Symmetra Mw Battery Back-up System

Transcript

400kW-1MW 480V Symmetra ® MW Battery Back-up System Installation and Maintenance Guide Copyright© 2002 APC USA 990-4170A IMPORTANT SAFETY INSTRUCTIONS The following important safety instructions should be followed during installation and servicing of the Symmetra MW battery cabinets and all associated battery system equipment. Save These Instructions! 1. Servicing of batteries should only be performed or supervised by qualified personnel and the required precautions taken. Keep unauthorized personnel away from the batteries! 2. Replace batteries with the same number and type as previously installed. 3. CAUTION – Do not dispose of a battery in a fire. The battery may explode. 4. CAUTION – Do not open or attempt to modify batteries in any way. Released electrolyte is harmful to the skin and eyes, and may be toxic. 5. CAUTION – A battery can present a risk of electrical shock and high short-circuit current. The following precautions should always be observed when working on batteries: a. Remove watches, rings or other metal objects. b. Use insulated tools and insulating materials. c. Wear protective clothing, such as rubber gloves, aprons, etc. d. Do not lay tools or metal parts of any kind on top of batteries. e. Disconnect charging source prior to connecting or disconnecting battery cables and busbar. f. Determine if any battery has been inadvertently grounded. If so, remove the source of the ground. Contact with any part of a grounded battery can result in electrical shock. The likelihood of this happening will be reduced if such grounds are removed during installation and maintenance. The installation and use of these products must comply with all applicable national, state, municipal and local codes. If you need assistance, call APC’s toll-free technical support phone number: 1-800-287-7835 (1-877-2UPS-TEK). Have your UPS model number and serial number available. You can find additional product information on the APC World Wide Web site at http://www.apc.com. See Section 13.0, How to Contact APC. 990-4170A Installation and Maintenance Guide i 990-4170A ii Symmetra MW Battery Back-up System TABLE OF CONTENTS 1 SAFETY WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 REQUIRED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4 BATTERY SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4.1 Battery Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4.2 MCCB Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.3 Side Car Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 5 SHIPPING, RECEIVING AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5.1 Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5.2 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 5.2.1 Check for Damages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 5.2.2 Check for Discrepancies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 5.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6 INSTALLATION SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 6.1 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 6.2 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 6.2.1 Moving the Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 6.2.2 Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 6.3 Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 6.3.1 Input to UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 6.3.2 Alignment With UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 6.4 Space Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 6.4.1 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 6.4.2 Service Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 6.4.3 Internal Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 7 CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 7.1 Standard Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 7.1.1 Straight-line Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 7.1.2 Back-to-back Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 7.2 Alternative Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 7.2.1 Two-location Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 7.2.2 Three-location Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 7.2.3 Four-location Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 8.1 Anchoring Enclosures (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 8.2 Connecting Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 8.2.1 The Assembly Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 8.2.1.1 Rules of Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 8.2.1.2 Simplifying Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 8.2.2 Mechanical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 8.2.3 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 990-4170A Installation and Maintenance Guide iii Table of Contents (continued) 8.2.4 Electrical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 8.2.4.1 Connecting the MCCBs to the UPS (via busbar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 8.2.4.2 Connecting the MCCBs to the UPS (via cabling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 8.2.4.3 Connecting MCCB 2 to MCCB 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 8.2.4.4 Connecting BATT 1 to MCCB 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 8.2.4.5 Connecting Battery Cabinets to Battery Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 8.2.4.6 Connecting Side Cars to Battery Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 8.2.4.7 Connecting Side Cars to Side Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 8.2.4.8 Connecting a Side Car to the MCCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 8.3 Connecting Fuse Signal Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 8.3.1 8.3.2 8.3.3 8.3.4 CAN Board Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Connecting to CAN Boards/Terminal Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Terminal Strip (in Side Car) Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 CAN Board (in MCCB 1) Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 8.4 Connecting Temperature Sensor Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 8.5 Reconnecting the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 8.5.1 Battery Cable Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 8.5.2 Rules of Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 8.5.3 Order of Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 8.6 Re-attaching Dead Front Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 8.7 Attaching Bottom Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 9 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 9.1 Battery Run Times (includes MCCBs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 9.2 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 9.3 Wire and Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 9.4 Cable Bolt and Lug Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 9.5 Fuse and Breaker Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 9.6 Rated Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 10 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 10.1 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 10.1.1 Equipment Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 10.2 Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 11 GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 12 LIFE SUPPORT POLICY/WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 12.1 Life Support Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 12.2 Factory Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 13 HOW TO CONTACT APC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 APPENDIX A: BATTERY LAYOUT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 990-4170A iv Symmetra MW Battery Back-up System LIST OF FIGURES FIGURE 1: Row of Battery System Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 FIGURE 2: Four Battery Cabinets (or 2 full-strings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FIGURE 3: Battery Cabinet Identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FIGURE 4: MCCB Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FIGURE 5: MCCB Identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FIGURE 6: Side Car Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FIGURE 7: Shipping Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FIGURE 8: Transporting Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FIGURE 9: Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 FIGURE 10: Input Options (left OR right side of UPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 FIGURE 11: Alignment Flexibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 FIGURE 12: Recommended Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 FIGURE 13: Front Service Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 FIGURE 14: Releasing the MCCB Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 FIGURE 15: Releasing the Side Car Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 FIGURE 16: Straight-line Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 FIGURE 17: Back-to-back Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 FIGURE 18: Two-location Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 FIGURE 19: Three-location Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 FIGURE 20: Four-location Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 FIGURE 21: Anchoring Battery Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 FIGURE 22: Anchoring MCCB Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 FIGURE 23: Anchoring Side Car Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 FIGURE 24: Mechanical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 FIGURE 25: Grounding the Battery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 FIGURE 26: Connecting the MCCBs to the UPS (via busbar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 FIGURE 27: Connecting the MCCBs to the UPS (via cabling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 FIGURE 28: Electrical Connections Between MCCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 FIGURE 29: Connecting BATT 1 to MCCB 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 FIGURE 30: Connecting Battery Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 FIGURE 31: Connecting Side Cars to Battery Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 FIGURE 32: Connecting Side Cars to Side Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 FIGURE 33: Connecting a Side Car to the MCCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 FIGURE 34: Connecting Fuse Signal Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 FIGURE 35: Side Car Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 FIGURE 36: CAN Board Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 990-4170A Installation and Maintenance Guide v List of Figures (continued) FIGURE 37: Temperature Sensing Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 FIGURE 38: Order of Battery Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 FIGURE 39: Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 FIGURE 40: Bottom Trim Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 FIGURE 41: Removing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 FIGURE 42: Installing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 FIGURE 43: Positive Battery Cabinets, Top Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 FIGURE 44: Positive Battery Cabinets, 2nd Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 FIGURE 45: Positive Battery Cabinets, 3rd Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 FIGURE 46: Positive Battery Cabinets, Bottom Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 FIGURE 47: Negative Battery Cabinets, Top Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 FIGURE 48: Negative Battery Cabinets, 2nd Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 FIGURE 49: Negative Battery Cabinets, 3rd Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 FIGURE 50: Negative Battery Cabinets, Bottom Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 LIST OF TABLES TABLE 1: Battery System Offerings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TABLE 2: Battery Run Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 TABLE 3: Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 TABLE 4: Wire and Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 TABLE 5: Cable Bolt and Lug Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 TABLE 6: Fuse and Breaker Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 TABLE 7: System Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 990-4170A vi Symmetra MW Battery Back-up System 1 SAFETY WARNINGS Observe the following important safety warnings during installation and maintenance of the Battery Cabinets and associated battery back-up system equipment. WARNINGS! - The battery system is supplied from multiple power sources and contains HAZARDOUS AC/DC VOLTAGES! Some battery terminals and other components remain LIVE even when the system is switched off! These voltages can cause SERIOUS BODILY INJURY or DEATH! - Ensure that NO ELECTRIC POWER SUPPLY SOURCE has been connected to the UPS for at least the last five (5) minutes! Ensure ALL BREAKERS are in the “OFF” position! - ONLY QUALIFIED ELECTRICIANS may perform this installation! The installation must further be performed in accordance with all applicable national and local codes! - INSULATED TOOLS and proper INSULATING MATERIALS (rubber floor stands, rubber mats, gloves, protective clothing, etc.) should be used by all installation and service personnel! - Observe all LOCKOUT/TAGOUT procedures as required! - Observe all requirements and limitations pertaining to FLOOR LOADING! - DO NOT install Battery Cabinets or operate the Battery Breakers without first referring to this Installation and Maintenance Guide! 2 INTRODUCTION This guide contains important information concerning installation and maintenance of the Symmetra ® MW (400kW-1MW 480V) Battery Cabinets and associated battery back-up system equipment. Read these instructions carefully before installing or servicing any of this equipment. Pay special attention to all safety instructions and safety warnings. Failure to comply could result in serious bodily injury or death and/or equipment damage. The term “battery back-up system” is used throughout this guide. It refers to the system as a whole: the Battery Cabinets (and the batteries contained therein), the MCCBs (Molded Case Circuit Breakers) and any Side Cars utilized to support the configuration. This system has achieved the following ratings: • UL 1778 and cUL certified • Seismic Zone 4 certified • Random Frequency and Sinusoidal Frequency Dwell (transportation) certified 990-4170A Installation and Maintenance Guide 1 3 REQUIRED TOOLS Installation and maintenance of the battery backup system requires use of the following tools: All tools used for installation and/or maintenance of electrical parts and equipment must be insulated! • Ratchet set w/sockets • Open end/box wrenches • Torque wrench • Torx-head screwdriver • Small, flat-head screwdriver • Phillips screwdriver • Crimpers • Voltmeter • Tape measure • Chalk (for floor markings) • Concrete drill (for optional floor anchoring) 990-4170A 2 Symmetra MW Battery Back-up System 4 BATTERY SYSTEM COMPONENTS Cabinet Type Product Number Weight Dimensions Application SYB400K1000GXR-2C 8400 lb (3810 kg) 66.14”W x 36”D x 80”H (1680 x 914 x 2032 mm) 400-1000 kVA 400-600 kVA (2 enclosures) SYSBB400K600G 1350 lb (614 kg) 46.06”W x 36”D x 80”H (1170 x 914 x 2032 mm) 400-600 kVA 800-1000 kVA (2 enclosures) SYSBB800K1000G 1400 lb (635 kg) 46.06”W x 36”D x 80”H (1170 x 914 x 2032 mm) 800-1000 kVA SYSC400K1000G 500 lb (227 kg) 23.03”W x 36”D x 80”H (585 x 914 x 2032 mm) 400-1000 kVA Battery Cabinets Full String (2 enclosures) MCCB Enclosures Side Car Enclosures Side Car (1 enclosure) Table 1: Battery System Offerings TT BA BA T BA M M B CC T TT 3 BA TT 4 C S- AR 2 1 2 B1 CC FIGURE 1: Row of Battery System Enclosures 990-4170A Installation and Maintenance Guide 3 4.1 Battery Cabinets The UPS is supported by (1) to (4) full-strings of batteries, depending on requirements for battery back-up time. A full-string consists of 64 batteries. Because each battery cabinet contains either a positive or negative “half-string” (32 batteries), these units are provided in multiples of two. They must likewise be installed in multiples of two. The enclosures are labelled as follows: “BATT 1, BATT 2, etc.” Check top of cabinet. The number specifies the unit’s position in terms of its connectivity to the UPS. BATT 1 always contains a positive half-string, and BATT 2 a negative half-string. Additional odd-numbered battery cabinets are positive, and even-numbered battery cabinets are negative. Rear View Each battery cabinet houses a half-string of 32 batteries. FIGURE 2: Four Battery Cabinets (or 2 full-strings) . 1 2 A B 4 D 3 C Positive (odd): The perpendicular busbar strips (A & B) connect to the first (Battery 1+) and second (Battery 1-) busbar strips from the front of the battery cabinet. Negative (even): The perpendicular busbar strips (C & D) connect to the third (Battery 2+) and fourth (Battery 2-) busbar strips from the front of the battery cabinet. FIGURE 3: Battery Cabinet Identifiers 990-4170A 4 Symmetra MW Battery Back-up System 4.2 MCCB Enclosures The system uses (2) MCCBs (Molded Case Circuit Breakers) to connect the battery strings to the UPS. Each MCCB is housed in its own enclosure and labelled as “MCCB 1” or “MCCB 2.” MCCB 1 provides connectivity to the positive half-strings in Battery Cabinets 1, 3, 5 and 7. MCCB 2 provides connectivity to the negative half-strings in Cabinets 2, 4, 6 and 8. The MCCB enclosures are shipped mechanically and electrically pre-assembled. The internal components of the MCCBs are slightly different: MCCB 2 contains (2) additional horizontal busbar strips. In addition, all of the busbar in MCCB 2 can be reversed to satisfy an on-site configuration change (i.e., inputting the battery system to the opposite side of the UPS). The MCCB enclosure offers top and bottom cable entry. Front View MCCB 1 (left) connects to the positive half strings. MCCB 2 (right) connects to the negative half-strings. MCCB 1 Positive Breaker MCCB 2 Negative Breaker FIGURE 4: MCCB Enclosures Rear View Battery 2Battery 2+ Battery 1MCCB 1 (right) has (5) horizontal busbar strips running across the rear of its enclosure. Battery 1+ MCCB 2 (left) has (7). Midpoint Positive Negative FIGURE 5: MCCB Identifiers 990-4170A Installation and Maintenance Guide 5 4.3 Side Car Enclosures Side Car enclosures are used to facilitate connectivity between separated battery cabinets and the MCCBs. With Side Cars, the battery back-up system DOES NOT have to be installed as a straight line of enclosures from the UPS. The system can instead be broken down into groups of enclosures positioned in other rooms or in different areas of the same room. All Side Cars are labelled as “S-CAR”. Side Cars offer a.) busbar connection with separated battery cabinets; and b.) cable connection with additional Side Cars or with the MCCBs. The terms “front-end” and “back-end” refer to the unit’s position with respect to the group of battery cabinets it supports. Every Side Car is built exactly alike and can be deployed in either mode (front-end or back-end). Side Car enclosures offer top and bottom cable entry. Front View VERTICAL BUSBAR STRIPS (4 on each side) FOR HARD BUS CONNECTION TO A BATTERY CABINET HORIZONTAL BUSBAR STRIPS (4 total) FOR CABLE CONNECTION WITH ANOTHER SIDE CAR OR WITH THE MCCBs. TERMINAL BLOCK FOR SIGNAL WIRE CONNECTIVITY FIGURE 6: Side Car Components 990-4170A 6 Symmetra MW Battery Back-up System 5 SHIPPING, RECEIVING AND STORAGE 5.1 Shipping Each Battery Cabinet is shipped on its own 39” x 40” pallet. The MCCBs and Side Cars (if employed) are shipped two units on a 52” x 40” pallet. For further stability, cabinets are base-bolted to pallets using (4) angle braces. Other equipment is crated separately. MCCB or SIDE CAR ENCLOSURES BATTERY CABINET 36 4) 91 ”( 33 .0 7 ” (8 36 ” 84.4” (2144) (9 9 1) ” 40 4) 40 ) 80” (2032) 39 ” ( 91 0 16 (1 46 .0 6 ”( 11 70 ) 84.4” (2144) 80” (2032) ) 52 ANGLE BRACE 1 - M10 bolt on top 2 - 3/8” lag bolts on bottom ”( 13 2 1) ” 40 ) 16 (10 FIGURE 7: Shipping Enclosures The enclosures are wrapped in packaging materials prior to shipping. The enclosures and the pallets on which they sit are suited for forklift or pallet-jack access. Enclosures offer both front and side access for lifting devices. FIGURE 8: Transporting Enclosures 990-4170A Installation and Maintenance Guide 7 5.2 Receiving 5.2.1 Check for Damages 1. Upon receipt, inspect enclosures and crates for obvious signs of rough handling and/or external damage that might have occurred during shipping. • DO NOT remove the protective packaging from an enclosure until it is off its pallet and ready for installation. • DO NOT remove an enclosure from its shipping pallet until all forklift or pallet-jack movement is completed. • A thorough internal inspection should be conducted only after the enclosure has been positioned for installation, and prior to making electrical connections. 2. Record any external and/or internal damage observed and call the carrier immediately to allow their personnel to conduct an equipment inspection. • DO NOT contact APC first – notify the carrier. Otherwise, APC may be unable to assist in recovering the realized amount of the claim against the carrier. • All damage claims should be as specific as possible. Information pertaining to the shipment should appear on the shipping label and related paperwork. BE SURE to request a copy of the carrier’s inspection report. 5.2.2 Check for Discrepancies The receiver should also make certain the shipment has arrived in its entirety. Compare information from the shipping label against what has actually been received. If anything is missing, contact APC immediately (see Section 13, How to Contact APC). 5.3 Storage If the equipment must be stored, it should be stored indoors and with its protective packaging still in place. The equipment warranty is not applicable when there is evidence of outdoor storage. • The stored equipment – particularly the battery cabinets – should be kept in a climate-controlled environment with a temperature range of 68o to 77o F (20o to 25o C) and with a relative humidity of 0% to 95% non-condensing. • Consider any and all restrictions pertaining to floor loading. • The equipment must be protected at all times from excessive moisture, construction dirt, corrosive elements and other contaminants. Enclosures (still on their pallets, if possible) should be set on a firm and level surface. • Stored batteries should be recharged every six (6) months. • DO NOT stack equipment on top of the enclosures, whether or not they are still wrapped in packaging material. 990-4170A 8 Symmetra MW Battery Back-up System 6 INSTALLATION SITE 6.1 Environment The same rules governing storage environments apply to installation locations for this equipment. One item for consideration, however, is that an installation location should be considered more permanent than a storage situation. • This equipment must remain in a climate-controlled environment with a temperature range of 68o to 77o F (20o to 25o C) and with a relative humidity of 0% to 95% non-condensing. • Consider any and all restrictions pertaining to floor loading. • Enclosures should be set on a firm and level surface, and equipment should not be stacked on top of them. • The equipment should not be exposed to excessive moisture, construction dirt, corrosive elements and other contaminants. 6.2 Handling 6.2.1 Moving the Enclosures The enclosures are tall (See Section 4, Battery System Components), but should have little trouble clearing most doorways. They are also heavy, so use a properly rated forklift or pallet-jack to transport each unit (on its pallet!) to the location where it will be installed. Consider weight restrictions for any floors or elevators that might be used during the transportation process. If enclosures are being stored prior to install, transport in the same manner. 990-4170A Installation and Maintenance Guide 9 6.2.2 Preparing for Installation pallet down on level surface close to 1 Set where unit will be installed. 2 Remove external packaging material. the (4) angle braces that secure 3 Remove the enclosure to its pallet (see Figure 7 for location of angle braces). BATTERY CABINET 4 Use lifting device to remove enclosure from pallet, and place close to final installation position. 5 Conduct a thorough internal inspection of the enclosure(s). rated lifting device to move unit to 6 Use final installation position. MCCB ENCLOSURES FIGURE 9: Preparing for Installation 990-4170A 10 Symmetra MW Battery Back-up System 6.3 Positioning 6.3.1 Input to UPS The (4) main busbar strips (Battery 1+, Battery 1-, Battery 2+, Battery 2-) carrying DC power from the battery system are linked to DC busbar strips in the UPS’s Input/Output section via busbar or cable. The battery system can be mechanically connected to either side of the UPS, provided the I/O section of the UPS is located on that side. TOP Battery Cabinets UPS MCCB 2 MCCB 1 MCCB 1 MCCB 2 Battery Cabinets BOTTOM FIGURE 10: Input Options (left OR right side of UPS) 6.3.2 Alignment With UPS Battery system enclosures have a smaller (4 inches less) depth dimension than the UPS. The battery system can therefore be aligned with either the front or the back of the main unit. The UPS contains two sets of bolt holes to accommodate customer preference. REAR ALIGNMENT BACK UPS MCCB 1 MCCB 2 BATT 1 BATT 2 BATT 3 BATT 4 BATT 2 BATT 3 BATT 4 FRONT FRONT ALIGNMENT BACK UPS MCCB 1 MCCB 2 BATT 1 FRONT FIGURE 11: Alignment Flexibility 990-4170A Installation and Maintenance Guide 11 6.4 Space Considerations 6.4.1 Clearances A front-access space of at least thirty-six inches (36”) is required to allow proper servicing of enclosures. A minimum of eighteen inches (18”) is required above for top ventilation. Bottom ventilation has been designed into each dead front panel. 18” 18” 36” Required clearances for servicing and top ventilation. 36” FIGURE 12: Required Clearances There are no specific requirements for rear clearance, so enclosures can be situated flush against a backing wall. Check your local codes to ensure that all specified levels of clearance are applicable. 6.4.2 Service Access All assembly and servicing can be conducted through the front of each enclosure. Dead front panels can easily be removed, and just as easily reattached. For complete system access, side and rear panels (see Section 7.1.2, Back-to-back Configuration) are not employed between adjacent units. All enclosures offer front access for servicing. FIGURE 13: Front Service Access 990-4170A 12 Symmetra MW Battery Back-up System 6.4.3 Internal Module An internal module is incorporated into both the MCCB and Side Car enclosures. The module can slide out for easier access to the busbar and other internal components. To Release the MCCB’s Internal Module:. the module’s (4) base all of the busbar connectors between 1 Remove 2 Remove bolts. the MCCB and its adjoining enclosures. washers and 3 Remove nuts from (4) studs at rear of module. 5 The module can now slide out of the enclosure. the (4) 904 Remove degree side brackets at front of module. FIGURE 14: Releasing the MCCB Module To Return the MCCB’s Internal Module: Repeat the above steps, only in reverse order (torque all except #4 below to 37-40 ft-lbs): 1) Use protrusions at rear of enclosure to guide module back into position; 2) Re-attach washers and nuts to (4) studs at rear of module; 3) Re-attach (4) 90-degree side brackets to front of module; 4) Re-attach (4) base bolts (torque to 62-65 ft-lbs); and 5) Re-attach busbar connectors between MCCB and adjoining enclosure(s). 990-4170A Installation and Maintenance Guide 13 To Release the Side Car’s Internal Module:. 1 Remove all of the busbar connectors between the Side Car and its adjoining battery cabinet. washers and nuts from (4) 3 Remove studs at rear of module. 5 2 Remove the module’s (4) base bolts. 4 Remove the (4) 90-degree side brackets at front of module. The module can now slide out of the enclosure. FIGURE 15: Releasing the Side Car Module To Return the Side Car’s Internal Module: Repeat the above steps, only in reverse order (torque all except #4 below to 37-40 ft-lbs): 1) Use protrusions at rear of enclosure to guide module back into position; 2) Re-attach washers and nuts to (4) studs at rear of module; 3) Re-attach (4) 90-degree side brackets to front of module; 4) Re-attach (4) base bolts (torque to 62-65 ft-lbs); and 5) Re-attach busbar connectors between Side Car and adjoining battery cabinet. 990-4170A 14 Symmetra MW Battery Back-up System 7 CONFIGURATIONS APC offers (5) basic configurations for its Symmetra MW battery systems: (2) “standard” configurations and (3) “alternative” configurations. Regardless of the chosen configuration, MCCB 1 is always positioned closest to the UPS. Please consider that each of the following diagrams is based on using the maximum of eight battery cabinets. It should be noted, however, that lesser numbers of battery cabinets can be accommodated in similar configuration formats. Consider also that the following diagams depict the battery system as being aligned in a left-to-right format from the UPS. The battery system can just as easily be aligned in a right-to-left format. Battery cabinets must always be situated in multiples of two (one positive half-string and one negative half-string). 7.1 Standard Configurations In a “standard” configuration, all battery system enclosures are positioned adjacent to one another. 7.1.1 Straight-line Configuration A Straight-line Configuration consists of a single row of interconnected battery system enclosures. The battery system enclosures may extend directly outward from the UPS, or may be placed in a straight line that stands apart from the UPS. Connect all enclosures via convenient bus-to-bus connectivity. MCCB 1 MCCB 2 CAN BATT 1 BATT 2 BATT 3 BATT 4 BATT 5 CAN ... FIGURE 16: Straight-line Configuration 990-4170A Installation and Maintenance Guide 15 7.1.2 Back-to-back Configuration A Back-to-back Configuration consists of two rows of interconnected battery system enclosures, whereby all of the enclosure fronts are facing away from the other row. The internal interconnect cable between Side Cars is provided for this configuration. Connect a “back-end” Side Car to the last battery cabinet in the front row, and a “front-end” Side Car to the first battery cabinet in the back row. The back row is not mechanically connected back-to-back with the front row. The Side Cars are linked via [internally located] cable (supplied). A side panel is pre-attached to the exposed side of Battery Cabinet-8. Side Panel BATT 8 MCCB 1 MCCB 2 BATT 1 BATT 7 BATT 2 BATT 6 BATT 3 BATT 5 BATT 4 S-CAR S-CAR internal cable (supplied) CAN CAN FIGURE 17: Back-to-back Configuration 990-4170A 16 Symmetra MW Battery Back-up System 7.2 Alternative Configurations In an “alternative” configuration, battery system enclosures are situated in multiple locations. 7.2.1 Two-location Configuration A Two-location Configuration consists of two separate groups of battery system enclosures. The external interconnect cable is not supplied for this configuration. A trough or ladder should be used to accommodate external cable running between enclosures. Connect a “back-end” Side Car to the last battery cabinet in the first group, and a “front-end” Side Car to the first battery cabinet in the second group. The Side Cars are then linked via cable. external cable cable (supplied)external cable (not supplied) MCCB 1 MCCB 2 BATT 1 S-CAR BATT 5 BATT 6 BATT 7 BATT 8 (2) BATT 2 BATT 3 BATT 4 S-CAR (1) CAN CAN FIGURE 18: Two-location Configuration 990-4170A Installation and Maintenance Guide 17 7.2.2 Three-location Configuration A Three-location Configuration consists of three separate groups of battery system enclosures. The external interconnect cable is not supplied for this configuration. A trough or ladder should be used to accommodate external cable running between enclosures. Connect a “back-end” Side Car to the last battery cabinet in each of the first two groups, and a “front-end” Side Car to the first battery cabinet in each of the last two groups. Side Cars 1 and 2 are then linked via cable, as are Side Cars 3 and 4. external cable (not supplied) S-CAR BATT 6 BATT 5 BATT 8 BATT 6 (4) external cable (not supplied) MCCB 1 MCCB 2 CAN BATT 1 BATT 2 S-CAR S-CAR (1) (2) BATT 3 BATT 4 S-CAR (3) CAN FIGURE 19: Three-location Configuration 990-4170A 18 Symmetra MW Battery Back-up System 7.2.3 Four-location Configuration A Four-location Configuration consists of four separate groups of battery system enclosures. The external interconnect cable is not supplied for this configuration. A trough or ladder should be used to accommodate external cable running between enclosures. Connect a “back-end” Side Car to the last battery cabinet in each of the first three groups, and a front-end Side Car to the first battery cabinet in each of the last three groups. Side Cars 1 and 2 are then linked via cable, as are Side Cars 3 and 4 and Side Cars 5 and 6. external cable (not supplied) S-CAR BATT 5 BATT 6 (4) MCCB 1 MCCB 2 CAN BATT 1 BATT 2 S-CAR S-CAR (5) (6) S-CAR S-CAR (1) (2) BATT 3 BATT 7 BATT 8 BATT 4 S-CAR (3) CAN FIGURE 20: Four-location Configuration 990-4170A Installation and Maintenance Guide 19 8 INSTALLATION Section 8.1 covers the option of anchoring battery system cabinets to a concrete floor. Sections 8.2 through 8.7 detail the battery system installation process in the order in which it should ideally take place. 8.1 Anchoring Enclosures (Optional) Any or all of the enclosures can optionally be bolted to a concrete floor for added stability. Each enclosure rests on a pair of rectangular metal feet. There are (4) pre-cut holes in each foot to accommodate anchoring bolts. Bolt locations should be appropriately chalk marked on the facility floor, then drilled prior to final placement of the enclosure. Anchoring hardware is not provided. Consult APC Technical Support for hardware specifications (see Section 12.0, How to Contact APC). See Figures 21-23 for details on anchoring Battery Cabinets, MCCBs and Side Cars, respectively. 29.96” [760.96] 1.56” [39.62] Top View 1.85” [46.92] 14.22” [361.19] 21.78” [553.21] 36.00” [914.40] .63” [15.88] BATTERY CABINET 34.15” [867.48] 33.07” [839.98] Dimensions in inches and [mm] FIGURE 21: Anchoring Battery Cabinets 990-4170A 20 Symmetra MW Battery Back-up System To properly anchor the pre-assembled MCCBs, only the two perimeter feet should be bolted. These are the feet farthest removed from the other MCCB enclosure, or the feet on the far left and far right in the diagram below. DO NOT bolt the adjacent feet to the floor. Top View 3.08” [78.24] 1.56” [39.62] 1.85” [46.92] 19.92” [505.96] 14.22” [361.19] 21.78” [553.21] 36.00” [914.40] MCCB ENCLOSURE MCCB ENCLOSURE 34.15” [867.48] Bolt this foot! Bolt this foot! 23.03” [584.96] .63” [15.88] 46.06” [1169.92] Dimensions in inches and [mm] FIGURE 22: Anchoring MCCB Enclosures 1.56” [39.62] Top View 1.85” [46.92] 19.92” [505.96] 14.22” [361.19] 21.78” [553.21] 36.00” [914.40] .63” [15.88] SIDE CAR ENCLOSURE 23.03” [584.96] 34.15” [867.48] Dimensions in inches and [mm] FIGURE 23: Anchoring Side Car Enclosures 990-4170A Installation and Maintenance Guide 21 8.2 Connecting Enclosures 8.2.1 The Assembly Process 8.2.1.1 Rules of Assembly Observe these IMPORTANT RULES pertaining to battery system assembly: 1. Battery system assembly, as described in this section, must be conducted in each unit’s FINAL installation location. 2. The mechanical assembly should always take place PRIOR to the electrical assembly. 3. Enclosures should be assembled individually and in order of connection FROM the UPS (i.e., the MCCBs first, followed by BATT 1, BATT 2, BATT 3, etc.). 8.2.1.2 Simplifying Assembly The following steps have been taken to ensure ease of assembly: • The mechanical assembly of adjacent enclosures involves threading (4) M12 bolts through properly aligned holes. • The (2) MCCB enclosures are shipped already mechanically and electrically assembled. • Most battery cables are properly connected prior to shipping. • Back panels are not used between enclosures that will be positioned back-to-back. 990-4170A 22 Symmetra MW Battery Back-up System 8.2.2 Mechanical Assembly Almost every enclosure combination will be mechanically connected in exactly the same way, and in accordance with the procedure outlined on the next page. However, there is one minor exception: • Connecting the MCCBs to the UPS. Decide whether the battery system will be aligned with the front or the back of the UPS, then line MCCB 1 up with the proper set of holes. Regardless, the ongoing procedure for bolting these enclosures together remains the same as for other combinations. WARNINGS! - The battery system is supplied from multiple power sources and contains HAZARDOUS AC/DC VOLTAGES! Some battery terminals and other components remain LIVE even when the system is switched off! These voltages can cause SERIOUS BODILY INJURY or DEATH! - Ensure that NO ELECTRIC POWER SUPPLY SOURCE has been connected to the UPS for at least the last five (5) minutes! Ensure ALL BREAKERS are in the “OFF” position! - INSULATED TOOLS and proper INSULATING MATERIALS (rubber floor stands, rubber mats, gloves, protective clothing, etc.) should be used by all installation and service personnel! - Observe all LOCKOUT/TAGOUT procedures as required! - Observe all requirements and limitations pertaining to FLOOR LOADING! 990-4170A Installation and Maintenance Guide 23 To Mechanically Assemble Enclosures: dead front panels to gain 1 Remove internal access. Remove (2) M6 panel away from enclosure and lift to 2 Angle remove from bottom clips. Torx-head screws on top and (1) M6 Torx-head screw on bottom. the enclosures 3 Position alongside one another, four (4) M12 x 70mm bolts 4 Thread through holes in one enclosure to facing in the same direction, and with their (4) side-assembly holes aligned. determine success of alignment. . a pallet-jack or forklift to fine-tune 5 Use alignment, if necessary. DO NOT 6 Tighten bolts to 62-65 ft-lbs of torque. PULL enclosures together using bolts. FIGURE 24: Mechanical Assembly 990-4170A 24 Symmetra MW Battery Back-up System 8.2.3 Grounding Before making any electrical connections between enclosures, the battery system must be grounded to the UPS. The battery system’s grounding bar is the narrow busbar strip located near the base of each MCCB enclosure (running front-to-back). NEC recommends using #4/0 copper cable (not supplied) with appropriate NEMA-specified lugs to properly ground a system of this size. The cable must further carry a grounding equipment conductor (GEC). Connect the grounding cable to the grounding bar in either of the MCCB enclosures (APC recommends using MCCB 1 because of its proximity to the UPS). Secure one of the cable’s lug ends to any hole in the grounding bar with an M10 bolt, washers, lock washer and hex nut. Torque to 37-40 ft-lbs. FIGURE 25: Grounding the Battery System The grounding cable can exit top or bottom from the MCCB (See Section 8.2.4.2 [step 4] for instructions on how to remove either plate from the enclosure) and enter top or bottom to the UPS. Refer to the Symmetra MW (UPS) Installation Guide for instructions on connecting the other end of the Battery System grounding cable to the UPS. 990-4170A Installation and Maintenance Guide 25 8.2.4 Electrical Assembly The electrical assembly of ALL POSSIBLE battery system enclosure combinations is presented in the following subsections. WARNINGS! - The battery system is supplied from multiple power sources and contains HAZARDOUS AC/DC VOLTAGES! Some battery terminals and other components remain LIVE even when the system is switched off! These voltages can cause SERIOUS BODILY INJURY or DEATH! - Ensure that NO ELECTRIC POWER SUPPLY SOURCE has been connected to the UPS for at least the last five (5) minutes! Ensure ALL BREAKERS are in the “OFF” position! INSULATED TOOLS and proper INSULATING MATERIALS (rubber floor stands, rubber mats, gloves, protective clothing, etc.) should be used by all installation and service personnel! - Observe all LOCKOUT/TAGOUT procedures as required! 990-4170A 26 Symmetra MW Battery Back-up System 8.2.4.1 Connecting the MCCBs to the UPS (via busbar) The lowest (3) horizontal busbar strips (Midpoint, Positive and Negative, top-tobottom) at the rear of MCCB 1 must be connected to corresponding busbar strips in the UPS’s I/O Section via busbar. See Figure 5 for exact location of busbar. on how the MCCBs are to be aligned with the UPS, either(A) Straight (for 1 Depending rear alignment) or (B) Z-shaped (for front alignment) busbar connectors and all necessary hardware have been specially kitted for this purpose. A B 2 Make certain the two sets of busbar strips being connected are properly aligned. MIDPOINT MIDPOINT DC+ POSITIVE MCCB 1 UPS DC- NEGATIVE 3 Apply and secure busbar connectors to MCCB 1’s studs using (12) washers, lock washers and M10 hex nuts. Torque to 37-40 ft-lbs. Refer to UPS Installation Guide for hardware specifications and torque values on that side of connection. MCCB 1 UPS FIGURE 26: Connecting the MCCBs to the UPS (via busbar) 990-4170A Installation and Maintenance Guide 27 8.2.4.2 Connecting the MCCBs to the UPS (via cabling) The (2) horizontal busbar strips (Battery 1- and Battery 1+) running front-toback in the lower part of MCCB 1 and the (2) horizontal busbar strips (Battery 2+ and Battery 2-) running front-to-back in the lower part of MCCB 2 must be connected to corresponding busbar strips in the UPS’s I/O Section via cable. The busbar strips are “staggered” to avoid cable congestion. The required kcmil-size cable and lug connectors are not supplied, and must be procured by the installer. Check the Cable Land options presented in Section 9.3. kcmil-size cable in sufficient quantities and lengths to achieve connection 1 Procure between the MCCBs and the UPS. Remember that parallel conductors must be the same size and cut to the same length to maintain identical levels of impedance! one cable end (for 2 Crimp the MCCB side of the connection) into a 2-hole lug connector that adheres to the specified NEMA hole pattern. Refer to the UPS Installation Guide for lug specification on the other cable end. cables into (4) bundles. (See Section 9.3 for Cable Land options.) The 3 Arrange cable bundles will carry DC power from the battery back-up system to appropriate DC connections in the I/O section of the UPS. POSITIVE (Battery 1+ and Battery 1-) and NEGATIVE (Battery 2+ and Battery 2-) cables must be run in SEPARATE conduits between the MCCBs and the UPS. Ferrous metallic conduits or ferrous metallic raceways are recommended. 990-4170A 28 Symmetra MW Battery Back-up System either the top plate (left) or the bottom plate (right) from the MCCBs to 4 Remove accommodate point of cable entry. Make certain there is an appropriate point of entry on the UPS as well. Refer to UPS Installation Guide for specific instructions. Remove top plate (below) by removing the (4) torx-head screws from each corner of the plate. Remove bottom plate (right) by removing the (6) nuts and lockwashers from each of the 6 mm upward-facing studs. 5 Make note of the busbar that will be connected via cable between MCCB 1 and the UPS and MCCB 2 and the UPS. These connections involve the two lowest horizontal busbar strips that run front-to-back in each of the MCCBs. MCCB 1 (side view, lower section) Battery 1back Battery 1+ front MCCB 2 (side view, lower section) Battery 2+ back front Battery 2- 990-4170A Installation and Maintenance Guide 29 6 Apply appropriate end of FIRST bundle’s 2-hole lug connectors to the 2-hole termination points in the higher of the two busbar strips (Battery 1-) in MCCB 1. Secure with M12 bolts, washers, lock washers and hex nuts. Torque to 62-65 ft-lbs. SECURE LUGS TO ACCOMMODATE EITHER TOP (LEFT) OR BOTTOM (RIGHT) CABLE ENTRY. Battery 1- Battery 1Battery 1+ Battery 1+ other end of FIRST bundle’s 2-hole lug connectors to the 2-hole termination 7 Apply points in corresponding midpoint busbar in UPS’s I/O section. Refer to UPS Installation Guide for location, hardware and torque value for UPS connection. appropriate end of SECOND bundle’s 2-hole lug connectors to the 2-hole 8 Apply termination points in the lower of the two busbar strips (Battery 1+) in MCCB 1. Secure with M12 bolts, washers, lock washers and hex nuts. Torque to 62-65 ft-lbs. Battery 1- Battery 1+ other end of SECOND bundle’s 2-hole lug connectors to the 2-hole 9 Apply termination points in corresponding positive busbar in UPS’s I/O section. Refer to UPS Installation Guide for location, hardware and torque value for UPS connection. 990-4170A 30 Symmetra MW Battery Back-up System appropriate end of THIRD bundle’s 2-hole lug connectors to the 2-hole 10 Apply termination points in the higher of the two busbar strips (Battery 2+) in MCCB 2. Secure with M12 bolts, washers, lock washers and hex nuts. Torque to 62-65 ft-lbs. SECURE LUGS TO ACCOMMODATE EITHER TOP (LEFT) OR BOTTOM (RIGHT) CABLE ENTRY. Battery 2+ Battery 2+ Battery 2Battery 2- other end of THIRD bundle’s 2-hole lug connectors to the 2-hole termination 11 Apply points in corresponding midpoint busbar in UPS’s I/O section. Refer to UPS Installation Guide for location, hardware and torque value for UPS connection. appropriate end of FOURTH bundle’s 2-hole lug connectors to the 2-hole 12 Apply termination points in the lower of the two busbar strips (Battery 2-) in MCCB 2. See Step 8 for similar pictorial example. Secure with M12 bolts, washers, lock washers and hex nuts. Torque to 62-65 ft-lbs. other end of FOURTH bundle’s 2-hole lug connectors to the 2-hole 13 Apply termination points in corresponding negative busbar in UPS’s I/O section. Refer to UPS Installation Guide for location, hardware and torque value for UPS connection. FIGURE 27: Connecting the MCCBs to the UPS (via cabling) 990-4170A Installation and Maintenance Guide 31 8.2.4.3 Connecting MCCB 2 to MCCB 1 MCCB 2 is shipped mechanically connected to MCCB 1, and most of the electrical between these units has been pre-connected as well. When opting for cable connection between the MCCBs and the UPS (see Section 8.2.4.2), no additional connections are required between MCCB 2 and MCCB 1. However, when opting for busbar connection between the MCCBs and the UPS (see Section 8.2.4.1), the (3) lowest horizontal busbar strips (Midpoint, Positive and Negative) at the rear of MCCB 1 and MCCB 2 must be connected. In this instance, (3) straight busbar connectors and all necessary hardware will be specially kitted. Apply and secure the busbar connectors between the strips using (24) washers, lock washers and M10 hex nuts. Torque to 37-40 ft-lbs. MCCB 2 MCCB 1 Rear View Battery 2Battery 2+ Battery 1Battery 1+ Midpoint Positive Negative If using busbar to connect MCCBs to UPS, make these (3) connections between the MCCBs. FIGURE 28: Electrical Connections Between MCCBs 990-4170A 32 Symmetra MW Battery Back-up System 8.2.4.4 Connecting BATT 1 to MCCB 2 The (4) horizontal busbar strips (Battery 1+, Battery 1-, Battery 2+, Battery 2-, front-to-back) running along the top of BATT 1 must be connected to corresponding vertical busbar strips in MCCB 2. busbar connectors and all necessary hardware have been specially kitted for 1 Angled this purpose. 2 Make certain the two sets of busbar strips being connected are properly aligned. back front BATT 1 BUSBAR STRIPS Battery 1+ Battery 1- Battery 2+ Battery 2- MCCB 2 BUSBAR STRIPS and secure busbar connectors to studs using (32) washers, lock washers and 3 Apply M10 hex nuts. Torque to 37-40 ft-lbs. FIGURE 29: Connecting BATT 1 to MCCB 2 990-4170A Installation and Maintenance Guide 33 8.2.4.5 Connecting Battery Cabinets to Battery Cabinets The (4) horizontal busbar strips (Battery 1+, Battery 1-, Battery 2+, Battery 2-, front-to-back) running along the top of the add-on battery cabinet must be connected to corresponding strips in the previously installed cabinet. busbar connectors and all necessary hardware have been specially kitted for 1 Straight this purpose. 2 Make certain the two sets of busbar strips being connected are properly aligned. and secure busbar connectors to studs using (32) washers, lock washers and 3 Apply M10 hex nuts. Torque to 37-40 ft-lbs. FIGURE 30: Connecting Battery Cabinets 990-4170A 34 Symmetra MW Battery Back-up System 8.2.4.6 Connecting Side Cars to Battery Cabinets The (4) horizontal busbar strips (Battery 1+, Battery 1-, Battery 2+, Battery 2-, front-to-back) running along the top of the Battery Cabinet must be connected to corresponding vertical busbar strips in the Side Car. busbar connectors and all necessary hardware have been specially kitted for 1 Angled this purpose. 2 Make certain the two sets of busbar strips being connected are properly aligned. front back BATTERY CABINET BUSBAR STRIPS Battery 1+ Battery 1- Battery 2+ Battery 2- SIDE CAR BUSBAR STRIPS and secure busbar connectors to studs using (32) washers, lock washers and 3 Apply M10 hex nuts. Torque to 37-40 ft-lbs. FIGURE 31: Connecting Side Cars to Battery Cabinets 990-4170A Installation and Maintenance Guide 35 8.2.4.7 Connecting Side Cars to Side Cars The (4) horizontal busbar strips (Battery 1+, Battery 1-, Battery 2+, Battery 2-, top-to-bottom) at the front of one Side Car must be connected to corresponding busbar strips at the front of the other Side Car via cable. These strips are “staggered” in the Side Cars to avoid cable congestion. The required kcmil-size cable and lug connectors are not supplied (except in a back-to-back configuration) and must be procured by the installer. Check the Cable Land options presented in Section 9.3. kcmil-size cable in sufficient quantities and lengths to achieve connection 1 Procure between the Side Cars. Remember that parallel conductors must be the same size and cut to the same length to maintain identical levels of impedance! each cable end into 2 Crimp a 2-hole lug connector that adheres to the specified NEMA hole pattern. cables into (4) bundles. (See Section 9.3 for Cable Land options.) The 3 Arrange cable bundles will carry DC power from the batteries (via the Side Cars) to appropriate connections on the MCCBs. POSITIVE (Battery 1+ and Battery 1-) and NEGATIVE (Battery 2+ and Battery 2-) cables must be run in SEPARATE conduits between the Side Cars. Ferrous metallic conduits or ferrous metallic raceways are recommended. 990-4170A 36 Symmetra MW Battery Back-up System either the top plate (left) or the bottom plate (right) from each Side Car to 4 Remove accommodate point of cable entry. If Side Cars are used in a Back-to-back Configuration (see Section 7.1.2), supplied cable must remain internal and run through the open backs between these enclosures. Remove top plate (below) by removing the (4) torx-head screws from each corner of the plate. Remove bottom plate (right) by removing the (6) nuts and lockwashers from each of the 6 mm upward-facing studs. 5 Make note of the busbar that will be connected via cable between the two Side Cars. SIDE CAR 1 (front view) Battery 1+ Battery 1- Battery 2+ Battery 2- SIDE CAR 2 (front view) Battery 1+ Battery 1- Battery 2+ Battery 2- 990-4170A Installation and Maintenance Guide 37 one end of FIRST bundle’s 2-hole lug connectors to the 2-hole termination points 6 Apply in the bottom busbar strip (Battery 2-) of the first Side Car. Secure with M12 bolts, washers, lock washers and hex nuts. Torque to 62-65 ft-lbs. SECURE LUGS TO ACCOMMODATE EITHER TOP (ABOVE) OR BOTTOM (BELOW) CABLE ENTRY. other end of FIRST bundle’s 2-hole lug connectors to the 2-hole termination 7 Apply points in the bottom busbar strip (Battery 2-) of second Side Car. Secure with M12 bolts, washers, lock washers and hex nuts. Torque to 62-65 ft-lbs. Steps 6-7 to connect the OTHER THREE corresponding busbar strips in each 8 Repeat Side Car via cable. Work upward (first Battery 2+, then Battery 1-, then Battery 1+) from the bottom strip to avoid cable congestion! Secure all lugs with M12 bolts, washers, lock washers and hex nuts. Torque to 62-65 ft-lbs. Battery 1+ Battery 1- Battery 2+ Battery 2- FIGURE 32: Connecting Side Cars to Side Cars 990-4170A 38 Symmetra MW Battery Back-up System 8.2.4.8 Connecting a Side Car to the MCCBs In instances when all of the Battery Cabinets are separated from the MCCBs, the first “front end” Side Car must be connected to the MCCBs via cable. The (4) horizontal busbar strips (Battery 1+, Battery 1-, Battery 2+, Battery 2-, top-to-bottom) at the front of the Side Car must be connected to the (2) horizontal busbar strips that run front-to-back in the upper section of each of the MCCBs. The strips are “staggered” to avoid cable congestion. The required kcmil-size cable and lug connectors are not supplied and must be procured by the installer. Check the Cable Land options presented in Section 9.3. kcmil-size cable in sufficient quantities and lengths to achieve connection 1 Procure between the Side Car and the MCCBs. Remember that parallel conductors must be the same size and cut to the same length to maintain identical levels of impedance! each cable end into 2 Crimp a 2-hole lug connector that adheres to the specified NEMA hole pattern. cables into (4) bunches. (See Section 9.3 for Cable Land options.) The 3 Arrange cable bundles carry DC power from the batteries (via the Side Cars) to appropriate connections on the MCCBs. POSITIVE (Battery 1+ and Battery 1-) and NEGATIVE (Battery 2+ and Battery 2-) cables must be run in SEPARATE conduits between the Side Cars and the MCCBs. Ferrous metallic conduits or ferrous metallic raceways are recommended. 990-4170A Installation and Maintenance Guide 39 either the top plate (left) or the bottom plate (right) from the Side Car and 4 Remove the MCCBs to accommodate point of cable entry. Remove top plate (below) by removing the (4) torx-head screws from each corner of the plate. Remove bottom plate (right) by removing the (6) nuts and lockwashers from each of the 6 mm upward-facing studs. note of the busbar that will be connected via cable between the Side Car and 5 Make MCCB 1 and the Side Car and MCCB 2. These connections involve the two highest horizontal busbar strips that run front-to-back in each of the MCCBs. MCCB 1 (side view, upper section) SIDE CAR (front view) Battery 1- Battery 1+ Battery 1+ Battery 1- MCCB 2 (side view, upper section) Battery 2+ Battery 2Battery 2Battery 2+ 990-4170A 40 Symmetra MW Battery Back-up System one end of FIRST bundle’s 2-hole lug connectors to the 2-hole termination 6 Apply points in the bottom horizontal busbar strip (Battery 2-) of the Side Car. Secure with M12 bolts, washers, lock washers and hex nuts. Torque to 62-65 ft-lbs. SECURE LUGS TO ACCOMMODATE EITHER TOP (ABOVE) OR BOTTOM (BELOW) CABLE ENTRY. other end of FIRST bundle’s 2-hole lug connectors to the 2-hole termination 7 Apply points in the higher of the two busbar strips (Battery 2-) in MCCB 2. Secure with M12 bolts, washers, lock washers and hex nuts. Torque to 62-65 ft-lbs. SECURE LUGS TO ACCOMMODATE EITHER TOP (ABOVE) OR BOTTOM (BELOW) CABLE ENTRY. Battery 2- Battery 2+ 990-4170A Installation and Maintenance Guide 41 upward, apply one end of SECOND bundle’s 2-hole lug connectors to the 8 Working 2-hole termination points in the third busbar strip (Battery 2+) in the Side Car. Secure with M12 bolts, washers, lock washers and hex nuts. Torque to 62-65 ft-lbs. other end ofSECOND bundle’s 2-hole lug connectors to the 2-hole termination 9 Apply points in the lower of the two busbar strips (Battery 2+) in MCCB 2. Secure with M12 bolts, washers, lock washers and hex nuts. Torque to 62-65 ft-lbs. Battery 2- Battery 2+ upward again, apply one end of THIRD bundle’s 2-hole lug connectors 10 Working to the 2-hole termination points in the second busbar strip (Battery 1-) in the Side Car. Secure with M12 bolts, washers, lock washers and hex nuts. Torque to 62-65 ft-lbs. other end of THIRD bundle’s 2-hole lug connectors to the 2-hole termination 11 Apply points in the higher of the two busbar strips (Battery 1-) in MCCB 1. See Step 7 for similar pictorial example. Secure with M12 bolts, washers, lock washers and hex nuts. Torque to 62-65 ft-lbs. one end ofFOURTH bundle’s 2-hole lug connectors to the 2-hole termination 12 Apply points in the top busbar strip (Battery 1+) in the Side Car. Secure with M12 bolts, washers, lock washers and hex nuts. Torque to 62-65 ft-lbs. other end of FOURTH bundle’s 2-hole lug connectors to the 2-hole 13 Apply termination points in the lower of the two busbar strips (Battery 1+) in MCCB 1. See Step 9 for similar pictorial example. Secure with M12 bolts, washers, lock washers and hex nuts. Torque to 62-65 ft-lbs. FIGURE 33: Connecting a Side Car to the MCCBs 990-4170A 42 Symmetra MW Battery Back-up System 8.3 Connecting Fuse Signal Wires The (2) fuse signal wires in each battery cabinet must be connected to a designated communications interface (or CAN) board in one of the MCCBs. These wires signal the UPS when the cabinet’s fuse needs replacement. The fuse is pre-connected to the Terminal Block in the battery cabinet’s upper frame and its signal wires extend from the opposite side of this Block. Fuse signal wires are not supplied. 8.3.1 CAN Board Configurations Each CAN board can accept up to (4) sets of fuse signal wires. • In “straight line” and “back-to-back” configurations, the first (4) battery cabinets are connected to MCCB 1’s CAN board; additional cabinets to MCCB 2’s CAN. • In the (3) “alternative” configurations, the first (4) battery cabinets are connected to MCCB 1’s CAN board and additional cabinets to a Terminal Block located in the next “front end” Side Car after the fourth battery cabinet. Wires must extend from Terminal Block to Terminal Block until terminating at the proper CAN board. Once all fuse signal wire connections are made, the two CAN boards must be linked via ABUS (DB-15) cable, and then MCCB 1’s CAN board must be linked to the UPS via ABUS cable. Refer to the UPS Installation Guide for wiring termination points on the UPS. 8.3.2 Connecting to CAN Boards/Terminal Blocks TERMINAL BLOCK Start at Terminal Block in battery cabinet farthest from MCCBs, and move (2) wires through specified holes into preceding cabinet. Continue process working forward. Use tie-wrap to bundle wires. TERMINAL BLOCKS CABLE LAND BATT 7 BATT 6 CAN BOARD CAN BOARD ABUS CABLE UPS BATT 5 S-CAR TERMINAL BLOCK BATT 8 TERMINAL BLOCKS MCCB 1 MCCB 2 BATT 1 BATT 2 BATT 3 BATT 4 S-CAR FIGURE 34: Connecting Fuse Signal Wires 990-4170A Installation and Maintenance Guide 43 8 Terminal Block (in Side Car) Wiring Diagram 8 8.3.3 7 7 6 6 To MCCB 2 CAN Board BATT 8 (2 wires) 5 5 4 4 BATT 7 (2 wires) 3 3 2 2 BATT 6 (2 wires) 1 1 BATT 5 (2 wires) FIGURE 35: Side Car Terminal Block 8.3.4 CAN Board (in MCCB 1) Wiring Diagram The diagram below is specific to the MCCB 1 CAN Board. The MCCB 2 CAN board has the same layout, but some of the connections are different: • The “UPS Connector” on MCCB 1 is the “CAN Board Connector” on MCCB 2. 1 2 3 TEMPERATURE SENSOR WIRES 4 2 3 2 THESE WIRES ARE PRECONNECTED 1 2 1 3 2 3 2 7 6 4 5 BATT 3 or 7 (2 wires) 2 3 BATT 2 or 6 (2 wires) BATT 1 or 5 (2 wires) 4 BATT 2 to MCCB 1 (2 wires) BATT 1 to MCCB 1 (2 wires) PRECONNECTED JUMPERS 1 BATT 4 or 8 (2 wires) 1 DEFAULT BOARD FUSE SIGNAL WIRES 8 1 MCCB STATUS 4 1 CAN BOARD CONNECTOR CAN board in other MCCB (15-pin) MCCB LAMPS 4 MCCB TRIG UPS CONNECTOR UPS to CAN board (15-pin) UVR SUPPLY • The “Can Board Connector” on MCCB 1 is not used on MCCB 2. FIGURE 36: CAN Board Wiring 990-4170A 44 Symmetra MW Battery Back-up System 8.4 Connecting Temperature Sensor Wires Temperature sensor wires are supplied for installation in each of the first (2) battery cabinets. These wires contain a sensing device called a “thermistor” that monitors temperature abnormalities. Through its connection to one of the CAN boards, the thermistor maintains an electrical link to the UPS. Should the temperature in the battery cabinet exceed the acceptable operational range, the UPS will alert the operator. The sensor wires are pre-attached to the upper frames of the MCCBs, and the twoconductor cable on one end of each wire has been pre-connected to MCCB 1’s CAN board. The left-side connection on the CAN board must be strung to BATT 1, and the right-side connection to BATT 2. Follow the same path going out as the fuse signal wires (described in Section 8.3) did coming in. Use jumper wires to extend the reach of the sensor wires, and zip-tie them near the internal roof of the battery cabinet. FIGURE 37: Temperature Sensing Device 990-4170A Installation and Maintenance Guide 45 8.5 Reconnecting the Batteries 8.5.1 Battery Cable Reconnection Certain battery cables are disconnected prior to shipping to reduce voltage, and decrease the risk of injury during transportation and handling. After all of the battery system enclosures have been mechanically and electrically connected, these disconnected cables must be reconnected. One end should be correctly fastened to a battery terminal, while the other end is temporarily secured to a stand-off insulator or packed in insulation. The lug on this unfastened end must be reconnected to either another battery terminal, the fuse or the midpoint connection. WARNINGS! - These batteries contain LETHAL VOLTAGE LEVELS and REMAIN LIVE and DANGEROUS even when other power supplies have been shut off! Ensure ALL BATTERY BREAKERS are in the “OFF” position! These voltages can cause SERIOUS BODILY INJURY or DEATH! - ONLY QUALIFIED ELECTRICIANS may perform this installation! Keep unauthorized personnel away from batteries! - INSULATED TOOLS and proper INSULATING MATERIALS (rubber floor stands, rubber mats, gloves, protective clothing, etc.) should be used by all installation and service personnel! - Observe all LOCKOUT/TAGOUT procedures as required! Battery wiring diagrams for positive (Battery Cabinets 1, 3, 5 and 7) and negative (Battery Cabinets 2, 4, 6 and 8) half-strings are provided in Appendix A, Battery Layout Diagrams. The on-site cable connections and the order in which they should take place are more clearly indicated in those diagrams. Use a voltmeter to ensure that the voltage potential between connection points is satisfactory. 8.5.2 Rules of Reconnection Observe these IMPORTANT RULES governing reconnection of battery cables: 1. Complete ALL battery cabling for one battery cabinet before moving on to address the next battery cabinet. 2. Start with the battery cabinet closest to the MCCBs. 3. Batteries should be re-connected in the order specified in Section 8.5.3 to reduce high-voltage risks. 990-4170A 46 Symmetra MW Battery Back-up System 8.5.3 Order of Reconnection 1 Make the (4) row-to-row connections. In all battery cabinets, these connections link battery #4 to battery #5 on the top shelf, battery #12 to battery #13 on the second shelf, etc. See Appendix A. 2 Make the midpoint connection. In BATT 1 and other positive half-string cabinets, battery #32 is connected to a node beneath the perpendicular busbar that runs to the Battery 1- busbar (second busbar strip from front). See Appendix A. In BATT 2 and other negative half-string cabinets, battery #1 is connected to a node beneath the perpendicular busbar that runs to the Battery 2+ busbar (third busbar strip from front). See Appendix A. CONNECT TO EITHER NODE BENEATH THE BUSBAR. 990-4170A Installation and Maintenance Guide 47 3 Make the fuse connection. In BATT 1 and other positive half-string cabinets, battery #1 is connected to one of the fuse nodes that runs to the Battery 1+ busbar (first busbar strip from front). See Appendix A. In BATT 2 and other negative half-string cabinets, battery #32 is connected to one of the fuse nodes that runs to the Battery 2- busbar (fourth busbar strip from front). See Appendix A. CONNECT TO EITHER NODE FUSE 4 Make the (3) shelf-to-shelf connections. In all battery cabinets, these connections link battery #8 on the top shelf to battery #9 on the second shelf, battery #16 on the second shelf to battery #17 on the third shelf, and battery #24 on the third shelf to battery #25 on the bottom shelf. See Appendix A. SHELF-TO-SHELF CONNECTORS ARE TYPICALLY FASTENED TO A STAND-OFF INSULATOR BETWEEN SHELVES FIGURE 38: Order of Battery Reconnection 990-4170A 48 Symmetra MW Battery Back-up System 8.6 Re-attaching Dead Front Panels After all interior work is completed, the dead front panels must be reattached and “finishing” panels added to their exterior. Battery Cabinets have (2) front panels, while MCCB and Side Car enclosures have one apiece. Once a front panel has been screwed in place, a column of (4) finishing panels should be attached to complete the design. To Attach Dead Front/Finishing Panels: 1 Angle slots at bottom of dead front panel onto (2) metallic clips at base of enclosure. panel and align its 2 Straighten holes with holes in frame. panel to frame by re-fastening 3 Secure the (2) M6 Torx-head screws. 4 Attach (4) “finishing” panels by angling bottom slots into front panel clips, and applying top-side magnetic fasteners firmly against metal in front panel. FIGURE 39: Front Panel Assembly 990-4170A Installation and Maintenance Guide 49 8.7 Attaching Bottom Trim To attach the decorative bottom trim to each enclosure, thread (4) corner screws through the rectangular trim sheet and into designated holes at the base of the enclosure. FIGURE 40: Bottom Trim Assembly 990-4170A 50 Symmetra MW Battery Back-up System 9 SPECIFICATIONS 9.1 Battery Run Times (includes MCCBs) # of Batteries Type Size (W x D x H) Weight 400 kVA 600 kVA 800 kVA 1 MVA 64 (1 string, or 2 cabinets) 130Ah VRLA 112.20” x 38” x 80” (2850 x 965 x 2032 mm) 9,800 lb (4445 kg) 5 min. runtime N/A N/A N/A 128 (2 strings, or 4 cabinets) 130Ah VRLA 178.34” x 38” x 80” (4530 x 965 x 2032 mm) 18,200 lb (8255 kg) 16 min. runtime 6 min. runtime N/A N/A 192 (3 strings, or 6 cabinets) 130Ah VRLA 244.48” x 38” x 80” (6210 x 965 x 2032 mm) 26,600 lb (12,066 kg) 31 min. runtime 16 min. runtime 9 min. runtime 6 min. runtime 256 (4 strings, or 8 cabinets) 130Ah VRLA 310.62” x 38” x 80” (7890 x 965 x 2032 mm) 35,000 lb (15,876 kg) 52 min. runtime 27 min. runtime 16 min. runtime 10 min. runtime Table 2: Battery Run Times 9.2 Torque Specifications Size Application Torque M6 All external panels 7-10 ft-lbs Battery connectors Specified on battery Ground bus to internal frame on MCCBs 17-20 ft-lbs Fuse connector on battery cabinets 17-20 ft-lbs Midpoint connector on battery cabinets 17-20 ft-lbs M10 Busbar connectors throughout system 37-40 ft-lbs M12 Mechanical assembly of enclosures 62-65 ft-lbs 2-hole lug connectors to busbar 62-65 ft-lbs Circuit Breaker busbar connections 97-100 ft-lbs M8 M14 Table 3: Torque Specifications 990-4170A Installation and Maintenance Guide 51 9.3 Wire and Cable Specifications Connectivity Spec. Total Units 4/0 copper 1 cable BATT (1-4) Terminal Block to MCCB 1 CAN board (direct) 16 gauge 2 wires per battery cabinet BATT (1-4) Terminal Block to Side Car Terminal Block 16 gauge 2 wires per battery cabinet Side Car Terminal Block to MCCB 1 CAN board 16 gauge 2 wires per battery cabinet BATT (5-8) Terminal Block to MCCB 2 CAN board (direct) 16 gauge 2 wires per battery cabinet BATT (5-8) Terminal Block to Side Car Terminal Block 16 gauge 2 wires per battery cabinet Side Car Terminal Block to MCCB 2 CAN board 16 gauge 2 wires per battery cabinet Side Car Terminal Block to Side Car Terminal Block 16 gauge 2 wires per battery cabinet MCCB 1 CAN board to BATT 1 24 gauge 2 wires MCCB 1 CAN board to BATT 2 24 gauge 2 wires Jumper Wires (not supplied) 24 gauge 2 wires Grounding Cable (not supplied) MCCB 1 (or MCCB 2) Grounding Bar to UPS Fuse Signal Wire (not supplied) Temperature Sensor Wire (supplied) CAN Board Connector (only supplied for CAN board-to-CAN board) MCCB 1 CAN board to MCCB 2 CAN board ABUS (DB-15) 1 cable MCCB 1 CAN board to UPS ABUS (DB-15) 1 cable Cable Land (only supplied for Side Car-to-Side Car in a back-to-back configuration) (option 1) 400 kcmil/phase NEMA hole pattern 20 per connection (4 bundles of 5 cables) (option 2) 500 kcmil/phase NEMA hole pattern 20 per connection (4 bundles of 5 cables) (option 3) 600 kcmil/phase NEMA hole pattern 16 per connection (4 bundles of 4 cables) Battery to Battery 4/0 24 per cabinet Row to Row 4/0 4 per cabinet Shelf to Shelf 4/0 3 per cabinet Battery to Midpoint 4/0 1 per cabinet Battery to Fuse 4/0 1 per cabinet MCCBs to UPS or Side Car to Side Car or Side Car to MCCBs Battery Cable (supplied) Table 4: Wire and Cable Specifications 990-4170A 52 Symmetra MW Battery Back-up System 9.4 Cable Bolt and Lug Specifications Cable Size Bolt Hole Size Lug Width Lug P/N (1) (2) Crimping Dies Dies 400 kcmil .5 in 1.39 in. Panduit Greenlee Greenlee Greenlee (12.7 mm) (39.12 mm) LCD400-12-6 Catalogue No. Catalogue No. Catalogue K22-GL K22-11 Colour Code Blue 500 kcmil .5 in 1.54 in. Panduit Greenlee Greenlee Greenlee (12.7 mm) (39.12 mm) LCD500-12-6 Catalogue No. Catalogue No. Catalogue K22-GL K22-12 Colour Code Brown 600 kcmil .5 in 1.7 in. Panduit Greenlee Greenlee Greenlee (12.7 mm) (43.18 mm) LCD600-12-6 Catalogue No. Catalogue No. Catalogue K22-GL K22-13 Colour Code Green Table 5: Cable Bolt and Lug Specifications 9.5 Fuse and Breaker Ratings Rated Discharge, A Maximum Discharge, A Fuse for each String, A Circuit Breaker Rating, A Instantaneous Trip Setting 400 kVA 542 638 800 1000 300% 600 kVA 814 958 800 1000 300% 800 kVA 1085 1276 800 1600 300% 1 MVA 1356 1595 800 1600 300% Table 6: Fuse and Breaker Ratings 9.6 Rated Certifications Category Certification Operation and Safety UL1778 and cUL certified Seismic Waveform IAW Bellcore GR-63 Section 4.4 and Section 5.4, Zone 4 certified Random Frequency IAW MIL-STD-810F (transportation) certified Sinusoidal Frequency Dwell IAW ASTM D999-96 (transportation) certified Table 7: System Certifications 990-4170A Installation and Maintenance Guide 53 10 MAINTENANCE WARNINGS! - Ensure that NO ELECTRIC POWER SUPPLY SOURCE has been connected to the UPS for at least the last five (5) minutes! Ensure ALL BREAKERS are in the “OFF” position! - INSULATED TOOLS and proper INSULATING MATERIALS (rubber floor stands, rubber mats, gloves, protective clothing, etc.) should be used by all installation and service personnel! - Observe all LOCKOUT/TAGOUT procedures as required! 10.1 Preventive Maintenance While the Symmetra MW battery back-up system should require a minimal amount of servicing, a regular program of preventive maintenance can nonetheless be beneficial to the overall performance and reliability of the system. A well-defined preventive maintenance program can provide: • Timely detection and correction of undesirable operating conditions • Fewer failures from unexpected sources • Improved overall system performance • Potentially longer lifetime for the batteries • The need for fewer replacement parts • Less time spent on repairs and overhauls • The option of scheduling maintenance at the best-possible times 990-4170A 54 Symmetra MW Battery Back-up System 10.1.1 Equipment Inspections Battery back-up system equipment should be periodically inspected. Carry out the first inspection 3-6 months after start-up. Perform subsequent inspections about once a year thereafter, depending on environmental conditions and operational frequency. The following components require regular inspection: • Front, Side and Back Panels should be held tightly and firmly against the frame of the enclosure. Check the bolts used to secure side and back panels to the frame. Check the bolts (on top) and clips (on bottom) used to hold front panels in place. • Cabinet Frames and Internal Modules should be checked for denting or deformity. • Circuit Breakers should be firmly secured to the MCCB assembly, and switching mechanisms should engage easily. The breakers should not be cracked or broken, and all cabling connections should be tight. • Batteries should be checked to ensure all cabling connections are tight. Voltage levels should also be checked. The expected life span of this battery type is anywhere from 2-5 years, depending on usage. Replacement batteries should always be of the same model and type as those previously installed. • Busbar connections should be firm, and not loose. Check that all internal busbar strips are properly secured to the appropriate frame or internal module. • Cable connections should be firm, and not loose. Check that all cabling connects to its proper termination points and that all connections are tightly secured. • Fuse Signal Wire and Temperature Sensor Wire terminations should likewise be firm, and not loose. 990-4170A Installation and Maintenance Guide 55 10.2 Replacing Fuses Blown-out fuses in the battery cabinets are detected by the UPS and must be replaced as quickly as possible. If not, the system’s operational effectiveness may be compromised. The battery back-up system uses European Style Square Body 800A fuses, which are mounted between a pair of slotted plates. Replacement fuses should be the same model as those previously installed. This procedure should only be performed when the UPS is off-line. Otherwise, the fuse will become “hot” to ground. If the red rectangular button on the fuse pops up, the fuse is bad. To Remove a Fuse: (2) signal wires from fuse by 1 Detach unplugging. 2 Using 17mm wrench, LOOSEN the (2) bolts holding fuse’s side plates in place. LEFT BOLT RIGHT BOLT SIGNAL WIRE PLUG RED INDICATOR BUTTON fuse’s right slotted plate down and 3 Slide away from its holding bolt. 4 Pull fuse’s left slotted plate down and away from its holding bolt. FIGURE 41: Removing Fuses 990-4170A 56 Symmetra MW Battery Back-up System To Install a Fuse: fuse’s left slotted plate onto 1 Push left holding bolt (between the two 2 Swing fuse’s right slotted plate up and onto right holding bolt (between the two conductor stabs). 4 Plug (2) signal wires into fuse. conductor stabs). 3 Using 17mm wrench, tighten both bolts to 17-20 ft-lbs of torque. LEFT BOLT RIGHT BOLT SIGNAL WIRE PLUG FIGURE 42: Installing Fuses 990-4170A Installation and Maintenance Guide 57 11 GLOSSARY ABUS 15-pin cable used to connect CAN boards. kcmil Large wire size measured in thousands of circular mills AC/DC Alternating current/direct current kg Kilogram APC American Power Conversion kVA Kilovolt ampere “back-end” Refers to Side Car on back end of battery cabinet grouping kW Kilowatt BATT Refers to Battery Cabinet MCCB Molded Case Circuit Breaker battery backup system All of the battery cabinets, MCCBs & Side Cars comprising this system midpoint Common busbar connection point for half-strings of batteries C (degrees) Centigrade mm Millimeters CAN board Communications Board in MCCBs that communicates with UPS MW Megawatt circular mil Circular area with a diameter of one thousandth (0.001) of an inch. NEMA National Electrical Manufacturers Association DB-15 15-pin cable used to connect CAN boards. S-CAR Refers to Side Car Enclosure Refers to Battery, MCCB or Side Car structure Terminal Block Termination point for fuse signal and temperature sensor wires F (degrees) Fahrenheit Thermistor Temperature sensing device “front-end” Refers to Side Car on front end of battery cabinet grouping UL Underwriters Laboratory; refers to product safety rating ft-lb Foot pounds; measure of torque pressure for tightening bolts UPS Uninterruptible Power Supply full-string The 64 batteries (32 positive & 32 negative) in a pair of cabinets USFDA United States Food and Drug Administration GEC Grounding Electrode Conductor V Volt half-string The 32 batteries (either positive or negative) in one cabinet VRLA Voltage Regulated Lead Acid; refers to battery type I/O Input/Output; UPS section that interfaces with battery system 990-4170A 58 Symmetra MW Battery Back-up System 12 LIFE SUPPORT POLICY/WARRANTY 12.1 Life Support Policy American Power Conversion (APC) does not recommend the use of any of its products in the following situations: • In life-support applications where failure or malfunction of the APC product can be reasonably expected to cause failure of the life support device or to affect significantly its safety or effectiveness. • In direct patient care. APC will not knowingly sell its products for use in such applications unless it receives in writing assurances satisfactory to APC that (a) the risks of injury or damage have been minimized, (b) the customer assumes all such risks, and (c) the liability of American Power Conversion is adequately protected under the circumstances. The term life support device includes but is not limited to neonatal oxygen analyzers, nerve stimulators (whether used for anesthesia, pain relief or other purposes), autotransfusion devices, blood pumps, defibrillators, arrhythmia detectors and alarms, pacemakers, hemodialysis systems, peritoneal dialysis systems, neonatal ventilator incubators, ventilators (for adults and infants), anesthesia ventilators, infusion pumps, and any other devices designated as “critical” by the U.S. FDA. Hospital-grade wiring devices and leakage current protection may be ordered as options on many APC UPS systems. APC does not claim that units with these modifications are certified or listed as hospital-grade by APC or any other organization. Therefore these units do not meet the requirements for use in direct patient care. 990-4170A Installation and Maintenance Guide 59 12.2 Factory Warranty APC warrants that the unit, when properly installed and commissioned by APC or APC authorized service personnel, shall be free from defects in materials and workmanship for a period of one (1) year from the date of installation or maximum 18 months after manufacturing. In the event that the unit fails to meet the foregoing warranty, APC shall for a period of one (1) year repair or replace any defective parts, without charge for on-site labor and travel, if trained and authorized APC personnel have conducted start-up of the unit. An APC Start-Up Service must be performed/completed by APC or APC-authorized service personnel or the on-site factory warranty will be voided and replacement of defective parts only will be covered. APC shall have no liability and no obligation to repair the installed unit if non-authorized personnel performed the start-up and caused the unit to be defective. APC SHALL NOT BE LIABLE UNDER THE WARRANTY IF ITS TESTING AND EXAMINATION DISCLOSE THAT THE ALLEGED DEFECT IN THE PRODUCT DOES NOT EXIST OR WAS CAUSED BY THE PURCHASER’S OR ANY THIRD PERSON’S MISUSE, NEGLIGENCE, IMPROPER INSTALLATION OR TESTING, UNAUTHORIZED ATTEMPTS TO REPAIR OR MODIFY, OR ANY OTHER CAUSE BEYOND THE RANGE OF THE INTENDED USE, OR BY ACCIDENT, FIRE, LIGHTNING OR OTHER HAZARD. THERE ARE NO WARRANTIES, EXPRESS OR IMPLIED, BY OPERATION OF LAW OR OTHERWISE, OF PRODUCTS SOLD, SERVICED OR FURNISHED UNDER THIS AGREEMENT OR IN CONNECTION HEREWITHIN. APC DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY, SATISFACTION AND FITNESS FOR A PARTICULAR PURPOSE. APC’S EXPRESS WARRANTIES WILL NOT BE ENLARGED, DIMINISHED, OR AFFECTED BY AND NO OBLIGATION OR LIABILITY WILL ARISE OUT OF, APC’S RENDERING OF TECHNICAL OR OTHER ADVICE OR SERVICE IN CONNECTION WITH THE PRODUCTS. THE FOREGOING WARRANTIES AND REMEDIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES AND REMEDIES. THE WARRANTIES SET FORTH ABOVE CONSTITUTE APC’S SOLE LIABILITY AND PURCHASER’S EXCLUSIVE REMEDY FOR ANY BREACH OF SUCH WARRANTIES. APC’S WARRANTIES RUN ONLY TO PURCHASER AND ARE NOT EXTENDED TO ANY THIRD PARTIES. IN NO EVENT SHALL APC, ITS OFFICERS, DIRECTORS, AFFILIATES OR EMPLOYEES BE LIABLE FOR ANY FORM OF INDIRECT, SPECIAL, CONSEQUENTIAL OR PUNITIVE DAMAGES ARISING OUT OF THE USE, SERVICE OR INSTALLATION OF THE PRODUCTS, WHETHER SUCH DAMAGES ARISE IN CONTRACT OR TORT, IRRESPECTIVE OF FAULT, NEGLIGENCE OR STRICT LIABILITY OR WHETHER APC HAS BEEN ADVISED IN ADVANCE OF THE POSSIBILITY OF SUCH DAMAGES. 990-4170A 60 Symmetra MW Battery Back-up System 13 HOW TO CONTACT APC For more information call: Tel: (800) 800-4APC - US and Canada Tel: (401) 789 -0204 - Worldwide APC Corporate 132 Fairgrounds Road West Kingston, RI 02892 USA Tel: (401) 789-0204 Fax: (401) 789-3710 Internet: [email protected] PowerFax: (800) 347-FAXX APC Denmark Silcon Alle DK-6000 Kolding Tel: (+45) 75 54 22 55 Fax: (+45) 72 19 03 50 Pre-sales Technical Support 1-877-474-5266 (1-877-4Silcon) Post-sales Technical Support 1-877-287-7835 (1-877-2UPS-TEK) Fax: 1-401-438-7761 Web: www.apc.com/support/contact/contact_support.cfm 990-4170A Installation and Maintenance Guide 61 APPENDIX A: BATTERY LAYOUT DIAGRAMS Cabinets 1, 3, 5 and 7: Top Shelf positive fuse to MCCB 1+ F to battery 9 + terminal 4 8 3 7 2 6 A 1 5 FRONT OF BATTERY CABINETS 1, 3, 5, 7 A F This is the first row-to-row battery connection. This is the fuse connection. Indicates connection is required during installation FIGURE 43: Positive Battery Cabinets, Top Shelf 990-4170A 62 Symmetra MW Battery Back-up System Cabinets 1, 3, 5 and 7: Second Shelf FIGURE 44: Positive Battery Cabinets, 2nd Shelf 990-4170A Installation and Maintenance Guide 63 Cabinets 1, 3, 5 and 7: Third Shelf FIGURE 45: Positive Battery Cabinets, 3rd Shelf 990-4170A 64 Symmetra MW Battery Back-up System Cabinets 1, 3, 5 and 7: Bottom Shelf E positive midpoint to MCCB 1- from battery 24 - terminal 28 32 27 31 26 30 I D 25 29 FRONT OF BATTERY CABINETS 1, 3, 5, 7 D E Indicates connection is required during installation I This is the fourth row-to-row battery connection. This is the midpoint connection. This is the third shelf-toshelf connection. FIGURE 46: Positive Battery Cabinets, Bottom Shelf 990-4170A Installation and Maintenance Guide 65 Cabinets 2, 4, 6 and 8: Top Shelf negative midpoint to MCCB 2+ E to battery 9 + terminal 4 8 3 7 2 6 A 1 5 FRONT OF BATTERY CABINETS 2, 4, 6, 8 A E This is the first row-to-row battery connection. This is the midpoint connection. Indicates connection is required during installation FIGURE 47: Negative Battery Cabinets, Top Shelf 990-4170A 66 Symmetra MW Battery Back-up System Cabinets 2, 4, 6 and 8: Second Shelf FIGURE 48: Negative Battery Cabinets, 2nd Shelf 990-4170A Installation and Maintenance Guide 67 Cabinets 2, 4, 6 and 8: Third Shelf FIGURE 49: Negative Battery Cabinets, 3rd Shelf 990-4170A 68 Symmetra MW Battery Back-up System Cabinets 2, 4, 6 and 8: Bottom Shelf F negative fuse to MCCB 2- from battery 24 - terminal 28 32 27 31 26 30 I D 25 29 FRONT OF BATTERY CABINETS 2, 4, 6, 8 D F Indicates connection is required during installation I This is the fourth row-to-row battery connection. This is the fuse connection. This is the third shelf-toshelf battery connection. FIGURE 50: Negative Battery Cabinets, Bottom Shelf 990-4170A Installation and Maintenance Guide 69