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GE Digital Energy SG Series Installation Manual

Uninterruptible power supply 10, 20, 30 and 40 kva
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General Electric Company
SG Series UPS
SG Series 10, 20, 30 and 40 kVA

INSTALLATION GUIDE

UNINT ERRUPT IBLE PO W ER SUPPLY
Digital Energy
SG Series
10 – 20 – 30 – 40 kVA
Series 0
2500 Discovery Blvd.
Rockwall, TX 75032
Technology for the digital world
TM
Telephone:
(972)-290-7400
Fax:
(972)-290-7500
GE

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  • Page 1: Installation Guide

    SG Series 10, 20, 30 and 40 kVA INSTALLATION GUIDE UNINT ERRUPT IBLE PO W ER SUPPLY Digital Energy SG Series 10 – 20 – 30 – 40 kVA Series 0 2500 Discovery Blvd. Telephone: (972)-290-7400 Rockwall, TX 75032 Fax: (972)-290-7500 General Electric Company SG Series UPS...
  • Page 2 The present publication and any other documentation supplied with the UPS system is not to be reproduced, either in part or in its entirety, without the prior written consent of GE. The illustrations and plans describing the equipment are intended as general reference only and are not necessarily complete in every detail.
  • Page 3 Please carefully read the Installation Guide. It contains all the necessary information about the installation of the UPS. Thank you for choosing GE ! START UP AND COMMISSIONING Global Services Field Engineer...
  • Page 4: Safety Instructions

    If any problems are encountered with the procedures contained in this manual, please contact your Service Center before you proceed. This document shall not be copied or reproduced without the permission of GE . Some of the information contained in this manual may be changed without notice to reflect technical improvements.
  • Page 5: Table Of Contents

    Table of contents Page IMPORTANT SAFETY INSTRUCTIONS................6 LAYOUT..........................9 LAYOUT SG Series 10 AND 20 KVA................9 LAYOUT SG Series 30 AND 40 KVA................10 INSTALLATION ......................11 TRANSPORT......................11 3.1.1 Dimensions and weight ....................11 DELIVERY ........................12 STORAGE ........................
  • Page 6: Important Safety Instructions

    1 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for models SG Series 10, 20, 30 and 40 kVA that should be followed during installation and maintenance of the UPS and battery. GENERAL Move the UPS in an upright position in its original package to the final destination room. To lift the cabinets, use a forklift or lifting belts with spreader bars.
  • Page 7 Safety instructions when working with battery EXTERNAL BATTERY MUST BE INSTALLED AND CONNECTED TO THE UPS BY QUALIFIED SERVICE PERSONNEL. INSTALLATION PERSONNEL MUST READ THIS ENTIRE SECTION AND REFER TO THE BATTERY MANUFACTURERS INSTALLATION MANUAL BEFORE HANDLING THE UPS AND BATTERY. UPS intended to be used with a remote battery supply –...
  • Page 8 Safety symbols and warnings Safety warnings The text of this manual contains some warnings to avoid risk to the persons and to avoid damages to the UPS system and the supplied critical loads. The non-observance of the warnings reminding hazardous situations could result in human injury and equipment damages.
  • Page 9: Layout

    2 LAYOUT LAYOUT SG Series 10 AND 20 KVA Fig. 2.1-1 SG Series general view Fig. 2.1-2 SG Series general view with open doors Opening for top cable entry Opening for bottom cable entry Terminals for Utility input and load output Terminals for external Battery connection BS Battery Shelf...
  • Page 10: Layout Sg Series 30 And 40 Kva

    LAYOUT SG Series 30 AND 40 KVA OF F Fig. 2.2-2 SG Series general view with open doors Fig. 2.2-1 SG Series general view Opening for top cable entry Opening for bottom cable entry Terminals for Utility input and load output Terminals for external Battery connection CR Connectivity Rack...
  • Page 11: Installation

    3 INSTALLATION TRANSPORT Forklift Transport UPS only in upright position! The UPS is packaged on a pallet suitable for handling with a forklift. Pay attention to the center of gravity. The UPS must be moved in upright position. Do not tilt cabinets more than +/- 10° during handling.
  • Page 12: Delivery

    DELIVERY When delivered, inspect the package integrity and the physical conditions of the cabinets carefully. In case of any damage sustained during transport, immediately inform the carrier and contact your local Service Center. A detailed report of the damage is necessary for any insurance claim. A DAMAGED UPS MUST NEVER BE INSTALLED OR CONNECTED TO UTILITY OR BATTERY! STORAGE...
  • Page 13: Place Of Installation

    PLACE OF INSTALLATION 3.4.1 UPS location A qualified electrical contractor must carry out the installation and cabling of the UPS. If optional cabinets and accessories are included with the UPS, please refer to those accompanying manuals for installation and operating instructions.
  • Page 14 Openings for input and output cable connections Battery Utility input Utility input Output Load Output Load Battery Fig. 3.4.1-3 Opening on top of the cabinet for input and Fig. 3.4.1-2 Opening on top of the cabinet for input and cables of SG Series 10 and 20 kVA SG Series cables of 30 and 40 kVA...
  • Page 15: Battery Location

    In case of parallel system, try to place the UPS modules in sequence of their numbers (marked on the packing). 3-4-5-6-7-8 If the units are positioned “side by side”, the side panels must be mounted on all UPS 2 UPS 1 units.
  • Page 16: Ventilation And Cooling

    VENTILATION AND COOLING Fig. 3.5-1 Installation on plain floor Fig. 3.5-2 Installation on raised floor The heat produced by the UPS is transferred to the environment by its ventilation. Air inlets for UPS ventilation are located on the front of the UPS, while air outlets are on top of the cabinet.
  • Page 17: Unpacking

    UNPACKING The UPS and battery cabinets may be shipped packaged in carton boxes or in wooden crates (if requested). Move the cabinets as close as possible to the final location before removing from the pallet. Remove the cabinet from the pallet with care because of the heavy weight of the equipment. To unpack the cabinet follow the instructions below: WOODEN CRATE WILL ARRIVE REMOVE FRONT AND TOP...
  • Page 18 For parallel systems, the delivery also includes the bus control cables for inter-connecting the UPS modules. Packing material recycling GE, in compliance with environment protection, uses only environmentally friendly material. UPS packing materials must be recycled in compliance with all applicable regulations.
  • Page 19: Electrical Wiring

    ELECTRICAL WIRING UPS installation and connection must be performed by qualified service personnel only. It is the responsibility of the installation technician to ensure that all local and national electric codes are adhered to. 3.7.1 Utility input connection Ensure that the AC and DC external isolators are OFF and locked out to prevent their inadvertent operation.
  • Page 20: Input/Output Over Current Protection And Wire Sizing

    3.7.2 Input/output over current protection and wire sizing The cabling of the UPS system has to be sized according to the UPS power rating. Sizing of circuit breakers, fuses and cables for Input Utility, Output Load and Battery must meet the requirements of local and national electrical codes. Before connecting the UPS, verify that the Utility Voltage and Frequency, the Output Load Voltage and Frequency and Battery Data (cells number, floating voltage, autonomy) are according to the required specifications.
  • Page 21: Battery Over Current Protection And Wire Sizing

    3.7.3 Battery over current protection and wire sizing • Please read the safety precautions at the front of this guide carefully, and thoroughly review the battery manufacturers installation and maintenance manual before connecting the batteries to the UPS. • If the UPS system has been purchased with an accompanying battery cabinet, that cabinet should have an integral battery circuit breaker- If the UPS has been purchased without a battery cabinet or remote rack mounted batteries are to be used then DC over current protection must be provided by others.
  • Page 22 WIRING Wire sizing according to NEC Section 210-20 (a) Table 310-16 Use 75°C (167°C) copper wire Wiring requirements: AC INPUT RECTIFIER: 3-Phase, 3 wire plus Ground AC INPUT BYPASS: 3-Phase, 4 wire plus Ground AC OUTPUT: 3-Phase, 4 wire plus Ground DC INPUT: 2 wire (positive and negative) plus Ground Maximum cable diameter that terminals can accept.
  • Page 23 NEC SECTION 210-20 (a) Table 310-16. Allowable Ampacities of Insulated Conductors Rated O Through 2000 Volts, 60°C Trough 90°C (140°F Trough 194°F) Not More than Three Current-Carrying Conductors in Raceway, Cable, or Earth (Directly Buried), Based on Ambient Temperature of 30°C (86°F).
  • Page 24: Wiring Connection

    WIRING CONNECTION WARNING! UPS installation and connection must be performed by qualified service personnel only. 3.8.1 Power connections Input/output and DC connections are provided with terminal blocks. Please refer to chart for torque specifications. Carefully read the following recommendations before proceeding: •...
  • Page 25 SG Series 10 & 20 kVA How to access the terminals for the cable connections. Top entry cables Bottom entry cables Fig. 3.8.1-1 Access to the input / output connections of SG Series 10 and 20 kVA To access input, output and Battery connections proceed as follows: •...
  • Page 26 SG Series 30 & 40 kVA How to access the terminals for the cable connections. Top entry cables Bottom entry cables Fig. 3.8.1-2 Access to the input / output connections of SG Series 30 and 40 kVA To access input, output and Battery connections proceed as follows: •...
  • Page 27: Power Connection With Common Input Utility Of Sg Series 10 And 20 Kva

    3.8.2 Power connection with common input utility of SG Series 10 and 20 kVA L3-1 L2-1 L1-1 Fig. 3.8.2-1 Power connections Common Input Utility of SG Series 10 and 20 kVA SG Series 10 and 20 kVA: Max. rating X1 terminals: 3 AWG (25mm Common Input Rectifier / Bypass L1-1...
  • Page 28: Power Connection With Common Input Utility Of Sg Series 30 And 40 Kva

    3.8.3 Power connection with common input utility of SG Series 30 and 40 kVA LOAD 1 - INPUT L3-1 RECTIFIER L2-1 L1-1 OF F O FF Fig. 3.8.3-1 Power connections Common Input Utility of SG Series 30 and 40 kVA SG Series 30 and 40 kVA: Max.
  • Page 29: Power Connection Separate Input Utility Of Sg Series 10 And 20 Kva

    3.8.4 Power connection separate input utility of SG Series 10 and 20 kVA L3-2 L2-2 L3-1 L1-2 L2-1 L1-1 Fig. 3.8.4-1 Power connections Separate Input Utility of SG Series 10 and 20 kVA SG Series 10 and 20 kVA: Max. rating X1 and X2 terminals: 3 AWG (25mm Separate Input Rectifier / Bypass L1-1...
  • Page 30 Notices for installation Fig. 3.8.4-2 Interconnection links BR1, BR2 and BR3 of SG Series 10 and 20 kVA For separate Bypass and Rectifier Input configuration, the interconnection links BR1, BR2 and BR3 must be removed. OPM_SGS_ISG_10K_40K_0US_V010.doc 30/45 Installation Guide SG Series 10, 20, 30 & 40 kVA...
  • Page 31: Power Connection Separate Input Utility Of Sg Series 30 And 40 Kva

    3.8.5 Power connection separate input utility of SG Series 30 and 40 kVA L3-2 L3-1 L2-2 L2-1 L1-1 L1-2 Fig. 3.8.5-1 Power connections Separate Input Utility of SG Series 30 and 40 kVA SG Series 30 and 40 kVA: Max. rating X1 and X2 terminals: 1 AWG (50mm Separate Input Rectifier / Bypass L1-1...
  • Page 32 Notices for installation BR1 BR2 Fig. 3.8.5-2 Interconnection links BR1, BR2 and BR3 of SG Series 30 and 40 kVA For separate Bypass and Rectifier Input configuration, the interconnection links BR1, BR2 and BR3 must be removed. OPM_SGS_ISG_10K_40K_0US_V010.doc 32/45 Installation Guide SG Series 10, 20, 30 & 40 kVA...
  • Page 33: Battery Connection Of Sg Series 10 And 20 Kva

    3.8.6 Battery connection of SG Series 10 and 20 kVA Fig. 3.8.6-1 Power connections of external battery for SG Series 10 and 20 kVA SG Series 10 and 20 kVA: Max. rating Battery terminals: 3 AWG (25mm Battery – Positive pole of the Battery Negative pole of the Battery Do not insert the Battery Fuses before the commissioning.
  • Page 34: Battery Connection Of Sg Series 30 And 40 Kva

    3.8.7 Battery connection of SG Series 30 and 40 kVA BATTERY Fig. 3.8.7-1 Power connections battery of SG Series 30 and 40 kVA SG Series 30 and 40 kVA: Max. rating Battery terminals: 1 AWG (50mm Battery Positive pole of the Battery –...
  • Page 35: Setup For Sg Series When Functioning As Frequency Converter

    3.8.8 Setup for SG Series when functioning as frequency converter When the SG Series is utilized for different output frequency compared to the input frequency, the Automatic Bypass and Manual Bypass functions are disabled, therefore the load cannot be transferred to Utility in case of overload, short circuit, or inverter failure. In situations where the UPS needs to be powered down for maintenance purposes, the critical load must also be powered down during this time, the UPS cannot be transferred to Manual Bypass, serious damage to the load could result.
  • Page 36: Power Wiring Of Parallel Units

    POWER WIRING OF PARALLEL UNITS To guarantee good load sharing between the units of a parallel system, we recommend it is recommended that the cable length from the input distribution board (5) to the output distribution board (10) are the same length for each unit (a+b = c+d = e+f = g+h = i+l = m+n = o+p = q+r).
  • Page 37: Parallel Control Bus Connection

    3.10 PARALLEL CONTROL BUS CONNECTION In cases of parallel operation, the communication between the units takes place through the control bus cables. Each parallel unit is equipped with an additional board “P13 – RPA Board IM0006“ where the connectors J52 (A) and J62 (B) are located. A short control cable provided with a ferrite ring core links the parallel board “P13 –...
  • Page 38 SGT5000_100-150_RPA-IM0048_02 IM 0048 Fig. 3.10-2 Bus connection on terminal units Terminal units On the parallel bus PCB “P34 – Bus Interface IM0048”, of the first and last units (terminal) of the parallel system the Jumpers JP1, JP2, JP3 and JP4 must be inserted. SGT5000_100-150_RPA-IM0048_03 IM 0048 Fig.
  • Page 39: Control Bus Cable Location

    3.11 CONTROL BUS CABLE LOCATION Warning! This installation must be verified by trained personnel before the initial start-up (ensure that the UPS installation is completely powered down). Access control connection. The control bus connection between parallel units must be made on the front of the electronic module fitted behind the front doors.
  • Page 40 O FF OF F O FF Fig. 3.11-3 Control Bus cable routing and connection Control bus cables routing Place and fix the cables JA-1/2/3/4/5/6/7 and JB-1/2/3/4/5/6/7 with the appropriate clamps inside the UPS cabinets in the position shown in the drawing Fig 3.11-1/2/3. Pay attention to the fact, that routing of cables shall allow the removal of the protection covers “A”.
  • Page 41: Customer Interface

    4 CUSTOMER INTERFACE CUSTOMER INTERFACE Serial port J3 - RS 232 (sub D - female 9 pin) Suitable for JUMP protocol Pin 2 : TX (out) Pin 3 : RX (in) Pin 5 : GND J2 (subD-female 25p) – Output signals on voltage free contacts J2 / 1, 2, 3 NO, C, NC - Utility Failure...
  • Page 42: Serial Port J3

    Total remote management of the system using new generation software JUMP (Java Universal Management Platform) for system protection and management of systems using GE UPS’s. JUMP system is written in JAVA and supports virtually all platforms having JAVA runtime environment version 1.1 or higher.
  • Page 43: Programmable Input Free Contacts

    4.1.3 Programmable input free contacts Some programmable UPS functions (indicated in Section 4.1), can be activated by closing an external contact, if connected, on: X1 / 10, 21 or J2 / 10, 23 User Input 1 (default = Not used) (RL1) X1 / 11, 22 or J2 / 11, 24...
  • Page 44: Epo (Emergency Power Off) Input Contact

    4.1.7 EPO (Emergency Power Off) Input contact An external Emergency switch (Normally Closed voltage-free contact) can be connected on terminals XB / 1 - 4 or connector J2 / 12 - 25 of the P4 - Interface Customer. Remove the cable short-circuiting terminals XB 2 - 3) when using this external switch.
  • Page 45: Notes

    5 NOTES NOTES FORM It is recommended to note in this section Notes, with date and short description all the operations performed on the UPS, as: maintenance, components replacement, anormal situations, etc. Date Description Done by OPM_SGS_ISG_10K_40K_0US_V010.doc 45/45 Installation Guide SG Series 10, 20, 30 & 40 kVA...