Eaton 40 kVA Manual

User’s and Installation Guide
UPS 40–160 kVA,
400V 50/60 Hz output

©2008 Eaton Corporation
All Rights Reserved
The contents of this manual are the copyright of the publisher
and may not be reproduced (even extracts)
unless permission granted.
Every care has been taken to ensure the accuracy of
the information contained in this manual, but no liability
can be accepted for any errors or omission. The right
to make design modifications is reserved.

UPS 40-160 kVA, 400 V 50/60 Hz output
User’s and Installation Guide
1023294 Revision C
1 Safety Instructions ............................................................................................................5
1.1 Audience..........................................................................................................................5
1.2 CE marking .....................................................................................................................5
1.3 User precautions..............................................................................................................6
1.4 Environment....................................................................................................................6
1.5 Inquiries ..........................................................................................................................6
2 Introduction ......................................................................................................................7
2.1 System description...........................................................................................................7
2.2 Feature: Active-Front Technology ...................................................................................8
2.3 Feature: Advanced Battery Management (ABM)™ .........................................................8
2.4 Feature: Hot Sync®technology........................................................................................8
2.5 Basic system configuration ..............................................................................................9
3 UPS installation ..............................................................................................................10
3.1 Planning installation......................................................................................................10
3.2 Unpacking and visual inspection ..................................................................................11
3.3 Delivery check ...............................................................................................................12
3.4 UPS cabinet installation.................................................................................................13
3.5 Unloading the Battery Cabinet from the Pallet..............................................................13
4 Electrical installation ......................................................................................................15
4.1 Procedure for locating the terminals ............................................................................15
4.2 UPS wiring procedure....................................................................................................16
4.2.1 Installing battery ferrite rings .................................................................................19
4.2.2 Installing ferrite clip for battery breaker.................................................................19
4.3 Battery cabinets .............................................................................................................19
4.3.1 Integral battery cabinet installation procedure.......................................................21
4.3.2 Integral battery cabinet electrical connections .......................................................23
4.3.3 Separate battery cabinet Installation.......................................................................25
4.3.4 Separate Battery Cabinet Electrical Connections ...................................................26
4.4 Battery racks ..................................................................................................................27
5 UPS communication interface.........................................................................................28
5.1 X-Slot communication...................................................................................................29
5.1.1 Wiring installation for X-slot connections .............................................................29
5.1.2 LanSafe....................................................................................................................30
5.2 Input and output connections.......................................................................................30
5.2.1 Wiring procedure....................................................................................................31
5.2.2 To install TB1 wiring to connections:.....................................................................31
5.2.3 To install TB2 wiring to connections:.....................................................................32
5.3 Remote emergency power off ........................................................................................33
5.3.1 Installation..............................................................................................................33
6 Control Panel .................................................................................................................35
6.1 Identification of the display areas..................................................................................35
6.2 Main Menu ....................................................................................................................36
6.2.1 Event Screens..........................................................................................................36
6.2.2 Meter Screens..........................................................................................................37
6.2.3 Controls screen.......................................................................................................38
6.2.4 Setup screen............................................................................................................38
6.2.5 Load Off Screen ......................................................................................................39
6.3 Mimic Screen .................................................................................................................40
6.4 Status Indicators ............................................................................................................40

7 Operating instructions ....................................................................................................41
7.1 Starting the UPS in Normal Mode .................................................................................41
7.2 Starting the UPS in Bypass Mode...................................................................................41
7.3 Starting the Power Module............................................................................................42
7.4 Transfer from Normal to Bypass Mode..........................................................................43
7.5 Transfer from Bypass to Normal Mode..........................................................................43
7.6 Transfer from Normal to Bypass Mode with UPS Shutdown.........................................44
7.7 UPS and Critical Load Shutdown..................................................................................44
7.8 Charger Control.............................................................................................................44
7.9 Using the LOAD OFF Pushbutton ................................................................................45
7.10 Using the REMOTE EMERGENCY POWER OFF Switch...........................................45
7.11 Using Mechanical Bypass Switch (40-80 kVA)............................................................46
7.11.1 Turn UPS from normal mode to mechanical bypass.............................................47
7.11.2 Turn UPS from mechanical bypass to normal mode.............................................48
8 Maintaining the UPS System...........................................................................................49
8.1 General ..........................................................................................................................49
8.2 Important Safety Instructions........................................................................................49
8.3 Performing Preventive Maintenance .............................................................................50
8.3.1 DAILY Maintenance................................................................................................50
8.3.2 MONTHLY Maintenance ........................................................................................50
8.3.3 ANNUAL Maintenance...........................................................................................50
8.3.4 BATTERY Maintenance...........................................................................................50
8.4 Advanced maintenance..................................................................................................51
8.4.1 Display UPS Control Panel.....................................................................................51
8.4.2 Event History Log...................................................................................................51
9 Wiring Parallel systems ..................................................................................................53
9.1 System Parallel Module .................................................................................................53
9.2. Installation instructions for 120/160 kVA Tie cabinet..................................................56
9.3 XSlot Hot Sync card.......................................................................................................59
10 Recycling the used UPS or batteries ...............................................................................62
11 Dimensional drawings ....................................................................................................63
12 Technical data .................................................................................................................68
12.1 Standards ....................................................................................................................68
12.2 Environmental specification........................................................................................68
12.3 Mechanical configuration............................................................................................68
12.4 System input................................................................................................................68
12.5 System DC circuit ........................................................................................................69
12.6 System output..............................................................................................................69
13 Warranty .........................................................................................................................70
13.1 Standard warranty .......................................................................................................70

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1 Safety Instructions
The UPS operates with mains, battery or bypass power. It contains components that carry high
currents and voltages. The properly installed enclosure is grounded to earth and IP20 rated
against electrical shock and foreign objects. However, only qualified personal is allowed to
install and service the UPS.
Warning!
Operations inside the UPS must be performed by a service engineer from the manufac-
turer or from an agent authorised by the manufacturer.
Do not ever service inside the UPS when mains power is applied or the UPS is running in
battery mode. Use the optional mechanical bypass if installed to the system. Remember to open
battery breaker. Always ensure by measuring with a multi-meter that no dangerous voltages are
present.
1.1 Audience
The intended audiences of this manual are people who plan the installation, install,
commission, and use or service the UPS. The manual provides guidelines to check delivery,
installing and commissioning of the UPS.
The reader is expected to know the fundamentals of electricity, wiring, electrical components
and electrical schematic symbols. This manual is written for a global reader.
Note!
Read the manual before operating or working on the UPS.
1.2 CE marking
The product has the CE marking in compliance with the following European directives:
• LVDirective(Safety) 72/23/EECand93/68/EEC
• EMCDirective  89/336/EEC,93/68/EECand92/31/EEC
Declaration of conformity with UPS harmonised standards and directives EN/IEC 62040-1-1
(Safety) and EN/IEC 62040-2 (EMC) are available on the web site (http://www.powerware.com).
Warning!
WARNING This is a product for restricted sales distribution to informed partners (EN/
IEC 62040-2). Installation restrictions or additional measures may be needed to prevent
electromagnetic disturbances.

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1.3 User precautions
The only user operations permitted are:
- Start up and shut down of the UPS, excluding the commissioning start-up.
- Use of the LCD control panel and Maintenance Bypass Switch (MBS)
- Use of optional connectivity modules and their software
The user must follow the precautions and only perform the described operations. Any
deviations from the instructions could be dangerous to the user or cause accidental load loss.
Warning!
The user is not permitted to open of any screws excluding connectivity plates. Failure to
recognise the electrical hazards could prove fatal.
1.4 Environment
The UPS must be installed according to the recommendations in this manual. Under no
circumstances the UPS should be installed in an airtight room, in the presence of flammable
gases, or in an environment exceeding the specification.
Excessive amount of dust in the operating environment of UPS may cause damage or lead to
malfunction. The UPS should be always protected from the outside weather. The recommended
operating temperature is from +15 to +25 Celsius degrees.
1.5 Inquiries
Address any inquiries about the UPS and battery cabinet to the local office or agent authorised
by the manufacturer. Please quote the type code and the serial number of the equipment.

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2 Introduction
The product described in this manual is a transformerless Uninterruptible Power System
(UPS). It is a true online, continuous duty, double conversion, static state, three-phase system,
providing conditioned and uninterruptible AC power to protect the customer’s load from all
nine power failures.
2.1 System description
The UPSs are used to protect sensitive IT equipment and prevent loss of valuable electronic
information, minimise equipment downtime, and minimise the adverse effect on production
equipment due to unexpected power problems.
The UPS system continually monitors incoming electrical power and removes the surges,
spikes, sags, and other irregularities that are inherent in commercial utility power. Working
with a building‘s electrical system, the UPS system supplies clean, consistent power that
sensitive electronic equipment requires for reliable operation. During brownouts, blackouts, and
other power interruptions, batteries provide emergency power to safeguard operation.
The UPS system is housed in single freestanding cabinets. The cabinets line up and match in
style and colour, and have safety shields behind the doors for hazardous voltage protection.
Figure 1. UPS cabinet 40-80 & 100-160 kVA, 400 VAC 50/60 Hz.

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2.2 Feature: Active-Front Technology
Traditional input THD filters are no longer needed with this UPS product. The build-in
advanced rectifier technology of UPS modules provides perfect sinusoidal input power quality at
0.99 input power factor with harmonic content less than 5% THD(i). This leads to more reliable
total system operation and savings in generator and transformer sizing as losses in the windings
are minimised.
Due to the active front rectifier, the UPS is comparable to a clean resistor load from the mains
perspective. Thus, the high input power factor provides minimised cabling and fusing costs due
to no reactive power consumption.
The low harmonic currents are due to high input power factor and provide the benefits:
• Noadditionallossesinwiresandcables
• Noextraheatingoftransformersandgeneratorswithshortenedservicelife
• Nofalsecircuitbreakertrippingandmalfunction
• Noerraticoperationofcomputers,telecommunication,monitors,electronictestequipment
etc.
• NoResonancewithpowerfactorcorrectioncapacitors
2.3 Feature: Advanced Battery Management (ABM)™
The ABM monitors the status of the battery and charges it only when the battery needs
charging. This is the key to long battery life with the ABM due to low generation of corrosion
inside the battery. It also monitors that the load never crashes because of bad or defected battery.
The main cause for corrosion is current flowing through battery. The more current going
through battery, the shorter the battery life. Current flows through battery when it is discharged
or charged. There is very little that can be done for discharging, because it depends on number
of power outages in utility line.
The ABM is very valuable feature since most of the time battery does not need any charging.
The charging is controlled and initiated on the following occasions:
- When turning the unit on
- After 18 days without charging
- If the open cell voltage decreases below predetermined voltage level
Hence, the function of ABM system is to prolong the battery life considerably compared to
traditional system that uses float-charging technology. This means that there is no current going
through batteries all the time and causing corrosion. In a traditional online UPS the inverter
also causes ripple-current to be fed to batteries causing corrosion.
2.4 Feature: Hot Sync®technology
The UPS product features U.S. #5,745,365 patented paralelling technology that provides N+X
redundancy without introducing a single-point-of-failure. The products utilising the Hot Sync
are completely autonomous and the only thing common among them is the critical output
power bus.
The Hot Sycn is 100% mathematical firmware that makes it more reliable than traditional
paralleling techniques. Because the solution is implemented intrinsically, and Hot Sync is always
active, the UPS modules do not know whether or not they are even in parallel.

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A parallel UPS system means the linking together of two or more UPS units in parallel so that in
the unlikely event one fails the other can automatically take up the load. Traditionally a parallel
redundancy configuration is achieved by having a random or fixed master-slave relationship
among the UPS units. This master logic gives out individual commands to all the slaves
units. Unfortunately this can lead to a single-point-of-failure for the whole system because if
the master logic or communication to slaves fails, and causes the whole UPS system to be in
trouble.
The Hot Sync® technology was developed to allow parallel capacity system and to maintain
the highest system availability. An industry leading paralleling technology in its own right,
the patented Hot Sync enables you to set up a parallel redundant system giving you 100%
conditioned power at all times. Its unique digital design eliminates the system level single
point of failure inherent in traditional parallel UPS modules, and exponentially increases the
reliability of the overall system.
Hot Sync allows up to four UPS units to cover the same load in parallel and redundant
configuration. No vulnerable master logic is needed in this patented design. It provides
automatic load sharing and module level redundancy with nothing other than the power
connecting the Hot Sync version of UPS modules.
2.5 Basic system configuration
The following basic UPS system configurations are available:
• AsingleUPSsystem:
– UPS cabinet (40-60-80 kVA, 100-120-160 kVA)
– Battery cabinet or battery rack (10-120 min back-up time)
– LCD display for easy configuration (Std.)
– Web/SNMP communication capability (Std./Optional)
Figure 2. UPS40-80kVAcongurationwithLargebatterycabinet.
Adding optional accessories can enhance the UPS system configuration. These include extensive
X-slot communication adapters. As a standard the selected UPS models are delivered with
advanced Web/SNMP communication capability to interface with a network management
system.

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3 UPS installation
Before installing the UPS systems read and understand how this manual applies to the system
being installed. Use the procedures and illustrations in the following chapters to create a logical
plan for installing the system.
3.1 Planning installation
The UPS and accessories are delivered on a specifically designed pallet that is easy to move with
a forklift or a pallet jack. Make sure that the floor surface is solid and suitable for the wheeling
and heavy weight. Keep the UPS always in upright position and do not drop the equipment. Do
not either stack the pallets because of high-energy batteries involved and the heavy weight
Use a forklift or pallet jack to move the packaged cabinet to the installation site, or as close as
possible, before unpacking. Insert the forklift or pallet jack forks between the pallet supports on
the bottom of the unit. Set the pallet on a firm, level surface, allowing a minimum clearance of
3m on each side for removing the cabinet from the pallet.
Note!
If the UPS is not immediately installed the following must be remembered:
• TheUPSshouldbestoredintheoriginalpackingandshippingcarton.
• DonottilttheUPScabinetmorethan10°fromverticalorcabinetmaytipover.
• Therecommendedstoringtemperatureisbetween+15°…25°.
• Theequipmentmustalwaysbeprotectedfrommoistureandweather.
The life of the UPS system is adversely affected if the installation does not meet the following
guidelines:
• Thesystemmustbeinstalledonaleveloorsuitableforcomputerorelectronicequipment.
• Thesystemmustbeinstalledinatemperatureandhumiditycontrolledindoorareafreeof
conductive contaminants.
• TheUPScabinetusesforcedaircoolingtoregulateinternalcomponenttemperature.Air
inlets are in the front of the cabinet and outlets are in the top. You must allow clearance in
front of and above each cabinet for proper air circulation.
The operating environment must meet the weight, clearance, and environmental requirements
in the technical specification.

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Figure 3. MinimumclearanceintopandfrontofUPS40-160kVA
3.2 Unpacking and visual inspection
The UPS cabinet is bolted to a wooden pallet supported by wood skids. To remove the pallet,
perform the following procedure:
1. If not already accomplished, use a forklift or other material handling equipment to move
the cabinet to the installation area, or as close as possible, before unloading from the
pallet. Insert the forklift jacks between the skids on the bottom of the unit.
2. Unfasten front door latch and swing door open.
3. If the levelling feet are not fully retracted, turn the levelling feet until they are retracted.
4. Remove bolts and shipping brackets, which are used to fasten UPS to the pallet.
5. Slowly roll the cabinet toward the rear of the pallet. Once the pallet tilts, continue rolling
the cabinet down the pallet until the cabinet is clear of the pallet.
6. Roll cabinet to final installation location.
7. Secure the UPS cabinet in position by lowering the levelling feet, until cabinet is not
resting on the casters and the cabinet is level.
Note!
The UPS cabinet is heavy. If unpacking instructions are not closely followed, the cabinet
may tip and cause serious injury.

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Figure 4. Removingboltsandshippingbrackets.
Unpack the equipment by removing the packing and shipping materials. If the equipment has
been transported in the upright position the outside ’Tip&Tel’ indicator should be intact.
Make a visual inspection and check that there are no signs of shipping damages. The inside
‘Drop&Tell’ indicator shall be intact if the equipment has been handled properly.
Note!
A claim for shipping damage must be filed immediately and the carrier must be
informed within 7 days of receipt of the equipment. The packing materials and indicators
should be stored for further investigation.
3.3 Delivery check
The UPS is delivered with the following items:
Plastic bag containing:
Web/SNMP adapter configuration guide (optional), English language
User’s Guide, paper format, English language
Residual voltage warning stickers
Software Suite, CD-ROM format, English language
Delivery documents
Check the information on the type designation label of the equipment to verify that the unit
is of the correct type. The type designation label includes ratings, a CE marking, a type code,
a part number and a serial number. The serial number is important when making inquiries. It
allows individual recognition of the equipment.

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3.4 UPS cabinet installation
UPS cabinets must be permanently bolted or welded to the floor using the shipping brackets.
Note!
UPS cabinets can fall over if the shipping brackets are not used. Both rear and front ship-
ping brackets must be used to secure the UPS cabinet to the floor.
3.5 Unloading the Battery Cabinet from the Pallet
The battery cabinet is bolted to a pallet consisting of four angle metal supports secured to two
four-inch by six-inch wood supports.
1. Unfasten front door latch and swing doors open.
2. Remove doors. Remove the retaining screw located inside each door at the bottom hinge
pivot point, then lift the door off. Save the retaining screws for reinstallation of the doors.
3. Locate the field kit (packed inside of the cabinet). Locate the four 1/2I jacking bolts
and install them in the threaded holes in the front and rear supports. Place a floor
protector underneath each jacking bolt, and screw the bolts down against them. The floor
protectors protect the floor from being marred by the jacking bolts.
Figure 5.RemovingShippingSupports
4. Loosen, but do not remove, the hardware holding the 4×6 supports to the front and rear
supports.

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Warning
SERIOUS INJURY MAY OCCUR. Battery cabinets are extremely heavy. If unloading in-
structions are not closely followed, cabinet may tip.
5. Turn each jacking bolt consecutively, two full turns, until the 4×6 supports clear the floor
by approximately 3 mm (1/8I).
Warning
RISK OF INSTABILITY. Turning the jacking bolts unevenly may cause the cabinet to be-
come unbalanced. To prevent tipping the cabinet, raise and lower the jacking bolts evenly.
Note
CABINET MAY TIP. The battery cabinet should only be raised approximately 3 mm (1/8I)
above the floor (just enough to allow removal of the 4×6 supports).
6. After the 4×6 supports clear the floor, remove the hardware loosened in Step 4. Pull the
4×6 supports out from under the battery cabinet. Please discard or recycle them in a
responsible manner.
Note
CABINET MAY FALL. Do not loosen the hardware attaching the side or front supports
to the cabinet base, or the front and side supports to each other, at this time. The cabinet
must be lowered by the jacking bolts before the supports can be removed.
7. Carefully and evenly lower the cabinet by turning each jacking bolt consecutively two
full turns (maximum) until the casters contact the floor, and the cabinet is no longer
supported by the jacking bolts.
8. After the battery cabinet is resting on the floor, remove the jacking bolts and discard or
recycle them in a responsible manner.
9. Remove the hardware holding the front, rear and side supports to the cabinet base.
Discard or recycle the hardware and support brackets in a responsible manner.
10. The battery cabinet is now ready to be rolled to its final location.
11. Repeat Steps 2 through 10 for each cabinet you are preparing to install.

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4 Electrical installation
The customer has to supply the wiring to connect the UPS to the local power source. The
electrical installation procedure is described in the following text. The installation inspection
and initial start up of the UPS and extra battery cabinet must be carried out by a qualified
service personnel such as a licensed service engineer from the manufacturer or from an agent
authorised by the manufacturer.
Warning!
Physical injury or death may follow, or damage may occur to the UPS or the load equip-
ment if these instructions are ignored.
4.1 Procedure for locating the terminals
Power and control wiring can be routed through the top or bottom of the cabinet (see
dimensional drawings) with connections made to easily accessible terminals.
1. If not already open, unfasten front door latch and swing door open.
2. Slide air filter up and remove from cabinet.
3. Remove screws securing bottom internal safety shield panel and remove panel to gain
access to input, output, and battery terminals.
4. If installing power wiring from the top of the cabinet, proceed to step 5; otherwise,
proceed to step 6.
5. Remove screws securing top internal safety shield panel and open panel to gain access to
top entry wire way.
6. Remove UPS cabinet top or bottom wire entry conduit landing plate to drill orpunch
conduit holes.
7. Route input and output cables through wire way to the UPS terminal blocks.
8. Reinstall conduit landing plate and install conduit.
9. Route and connect wiring.
10. When all wiring is complete, reinstall safety shield panels removed in previoussteps.
11. Close door and secure with latch.

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Figure 6. UPS(40-80,100-160kVA)powerandcommunicationterminallocations
4.2 UPS wiring procedure
The proper connection order is as follows:
1. Switch off the supply to the distribution point to which the UPS unit is to be connected.
2. For extra safety, also remove the fuses from the selected lines. Make absolutely sure with
measurement that there is no power.
3. A readily accessible disconnect device must be incorporated in all fixed input wiring. The
disconnect device shall have a contact separation of at least 3 mm.
The UPS has automatic backfeed isolation but for extra safety a warning label can be
added on all primary power isolators installed remote from the UPS area to warn electrical
maintenance personnel.
The warning label shall carry the following wording or equivalent:
“ISOLATE UPS BEFORE WORKING ON THIS CIRCUIT”.
4. Check that electrical connections to the installation site have been properly executed.
Also check fuse or circuit breaker ratings and cable dimensions against tables for
40-160 kVA systems.
5. The UPS should be connected in accordance with the wiring diagram. Be sure to ground
the system according to local and/or national electrical wiring standards.

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6. Connect phase L1, L2, and L3 rectifier input power wiring from source to the Rectifier
Input Terminals in the UPS cabinet. See wiring diagram for cable and fusing requirements.
Note!
The rectifier requires a Neutral to operate. It’s connected internally from the bypass ter-
minal to the rectifier, see wiring diagram.
7. Connect phase L1, L2, L3, and Neutral bypass input power wiring from source to the
Bypass Input Terminals and Neutral Terminals in the UPS cabinet.
8. Connect phase L1, L2, L3, and Neutral power wiring from Output Terminals and Neutral
Terminals to the critical load.
9. Route battery cables from the Battery Cabinet to UPS Battery Terminal Block
Note!
UPS 40-80 kVA are delivered with (4) ferrite rings for battery cables and (2) ferrite clips
for control cables. Those should be installed both at the UPS cabinet end to improve the
EMC according to EU directives.
10. Connect positive, negative, and ground DC power wiring from battery cabinet to the
battery terminal Block and ground terminals in the UPS cabinet.
Note that the battery cables delivered with the battery cabinets are to be installed next to
the UPS cabinet. Cables with higher current capacity are needed if the external battery
cabinets or racks are installed with a distance from the UPS.
11. When all wiring is complete and the UPS system is connected to the facility power and
critical load, reinstall safety shield panels removed in previous steps.
12. Close door and secure with latch. If an external bypass switch shall be used, contact your
dealer first.
The UPS unit is now connected to the mains and to the load but there is no power. Make sure
that the connections are properly made.
Standards SFS 6000-5-52 (2002) and IEC 60364-5-52 (2001-08) “Electrical installations of
buildings” with normal 1.7xNeutral conductor rating for IT loads are used as a sizing guide.
For any other conditions, size the cables according to the local safety regulations regarding
installation environment, appropriate voltage and currents of the UPS.
Fuses are sized according to local safety regulations, appropriate input voltage and the rated
current of the UPS. Therefore, protect the input and bypass cables with gG (gL) fuses or B-C-D
type of circuit breakers against overload and short-circuit.
Contact the manufacturer’s authorised agent or the local office for assistance at fuse and cable
sizing. Refer to the recommended cable and fuse ratings in the below table.
Note!
In local solutions the two pole battery breaker ratings must be 300A / 500VDC with thermal mag-
netic trip and 48VDC undervoltage release (e.g. ABB’s S5N300TDD-2AU7).

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Figure 7. Five-wireinstallationoftheUPSsystem40–80kVAwithMBS
Figure 8. Five-wireinstallationoftheUPSsystem40–80kVAwithoutMBS
Table 1. Recommendedmulti-corecableandfusesizesforUPS40-80kVA.
(Cableswithcopperconductortemp.70ºC,PCVinsulation,andinstallationmethodC)
UPS rating Rectifier input Bypass input Load PE Battery
Fusing Cable Fusing Cable Cable I nom Cable Cable
40 kVA 3-phase 3x80 A 3x35 mm23x63 A 4x25 mm23x25 mm258 A 16 mm22x70 mm2
60 kVA 3-phase 3x100 A 3x50 mm23x100 A 4x50 mm23x50 mm287 A 25 mm22x95 mm2
80 kVA 3-phase 3x125 A 3x70 mm23x125 A 4x70 mm23x70 mm2116 A 35 mm22x95 mm2
Maximum 3-phase n/a 3x95mm2n/a 4x95 mm23x95mm2n/a 50 mm295 mm2

UPS 40 – 160 kVA, 400V 50/60 Hz output
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Figure 9. Five-wireinstallationoftheUPSsystem100–160kVAwithoutMBS
UPS rating Rectifier input Bypass input Load PE Battery
Fusing Cable Fusing Cable Cable I nom Cable Cable
100 kVA 3-phase 3x160 A 3x95 mm23x160 A 4x95 mm23x95 mm2144 A 50 mm2120 mm2
120 kVA 3-phase 3x200 A 3x120 mm23x200 A 4x120 mm23x120 mm2174 A 70 mm2150 mm2
160 kVA 3-phase 3x250 A 3x185 mm23x250 A 4x185 mm23x185 mm2231 A 95 mm2185 mm2
Maximum 3-phase n/a 3x185 mm2n/a 4x185 mm23x185mm2n/a 120 mm2185 mm2
Table 2. Recommendedmulti-corecableandfusesizesforUPS100-160kVA.
(Cableswithcopperconductortemp.70ºC,PCVinsulation,andinstallationmethodC)
4.2.1 Installing battery ferrite rings
Four ferrite rings are delivered with 40-80 kVA UPS and meant for DC power cables. It is recommended that
all power wires (+ and -) are routed through the four ferrite rings. If the double cable is used, one pair of
positive and negative (+ and -) wires should be routed through two ferrite rings and another pair of positive
and negative (+ and -) wires should be routed though another two ferrite rings. In every situation place the
ferrite rings as close the inside wall of the UPS cabinet as possible.
4.2.2 Installing ferrite clip for battery breaker
The ferrite clips are delivered and meant for control wires between the UPS and the battery breaker. Place
the control wires to the notch of the clip, make a loop at least once and close the ferrite clip. Place the
ferrite clip as close the inside wall of the UPS cabinet as possible.
4.3 Battery cabinets
Power and control wiring for integral line-up and match battery cabinets are supplied with the cabinets.
The battery cabinet may be located either to the left or right of the UPS cabinet. Due to easier service
access the recommended location is to the left of the UPS cabinet. The line up and match battery cabinets
are wired through the side panels of the units.
Mechanical lugs, located at the front of the cabinet, reduce installation time, and removable battery trays
with quick disconnects between trays reduce battery maintenance time. A DC-rated circuit breaker within
each cabinet provides protection and servicing isolation.
The battery cabinets use convection cooling to regulate internal component temperature. Air inlets are in
the front of the cabinet and outlets are in the top. Clearance must be allowed in front of and above each
cabinet for proper air circulation.
• Thesystemmustbeinstalledonaleveloorsuitableforcomputerorelectronicequipment.
•The system must be installed in a temperature and humidity controlled indoor area free of
conductive contaminants.

UPS 40-160 kVA, 400 V 50/60 Hz output
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Figure 10. UPS40-80kVAwithintegralLargebatterycabinet.
The battery cabinet is designed for industrial or computer room applications and should be handled
with appropriate care. Observe these precautions when working on or around battery cabinets:
• Removewatches,rings,orothermetalobjects.
• Usetoolswithinsulatedhandles.
• Wearrubberglovesandboots.
• Donotlaytoolsormetalpartsontopofbatteriesorbatterycabinets.
• Donottiltthecabinetsmorethan+/-10°duringinstallation.
Figure 11. SmallandLargeBatterycabinetwithdoorsopenandlocationofterminals.
Note!
The distance between large battery cabinet trays is 290 mm that includes local battery
height and safety clearance. The maximum bottom size of a battery is 175 mm x 329 mm.