturbances. Battery modules are charged immediately following a disturbance event. The duration of the charge is directly related to the magnitude and duration of the event. The batteries are charged for two minutes for each second of discharge at full load. The battery charger will remain on for one hour after the batteries are charged. Equalize Charge: A complete equalization charge cycle will be automatically performed every two months. Equalize charging is a battery conditioning function that ensures top performance of the batteries. Manual Charge: If the battery modules are to be stored after shipment, the battery modules must be stored in a cool place (50°- 60°F). Manual charging may be required if the PureWave UPS System is not commissioned within 30 days of shipment or if the PureWave UPS System is in bypass for more than 30 days. If the battery module voltage is 600 V or less, a maintenance charge must be performed. Contact your nearest S&C Sales Office to make arrangements for a service visit to perform the maintenance change. NOTICE Failure to maintain the battery module charge during storage will void S&C’s battery warranty. 653-502 30 OPERATING MODES AND PROCEDURES Generator Interface (Optional) The PureWave UPS System control can be electrically connected to the transfer switch via a dry contact. Actuating the contact (transfer signal) commands the transfer switch to start the generator and transfer to the generator (after the generator is at rated voltage and frequency). The PureWave UPS System will actuate the transfer signal after the PureWave UPS System has been running for 5 to 10 seconds (5 seconds at full load, 10 seconds at half-load or less). Following is a sequence of events listing the events that occur during an outage of more than 5 seconds (this example assumes full load): 1. Upon a voltage disturbance the PureWave UPS System goes into the run state. 2. After 5 seconds the PureWave UPS System actuates the transfer signal to the transfer switch. 3. The transfer switch sends a start signal to the generator. 4. After the generator is at rated voltage and frequency (as determined by the transfer switch), the transfer switch transfers to the generator. 5. The PureWave UPS System “soft” loads the generator. 6. After the generator has accepted the load, the PureWave UPS System returns to the standby-ready state. 7. The PureWave UPS System maintains the transfer signal to the transfer switch until the batteries have charged. After the batteries have charged, the PureWave UPS System will de-actuate the transfer signal. 8. The transfer switch will transfer the load back to the utility after the utility voltage is restored and all applicable time delays have timed-out. 9. The PureWave UPS System will go into the run state while the transfer switch returns the load to the utility. The above example assumes the load is at 100% of the PureWave UPS System rating, therefore the PureWave UPS System actuates the transfer signal after it has been running for 5 seconds. If the load is at 50% or less of the PureWave UPS System rating, the PureWave UPS System will wait for 10 seconds before actuating the transfer signal. 31 653-502 REMOTE MONITORING HARDWARE AND SOFTWARE Overview The optional computer located inside the PureWave UPS System is referred to as the monitoring computer. The computer connected remotely which is running the remote monitoring software is referred to as the remote computer. The PureWave UPS System operational information is displayed on the system LCD, it is also stored and displayed in the monitoring computer. In addition to displaying the present operating status and information, the monitoring computer records information for service and performance evaluation. The system can be accessed remotely using a modem link or Ethernet connection to display system status. Remote Communication Remote communication is done through Windows NT® internal dial-up networking. A user may run the PureWave UPS System remote monitoring software on their Windows NT 4.0 Service Pack 3 personal computer, and use a modem to call up the monitoring computer. All displayed information is updated in real-time. Remote Access Computer The PureWave UPS System can be monitored remotely via a modem using Windows NT dial-up networking and the PureWave UPS System remote monitoring software. A user name and password obtained from S&C, and the computer hardware and software specified in Table 1 are required. TABLE 1. Requirements for PureWave UPS System Remote Access Computer Item Requirement Computer IBM PC Compatible Computer Processor Intel 650-MHz Microprocessor Compatible (or greater) Storage 10-GB Hard Drive Memory 128-MB RAM Modem 56K-bps Modem (USRobotics vs. Everything recommended) Network Communications Ethernet Card Monitor VGA, 1024 ⫻ 768 resolution or greater Operating System Windows 2000 or NT 4.0 (Service Pack 3) Windows Dial-Up Networking Software (included with WinNT) Software Remote Monitoring Software 653-502 S&C PureWave UPS System Monitoring Software When using a remote computer to access the system information, the system is displayed as a single-line diagram. 32 REMOTE MONITORING HARDWARE AND SOFTWARE Status Screen The status screen shown in Figure 16, a single-line representation of the PureWave UPS System, actively displays the power flow path through the system, providing the user with accurate and timely system information. Icons on the status screen change according to the state of the system. The icons and the lines connecting the icons change color depending on the state of the object represented by the icon. For example: A green CB icon with the circuit breaker shown open indicates that the input circuit breaker is open. A red CB icon with the circuit breaker shown closed indicates that the circuit breaker is closed. A green line indicates that power is not flowing through the line. A red line indicates that power is flowing through the line. Figure 16. PureWave UPS System status screen. Utility Source The utility source is represented by the icon shown in Figure 17. The utility source icon shows the status of the utility source (“good” or “not good”). If the utility source icon is red, it indicates a “good” source (the source is within voltage and frequency tolerance). If the utility source icon is green, it indicates a source that is “not good” (the source is not within voltage and frequency tolerance). Figure 17. Utility source icon. Power-Electronic Switch (PES) The power-electronic switch icon shows the condition of the power-electronic switch (static switch). If the icon is green, the switch is open, if the icon is red, the switch is closed. See Figure 18. Figure 18. Power-electronic switch icon. Circuit Breakers The circuit breaker icons display the condition of the input circuit breaker (input CB), the output isolation switch (output CB), and the bypass circuit breaker (bypass CB). If the icon is green, the circuit breaker is open. If the icon is red, the circuit breaker is closed. The internal circuit breaker symbol on the icon, also shows whether the circuit breaker is open or closed. See Figure 19. Figure 19. Circuit breaker icon. 33 653-502 REMOTE MONITORING HARDWARE AND SOFTWARE Battery Modules Battery module status is displayed on the battery module icon. The icon indicates available energy of the battery module via a tank-like display. Maximum energy is indicated by an all-green tank. Energy drained is indicated in red. See Figure 20. Figure 20. Battery module icon. Load The load is represented by a load icon. When the load is being supplied with power, the icon background is red. The background turns green if the factory is not being supplied with power. See Figure 21. Figure 21. Load icon. Power Flow Path The status screen displays the condition of the system components and the flow of power through the system. The line that shows the power flow path from the source to the load is shown in red. All other lines are shown in gray. Under normal conditions, the PureWave UPS System will route power from the utility source through the input CB, the static switch, through the output CB, to the load. The path is displayed in red while all others are gray. See Figure 22. When the PureWave UPS System is supplying power to the load from the batteries, the line connecting the module to the output CB icon and the line connecting the output CB icon to the load are red, while all other lines are gray. When the utility source is supplying the load in the bypass mode, the power flow path from the utility source through the bypass CB to the load is shown in red on the status screen. All other paths are gray. System Reset A system reset can be initiated from the status screen of the monitoring computer. Resetting the PureWave UPS System has no effect on the system if the system is in the standby ready state. If the system is in bypass, activating the reset control will cause the controls to reset all latched alarms. The system will then attempt to go to the standby ready state. If the cause of the latched alarm has not been resolved, the latched alarm will send the system back to bypass. This is the only user-accessible control available from the monitoring software. 653-502 34 Figure 22. Normal utility supplying load displayed. REMOTE MONITORING HARDWARE AND SOFTWARE Machine Setup The following steps are necessary to prepare the remote computer for remote access. These steps cannot be automated with an install program. 1. Install Linux Software. 2. Install a modem under Linux. 3. Install a network card. 4. Install RAS with TCPIP with a static IP address. 5. Run the PureWave UPS System remote access setup program on the provided CD. NOTICE The IP address must not conflict with the IP address assigned to the PureWave UPS System monitoring computer. Remote Access With your computer configured, perform the following steps to access PureWave UPS System information. 1. Connect to the system using your remote access service (RAS). You will need to enter the user name and password supplied to you by S&C’s Power Quality Products Division. 2. Run the application file by double-clicking the desktop shortcut labeled “shortcut to Remote PW.exe.” The application will open and the PureWave UPS System remote access status screen displays a real time representation of the system. System Security The PureWave UPS System monitoring computer can only be accessed by users with the appropriate security clearance. A valid user name and password are necessary to access system information. 35 653-502 SPECIFICATIONS The PureWave UPS System is capable of serving the power quality needs of the electric utility and its customers when operated within its design limitations and specifications as listed herein. Non-proprietary PureWave UPS System operation specifications beyond those identified in this instruction sheet may be obtained from S&C. System Ratings below are for Catalog Number 910250 PureWave UPS System. TABLE 2. Power and Current Ratings for Catalog Number 910250 Voltage kVA kW Current (Amperes) 208 135 135 376 240 156 156 376 380 250 250 376 400 261 250 376 415 270 250 376 440 287 250 376 480 313 250 376 575 313 250 314 600 313 250 301 690 313 250 262 Ratings below are for Catalog Number 910500 PureWave UPS System. TABLE 3. Power and Current Ratings for Catalog Number 910500 Voltage kVA kW Current (Amperes) 208 271 271 752 240 313 313 752 380 500 500 752 400 521 500 752 415 541 500 752 440 573 500 752 480 625 500 752 575 625 500 628 600 625 500 601 690 625 500 523 Utility Input Frequency ................................................................ 50 Hz or 60 Hz, +1.0/-1.5 Hz Output Frequency Regulation ............................................................50 Hz or 60 Hz, ±0.5 Hz Number of Phases...............................................................................................................Three Recharge Time .............................. 2 minutes for every 1 second of discharge at full power Ambient Operating Temperature Range ........................... -30°F to +113°F (-35°C to +45°C) [De-rate operating ambient temperature range by 0.81°F (0.45°C) for every 328 ft. (100 m) above 3,280 ft. (1000 m)] Ambient Storage Temperature Range ...............................-30°F to +122°F (-35°C to +50°C) (Not to exceed two (2) months) Relative Humidity ...................................................................................0 to 100%, condensing 653-502 36 SPECIFICATIONS Components System Enclosure The system enclosure contains the following components: • PureWave UPS Battery Module(s) • PureWave UPS Power Conversion Module(s) (inverter) • One monitoring computer (optional) • One ac capacitor bank assembly • One control system • One electrical switchgear assembly • One isolation transformer. Figure 23. System isometric view (Catalog Number 910250). 37 653-502 SPECIFICATIONS System Enclosure Mechanical and Environmental Size (Catalog Number 910250) ............................................................ 120⬙ W ⫻ 42⬙ D ⫻ 96⬙ H (3048 mm ⫻ 1073 mm ⫻ 2432 mm) Size (Catalog Number 910500) ............................................................ 188⬙ W ⫻ 42⬙ D ⫻ 96⬙ H (3048 mm ⫻ 1073 mm ⫻ 2432 mm) Weight (Catalog Number 910250) ...........................................9200 lbs. (est.), 4168 kg. (est.) Weight (Catalog Number 910500) ........................................ 15,600 lbs. (est.), 7067 kg. (est.) Construction.....................................................................................Welded/bolted steel frame Exterior Finish ........................... Two-part polyurethane enamel over epoxy mastic primer Handling Requirements......................................... Overhead crane with straight lift-on eyes Enclosure Rating ......................................................................................................... NEMA 3R Altitude Range...........................Up to 3,280 ft. (1,000 m) above sea level without de-rating Cooling ....................................... Closed-circuit 13,500 BTU (3,400 KCal) air conditioner(s) Heating ............................................................................. 1600 W resistive heating element(s) Hydrogen Removal ...................................................................................... Natural ventilation Seismic Rating................................................................Zone 4 (container structural design) Battery Module Each battery module is comprised of 48 batteries series connected in five layers/trays. The bottom four trays consist of 10 batteries each and the top tray consists of eight batteries. Module Size ............................. 31⬙ D ⫻ 42⬙ W ⫻ 64.5⬙ H (787 mm ⫻ 1067 mm ⫻ 1638 mm) Weight...........................................................................................................3,300 lbs. (1,497 kg) Battery Module Rating ................................................................................250 kW, 60 seconds Rated Voltage ......................................................360 Vdc min/576 Vdc nominal/768 Vdc max Figure 24. Battery module. 653-502 38 SPECIFICATIONS Battery Type ..................................................................... Maintenance free, sealed, flooded lead acid Battery Voltage ................................................................................................ 12.0 Vdc nominal Size ................................................. 13⬙ L ⫻ 6.8⬙ W ⫻ 9.5⬙ H (330 mm ⫻ 171 mm ⫻ 241 mm) Weight.....................................................................................................................63 lbs. (28 kg) Volume of Electrolyte..............................................................................1.6 gallons (6.1 liters) Power Conversion Module (Inverter) Each power conversion module is comprised of one inverter module consisting of power conversion electronics and controls, panel mounted and supported by a welded and bolted steel structural base. Max Power Output ........................................................................................... 313 kVA/250 kW Operating Voltage ...........................................................................................208/120 Vac ±10% Operating Current.......................................................................................... 867 aac (at 208 V) Number of Phases............................................................................................................... Three Output Frequency Regulation ............................................................. 60 Hz or 50 Hz, ±0.5 Hz Size ............................................. 34.5⬙ W ⫻ 13⬙ D ⫻ 54⬙ H (876 mm ⫻ 330 mm ⫻ 1372 mm) Weight......................................................................................................................... 650 pounds Monitoring Computer (Optional) The optional monitoring computer system logs key information related to service and performance. The system specifications for the monitoring computer are detailed in Table 4. A computer monitor is not included. System data must be accessed via a modem or Ethernet connection. TABLE 4. Monitoring Computer Specification Item Requirement Computer IBM pc compatible computer Processor Intel 650-MHz microprocessor compatible Storage 10-GB hard drive Memory 128-MB RAM Modem 56 K bps US Robotics Modem Network Communications Ethernet card Operating System Red Hat Linux 6.2 Software S&C PureWave UPS monitoring software Data Communication Equipment (DCE) Connector Type ................................................................................................9-pin female DIN Data Rate ......................................................................................................................9600 baud Handshake ............................................................................................................................None Parity ......................................................................................................................................... No Data Format ...............................................................................................8 bit with 1 stop bits 39 653-502 SPECIFICATIONS Circuit Breaker The PES contains three circuit breakers: 1. Input (CB1) 2. Bypass (CB3) 3. Output (CB2). Number of Poles ................................................................................................................. Three Rated Voltage .......................................................................................................... 600 Vac max Rated Continuous Current (Frame Size) Catalog Number 910250 ...................400 aac max Rated Continuous Current (Frame Size) Catalog Number 910500 ...................800 aac max Interrupting Ratings: TABLE 5. Circuit Breaker Interrupting Rating Voltage (Volts) Catalog Number 910250 Interrupting Rating (kA, RMS) Catalog Number 910500 Interrupting Rating (kA, RMS) 240 65 65 380 35 35 400 35 35 415 35 35 440 30 30 480 35 50 575 20 25 600 20 25 Protective Functions: “L” Overload at Inverse Long Time (It) ………………. Off, 0.4-1.0 ⫻ In “I” Instantaneous Trip with Short Circuit (I2t)……….Off, 1.5-15.0 ⫻ In 653-502 40 MAINTENANCE Maintenance Checklists The following checklists indicate the PureWave UPS System inspection and testing activities which should be performed on a quarterly and an annual basis. The amount of dust and dirt varies from site to site. Therefore the schedules for maintenance should be reviewed by the customer based upon the given site conditions, and if required, the frequency of the recommended maintenance increased to ensure the reliability and availability of their PureWave UPS System. S&C has extended service agreements and spare parts kits available for PureWave UPS Systems. Please contact your nearest S&C Sales Office. PureWave UPS System Quarterly Maintenance Checklist Visual Inspection/ Cleaning Inspect/clean the following items: Initials ______ Air intake vent and filter (replace filter if required) The air intake vent and filter are located on the inside of side door. Check vent and filter for dirt, leaves, insect structures, or other obstructions that could cause constriction of the vent area. Clean as necessary. Replace air filter as necessary. ______ Air outlet vent The air outlet vent is located on top of the PureWave UPS System. Check vent for dirt, leaves, insect structures, or other obstructions that could cause constriction of the vent area. Clean as necessary. S&C Representative: ________________________________________________________ (Signature and date) 41 653-502 MAINTENANCE PureWave UPS System Annual Maintenance Checklist Visual Inspection/ Cleaning In addition to the quarterly inspection items, these items should be performed on an annual basis. These items are to be performed by S&C qualified personnel only. Inspect/clean the following items: Initials Equipment Calibration 653-502 ______ Hydrogen vents ______ Air conditioner heat exchanger fins ______ PCS panel, monitoring computer, general interior ______ Hydrogen detector (if supplied): inspect sensor port, unclog/clean of necessary ______ General interior ______ LCD display Test the following items: Pass/Fail/Initials ______ Phase-lock-loop ______ C-sync ______ Dc voltage offset circuit ______ Hydrogen detector (if supplied) 42 MAINTENANCE System Protection Test Environmental Controls and Auxiliaries Operational Testing Test the following items: Pass/Fail/Initials ______ Temperature sensing ______ Smoke detector (if supplied) ______ Hydrogen detector (if supplied) ______ Broken thermocouple ______ Audible alarm Test the following items: Pass/Fail/Initials ______ Air conditioners and heaters ______ Auxiliary outlets and lights Test the following items: Pass/Fail/Initials ______ Disable PureWave UPS System; re-enable—ensure battery chargers run ______ Simulate a utility outage to ensure PureWave UPS System runs properly S&C Representative: _________________________________________________________ (Signature and date) 43 653-502 653-502 44 40.5 (1029 ) 70 (1773 ) APPROX 33 (838) BATTERY BAY CG APPROX. 6,000 LBS (2,730 KG) 53 APPROX (1336) 92 APPROX (2336) 66.6 (1692 ) 7 48.0 (1219 ) CONTROL BAY CG APPROX. 3,200 LBS (1,455 KG) 48.0 (1219 ) FRONT SYSTEM CG APPROX. 9,200 LBS (4,185 KG) 118.0 ( 2997 ) 44.62 ( 1133 ) 3.38 (86 ) 6 Figure 25. Catalog Number 910250 PureWave UPS System. B C D 8 92.9 81.0 (2359) (2057) SIDE 3.2 ( 82 ) 94.9 (2411) 4 PROPRIETARY STATEMENT 42.25 (1073 ) 38.5 ( 978 ) CMA-4890 AIR INTAKE VENT THIS DOCUMENT AND ALL PREVIOUS ISSUES ARE THE SECRET AND CONFIDENTIAL PROPERTY OF S&C ELECTRIC COMPANY ("S&C"), POWER ELECTRONICS DIVISION, 7100 TPC DRIVE, SUITE 700, ORLANDO, FLORIDA, AND NEITHER RECEIPT NOR POSSESSION THEREOF INFERS OR TRANSFERS ANY RIGHT IN OR LICENSE TO USE THIS DOCUMENT, THE SUBJECT MATTER THEREOF, OR ANY DESIGN OR TECHNICAL INFORMATION SHOWN THEREON, OR ANY RIGHT TO REPRODUCE THIS DOCUMENT OR ANY PART THEREOF. NEITHER THIS DOCUMENT NOR ANY INFORMATION CONTATINED THEREIN MAY BE COPIED, REPRODUCED, OR OTHERWISE USED OR DISCLOSED TO ANY OTHER PARTY WITHOUT FIRST OBTAINING THE EXPRESS WRITTEN PERMISSION OF S&C. THIS DOCUMENT IS PROVIDED UNDER THE EXPRESS CONDITION THAT IT WILL BE HELD IN CONFIDENCE BY THE RECIPIENT, THAT IT IS SUBJECT TO RETURN UPON DEMAND, AND THAT IT WILL NOT BE USED IN ANY WAY DETRIMENTAL TO S&C. AIR OUTLET VENT 7/8 x 1-3/4 LONG SLOT 5 PRODUCT DESCRIPTION 10-10-04 DATE APP. BY GR CH. BY WRK DR. BY 1:10 SCALE POWER QUALITY PRODUCTS DIVISION FRANKLIN, WISCONSIN S&C ELECTRIC COMPANY 5.9 GROUND BUS ( 151) 1/2" O HOLES 27.8 ( 707 ) 18.2 OUTPUT BUS ( 464 ) NEUTRAL BUS 47.4 ( 1205 ) INPUT BUS NEMA 2-HOLE, 1/2" O PATTERN UP TO 4 LUGS PER PHASE AND NEUTRAL NEMA 2-HOLE, 1/2" O PATTERN UP TO 4 LUGS PER PHASE AND NEUTRAL PUREWAVE UPS 250 KW 208-600V INSTALLATION DRAWING DESCRIPTION SECTION A-A USED ON NEXT ASSEM. 3 902054 DRAWING NO. SH 1 OF 2 REV 2 SE Specialists in Electric Power Switching and Protection DRAWINGS 45 B 33 (837) 70.0 (1778) 90.0 APPROX (2286 ) APPROX 70.0 ( 1778 ) 66.62 ( 1692 ) 3.38 ( 86 ) 103 APPROX (2616) APPROX 188.0 ( 4775 ) 70.0 (1778) 162 (4114) 66.62 ( 1692 ) FRONT BATTERY BAY CG SYSTEM CG APPROX. 6,000 LBS APPROX 15,600 LBS (2,730 KG) (17,090 KG) 7 A 48.0 (1219 ) 42.0 APPROX (1067) A 48.0 ( 1219 ) 44.6 ( 1133 ) 5 3.2 ( 82 ) 95.4 ( 2423 ) PROPRIETARY STATEMENT SIDE AIR OUTLET VENT 38.5 ( 978 ) 40.5 (1029 ) 42.2 (1073) CMA-4419 THIS DOCUMENT AND ALL PREVIOUS ISSUES ARE THE SECRET AND CONFIDENTIAL PROPERTY OF S&C ELECTRIC COMPANY ("S&C"), POWER ELECTRONICS DIVISION, 7100 TPC DRIVE, SUITE 700, ORLANDO, FLORIDA, AND NEITHER RECEIPT NOR POSSESSION THEREOF INFERS OR TRANSFERS ANY RIGHT IN OR LICENSE TO USE THIS DOCUMENT, THE SUBJECT MATTER THEREOF, OR ANY DESIGN OR TECHNICAL INFORMATION SHOWN THEREON, OR ANY RIGHT TO REPRODUCE THIS DOCUMENT OR ANY PART THEREOF. NEITHER THIS DOCUMENT NOR ANY INFORMATION CONTATINED THEREIN MAY BE COPIED, REPRODUCED, OR OTHERWISE USED OR DISCLOSED TO ANY OTHER PARTY WITHOUT FIRST OBTAINING THE EXPRESS WRITTEN PERMISSION OF S&C. THIS DOCUMENT IS PROVIDED UNDER THE EXPRESS CONDITION THAT IT WILL BE HELD IN CONFIDENCE BY THE RECIPIENT, THAT IT IS SUBJECT TO RETURN UPON DEMAND, AND THAT IT WILL NOT BE USED IN ANY WAY DETRIMENTAL TO S&C. 92.9 ( 2359 ) 81.0 ( 2057 ) B 4 7/8 x 1-3/4 LONG SLOT 40.5 42.38 ( 1029 ) ( 1076 ) CONTROL BAY CG APPROX. 3,600 LBS (1,630 KG) 3.37 ( 86 ) BATTERY BAY CG APPROX. 6,000 LBS (2,730 KG) 6 Figure 26. Catalog Number 910500 PureWave UPS System. A B C D 8 PRODUCT DESCRIPTION USED ON NEXT ASSEM. 10-10-04 DATE APP. BY GR CH. BY WRK DR. BY 1:10 SCALE AIR INLET VENT POWER QUALITY PRODUCTS DIVISION FRANKLIN, WISCONSIN S&C ELECTRIC COMPANY 902055 DRAWING NO. SH 1 OF 2 REV 1 SE Specialists in Electric Power Switching and Protection 5.9 GROUND BUS (151) 1/2" O HOLES PUREWAVE UPS 500 KW 208-600V INSTALLATION DESCRIPTION SECTION A-A 47.4 (1205 ) INPUT BUS 27.8 ( 707 ) 18.2 (464) OUTPUT BUS NEUTRAL BUS NEMA 2-HOLE, 1/2" O PATTERN UP TO 4 LUGS PER PHASE AND NEUTRAL NEMA 2-HOLE, 1/2" O PATTERN UP TO 4 LUGS PER PHASE AND NEUTRAL DRAWINGS 653-502 653-502 46 OPTIONAL REMOTE DISABLE OPTIONAL GENERATOR INTERFACE ) TRANSFER SIGNAL B SYSTEM WARNING SYSTEM FAULT GROUND BUS NEUTRAL BUS N.C. AUX CONTACTS OF GENERATOR BREAKER NO CONNECTION TB10-3 & TB10-4 TB10-7, TB10-8, & TB10-9 N.C. AUX CONTACTS OF UTILITY BREAKER N.C. AUX CONTACTS OF TRANSFER SWITCH TB10-1 & TB10-2 REMOTE TEST / REMOTE TRANSFER TO GENERATOR FEATURE OF TRANSFER SWITCH BREAKER-TYPE TRANSFER SWITCH CONTACTOR-TYPE TRANSFER SWITCH GENERATOR INTERFACE UTILIZATION (APPLY SWITCH CLOSURE ACROSS TB2-1 AND TB2-2 TO DISABLE UPS) 120VAC SUPPLIED BY UPS REMOTE DISABLE INPUT TRANSFER SIGNAL A TRANSFER SWITCH POSITION C1 UTILITY IN PureWave UPSTM NOTE: CONTACTS AT TB1 AND TB2 ARE OPTICALLY-COUPLED SCR OUTPUT MODULES, PROVIDING 4000 VAC OF ISOLATION. THEY ARE EQUIVALENT TO A FORM A, SPST, NORMALLY OPEN CONTACT PAIR THAT ARE OPEN WHEN NOT ACTIVATED AND CLOSED WHEN ACTIVATED. TB2 1 2 3 4 5 6 7 8 9 10 11 12 TB10 1 2 3 4 5 6 7 8 9 10 11 12 GROUND NEUTRAL C1 B1 UTILITY IN B1 Figure 27. Electrical connections. NOMINAL CONTINUOUS VOLTAGE: 240 VAC MAX CONTINUOUS CURRENT: 2 A MINIMUM LOAD CURRENT: 20 mA TB2 CONTACT RATINGS ( 3-WIRE OPTIONAL INPUT FROM UTILITY SERVICE 3-PHASE, 4-WIRE A1 UTILITY IN A1 REMOTE DISABLE ACTIVE SMOKE DETECTED HYDROGEN LEVEL HIGH UPS RUNNING OVERCURRENT LOW BATTERY OPTIONAL MODEM MONITORING COMPUTER CAT5 TB1 1 2 3 4 5 6 7 8 9 10 11 12 GROUND TELEPHONE JACK CAT4 C2 B2 A2 NEUTRAL NETWORK HUB C2 LOAD OUT B2 LOAD OUT A2 LOAD OUT ) NOMINAL CONTINUOUS VOLTAGE: 240 VAC MAX CONTINUOUS CURRENT: 2 A MINIMUM LOAD CURRENT: 20 mA TB1 CONTACT RATINGS OPTIONAL ( OUTPUT TO CRITICAL LOADS 3-PHASE, 4-WIRE 3-WIRE OPTIONAL DRAWINGS

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