GE SG 300 User manual

GE Digital Energy
Power Quality
Installation Guide
Uninterruptible Power supply
SG Series 225 & 300
225 & 300 kVA / 480Vac UL / S2
GE Consumer & Industrial SA
General Electric Company
CH – 6595 Riazzino (Locarno)
Switzerland
T +41 (0)91 / 850 51 51
F +41 (0)91 / 850 52 52
www.gepowerquality.com
imagination at work

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Model: SG Series 225 & 300 UL S2
Issued by Product Document Department – Riazzino - CH
Date of issue: 06/15/2010
File name: OPM_SGT_ISG_M22_M30_2US_V010
Revision: 1.0
Identification No.:
Up-dating
Revision Concerns Date
COPYRIGHT © 2010 by GE Consumer & Industrial SA
All rights reserved.
The information contained in this publication is intended solely for the purposes indicated.
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.
The content of this publication may be subject to modification without prior notice.

Dear Customer,
We thank you for selecting our products and are
pleased to count you amongst our very valued
customers at GE.
We trust that the use of the SG Series 225 & 300
Uninterruptible Power Supply system, developed and
produced to the highest standards of quality, will give
you complete satisfaction.
Please read carefully the Installation Guide, which
contains all the necessary information and describes all
you need to know about the installation of the UPS.
Thank you for choosing GE !
START UP AND COMMISSIONING
A GE GLOBAL SERVICES FIELD ENGINEER must perform start-up and
commissioning of the UPS.
Please Contact GE. GLOBAL SERVICES at least two weeks prior to schedule
start-up and commissioning at 1-800-637-1738, or by E-mail at
[email protected] .
Distributed in the USA by:
Your service contact:
g
GE Consumer & Industrial SA
General Electric Company
CH – 6595 Riazzino (Locarno)
Switzerland
www.gepowerquality.com
g
GE Digital Energy
Power Quality
2501 Pecan Street
Bonham, TX 75418
T: [phone]
F: [phone]
E: [email protected]om
http://www.gedigitalenergy.com/ups
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Preface
Congratulations on your choice of a SG Series Uninterruptible Power Supply (UPS).
It will help eliminate load disturbances due to unexpected power problem.
This manual describes how to prepare the installation site, and it provides weight and
dimensions and procedures for moving, installing and connecting the UPS.
Please refer to the Operating Manual, which describes the function of the UPS module, the
purpose and location of the switches, the meaning of the system events related to the
front panel indication, and provides procedures for starting and stopping the equipment.
While every care has been taken to ensure the completeness and accuracy of this manual,
GE assumes no responsibility or liability for any losses or damages resulting from the use
of the information contained in this document.
WARNING!
SG Series 225 & 300 is a product that needs to be installed by a licensed and
knowledgeable contractor.
We recommend that this manual be kept next to the UPS for future references.
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.
Safety instructions
Read the safety instructions contained on the following pages carefully before the
installation of the UPS, options and battery system.
Pay attention to the rectangular boxes included in the text:
They contain important information and warning concerning electrical connections and
personnel safety.
Parallel version secured with RPA
When included in the text, this symbol refers to operation needed
only for parallel system.
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Table of contents Page
1IMPORTANT SAFETY INSTRUCTIONS ........................................................................................................ 6
2LAYOUT.......................................................................................................................................................... 9
2.1 LAYOUT SG Series 225 & 300 .......................................................................................................................................................9
3INSTALLATION............................................................................................................................................ 10
3.1 TRANSPORT....................................................................................................................................................................................... 10
3.1.1 Dimensions and weight................................................................................................................................................................. 10
3.2 DELIVERY ............................................................................................................................................................................................ 11
3.3 STORAGE ............................................................................................................................................................................................ 11
3.3.1 Storage of the UPS .......................................................................................................................................................................... 11
3.3.2 Storage of battery ........................................................................................................................................................................... 11
3.4 PLACE OF INSTALLATION ............................................................................................................................................................ 12
3.4.1 UPS location ....................................................................................................................................................................................... 12
3.4.2 Battery location................................................................................................................................................................................ 14
3.5 VENTILATION AND COOLING..................................................................................................................................................... 15
3.6 UNPACKING ...................................................................................................................................................................................... 16
3.7 ELECTRICAL WIRING...................................................................................................................................................................... 17
3.7.1 Utility input connection................................................................................................................................................................. 17
3.7.2 Input/output over current protection and wire sizing..................................................................................................... 18
3.7.3 Battery over current protection and wire sizing................................................................................................................ 19
3.8 WIRING CONNECTION.................................................................................................................................................................. 21
3.8.1 Power connections.......................................................................................................................................................................... 21
3.8.2 Power connection with common input utility..................................................................................................................... 23
3.8.3 Power connection dual input utility (option)........................................................................................................................ 25
3.8.4 Battery and External Battery Breaker connection ........................................................................................................... 28
3.8.5 Interface to External Bypass for single unit......................................................................................................................... 29
3.8.6 Connections to External Bypass switch in case of RPA Parallel System................................................................ 29
3.8.7 Setup for SG Series 225 & 300 intended to be operated in eBoost™ Operation Mode.................................... 30
3.9 RPA PARALLEL SYSTEM CONNECTION .................................................................................................................................. 31
3.9.1 Power wiring of parallel units..................................................................................................................................................... 31
3.9.2 Parallel control bus connection................................................................................................................................................. 32
3.9.3 Control bus cable location........................................................................................................................................................... 34
4CUSTOMER INTERFACE............................................................................................................................. 36
4.1 CUSTOMER INTERFACE ................................................................................................................................................................ 36
4.1.1 Serial Port J3 ...................................................................................................................................................................................... 37
4.1.2 Output free potential contacts .................................................................................................................................................. 37
4.1.3 Programmable input free contacts ......................................................................................................................................... 38
4.1.4 Gen Set Signaling (GEN ON)......................................................................................................................................................... 38
4.1.5 AUX external Maintenance Bypass ......................................................................................................................................... 38
4.1.6 Auxiliary Power Supply (APS) 24Vdc........................................................................................................................................ 38
4.1.7 EPO (Emergency Power Off) Input contact........................................................................................................................... 39
5NOTES .......................................................................................................................................................... 40
5.1 NOTES FORM .................................................................................................................................................................................... 40
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1 IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions for models SG Series 225 & 300 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.
- Check for sufficient floor and elevator loading capacity.
- Check the integrity of the UPS equipment carefully.
If you notice visible damage, do not install or start the UPS.
Contact the nearest Service Center immediately.
- WARNING! RISK OF ELECTRICAL SHOCK:
Do not remove covers, there are no user serviceable parts inside.
- After switching off takes 5 minutes for the DC capacitors to discharge because a lethally high voltage
remains at the terminals of the electrolytic capacitors.
- All maintenance and service work should be performed by qualified service personnel.
The UPS contains its own energy source (battery).
- The field-wiring outlets may be electrically live, even when the UPS is disconnected from the utility.
- Dangerous voltages may be present during battery operation.
- The battery must be disconnected during maintenance or service work.
- This UPS contains potentially hazardous voltages.
- Be aware that the inverter can restart automatically after the utility voltage is restored.
INSTALLATION
- This UPS must be installed and connected only by trained personnel.
- Verify accurately during Commissioning and Maintenance of the UPS, for the following:
Damaged components, squeezed wires and cables, or not correctly inserted plugs.
- After removing the sidewalls of the UPS, make sure that all earth connections when reassembling, are
correctly reattached.
- This UPS is intended for use in a controlled indoor environment free of conductive contaminants and
protected against animals intrusion.
- WARNING! HIGH EARTH LEAKAGE CURRENT:
Earth connection is essential before connecting to AC input!
- Switching OFF the unit does not isolate the UPS from the utility.
- Do not install the UPS in an excessively humid environment or near water.
- Avoid spilling liquids on or dropping any foreign object into the UPS.
- The unit must be placed in a sufficiently ventilated area; the ambient temperature should not exceed 104°F (40°C).
- Optimal battery life is obtained if the ambient temperature does not exceed 77°F (25°C).
- It is important that air can move freely around and through the unit. Do not block the air vents.
- Avoid locations in direct sunlight or near heat sources.
STORAGE
- Store the UPS in a dry location; storage temperature must be within -13°F (-25°C) to 131°F (+55°C).
- The optimal temperature for Battery storage is 68°F (20°C) to 77°F (25°C) and shall never exceed the range -
4°F (-20°C) to 104°F (40°C).
- If the unit is stored for a period exceeding 3 months, the battery must be recharged periodically (time
depending on storage temperature).
BATTERY
- The battery-voltage is dangerous for person’s safety.
- When replacing the battery, use the same cells number, voltage (V), capacity (Ah).
All the battery used, shall be of the same manufacturer and date of production.
- Proper disposal or recycling of the battery is required.
Refer to your local codes for disposal requirements.
- Never dispose of battery in a fire: they may explode.
- Do not open or mutilate battery: their contents (electrolyte) may be extremely toxic.
If exposed to electrolyte, wash immediately with plenty of water.
- Avoid charging in a sealed container.
- Never short-circuit the batteries.
When working with batteries, remove watches, rings or other metal objects, and only use insulated tools.
- In case of air shipment, the cables +/- going to the battery fuses/terminals shall be disconnected and isolated.

Safety instructions when working with battery
EXTERNAL BATTERY MUST BE INSTALLED AND CONNECTED TO THE UPS BY
QUALIFIED SERVICE PERSONNEL ONLY.
INSTALLATION PERSONNEL MUST READ THIS ENTIRE SECTION BEFORE HANDLING
THE UPS AND BATTERY.
DANGER!
Full voltage and current are always present at the battery terminals.
The battery used in this system can provide dangerous voltages, extremely high currents and a
risk of electric shock.
If the terminals are shorted together or to ground they may cause severe injury.
You must be extremely careful to avoid electric shock and burns caused by contacting battery
terminals or shorting terminals during battery installation.
Do not touch uninsulated battery terminals.
A qualified service person, who is familiar with battery systems and required precautions, must
install and service the battery.
The installation must conform to national and local codes.
Keep unauthorized personnel away from the battery.
The qualified service person must take these precautions:
1 Wear protective clothing, such as rubber gloves and boots and protective eye wear
Batteries contain caustic acids and toxic materials and can rupture or leak if mistreated.
Remove rings and metal wristwatches or other metal objects and jewelry.
Do not carry metal objects in your pockets where the objects can fall into the battery
cabinet.
2 Tools must have insulated handles and must be insulated so that they will not short battery
terminals.
Do not allow a tool to short between individual or separate battery terminals or to the
cabinet or rack.
Do not lay tools or metal parts on top of the battery, and do not lay them where they could
fall onto the battery or into the cabinet.
3 Install the battery as shown on the drawing provided with the battery.
When connecting cables, never allow a cable to short across a battery’s terminals, the
string of battery, or to the cabinet or rack.
4 Align the cables on the battery terminals so that the cable lug will not contact any part of
the cabinet or rack, even if the battery is moved.
Keep the cable away from any sharp metal edges.
5 Install the battery cables in such a way that the UPS or battery cabinet doors cannot pinch them.
6 Do not connect the battery terminal to Ground.
If any battery terminal is inadvertently grounded, remove the source of the ground.
Contacting any part of a grounded battery can cause a risk of electric shock.
7 To reduce the risk of fire or electric shock, install the battery in a temperature and humidity
controlled indoor area, free of contaminants.
8 Battery system chassis ground (earth) must be connected to the UPS chassis ground (earth).
If you use conduits, this ground conductor must be routed in the same conduit as the
battery conductors.
9 Where conductors may be exposed to physical damage, protect the conductors in
accordance with all applicable codes.
10 If you are replacing the battery or repairing battery connections, shut OFF the UPS and
remove the battery fuses.
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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.
Please pay attention to the meaning of the following warnings and symbols.
Throughout this manual the following symbols are defined:
WARNING, if instruction is not followed injury or serious equipment damage may
occur!
CAUTION, internal parts have dangerous voltage present.
Risk of electric shock!
PE (Earth) – GND (Ground)
PROTECTIVE GROUNDING TERMINAL:
A terminal which must be connected to earth ground prior to making any other
connection to the equipment.
A terminal to which or from which an alternating (sine wave) current or voltage
may be applied or supplied.
A terminal to which or from which a direct current or voltage may be applied or
supplied.
This symbol indicated the word “phase”.
This symbol indicates the principal on/off switch in the on position.
This symbol indicates the principal on/off switch in the off position.
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2 LAYOUT
2.1 LAYOUT SG Series 225 & 300
SGS_225-300_S2_UPS_GE_02
Fig. 2.1-1 SG Series 225 & 300 general view
SGS_225-300_S2_UPS_03
0OFF
Q2
I ON Q1
I ON
0OFF
4
3
2
1
2
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3
4
1
43
2
1
15
14
13
12 98
20
19
567
17
16 18 21
10
22
11
Fig. 2.1-2 SG Series 225 & 300 general view with open doors
SGS_225-300_S2_UPS_04
0OFF
Q1
I ON
I ON
Q2
0OFF
1
4
3
2
CRXA XBPA
10
20
19
98 21
7
18
6
17
11
22
16
4
3
15
14
5
12
12
13
1
2
3
42
1
3
4
Fig. 2.1-3 SG Series 225 & 300 general view with optional 5th harmonic filter
and removed protection panels
1Opening for top cable entry
(*)
2Opening for bottom cable
entry
3Compression lugs for Utility
input and Load output
4Compression lugs for
external Battery
connection
CR Connectivity Rack
PA 24Vdc Auxiliary Power
Supply
XA Terminals for 24Vdc
Auxiliary Power Supply
connection
XB Terminals for EPO
connection
*)Remove this panel or
provide means to capture
metal filings from cutting
conduit entry holes.

3 INSTALLATION
3.1 TRANSPORT
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.
Move the UPS in it’s original package to the final
destination site.
Do not stack other packages on top: This could damage
the UPS.
If the UPS must be lifted by crane, use suitable lifting straps
and spreader bars.
Note of the center of gravity marked on the package.
Take all necessary precautions to avoid damage to the
cabinet while hoisting the UPS.
Forklift
Crane
NOTE !
Fig. 3.1-1 UPS cabinets moving
Check for sufficient floor and elevator
loading capacity.
3.1.1 Dimensions and weight
Dimensions SG Series 225 & 300
(W x D x H)
64.96 x 31.50 x 70.90 inches
1,650 x 800 x 1,800 mm
SGS_225-300_S2_UPSdimensions_GE_01US
H
W
D
Fig. 3.1.1-1 UPS cabinet dimensions
Weight SG Series 225 & 300
UPS rating Weight Floor loading
lbs/sq.ft - kg/m2lbs / kg
SG Series 225 & 300 3,087 / 1,400 218 / 1,061
P.S.: Weights including the 5th harmonic filter.
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3.2 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.
NOTE !
A DAMAGED UPS MUST NEVER BE INSTALLED OR CONNECTED TO UTILITY OR
BATTERY!
3.3 STORAGE
3.3.1 Storage of the UPS
The UPS is carefully packed for transport and storage so that it is in perfect condition when installed.
Never leave a UPS outside the building and don’t store other packages on the top of the UPS.
It is advisable to store the UPS in its original package in a dry, dust-free room, away from chemical
substances, and with a temperature range not exceeding -13°F (-25°C) to 131°F (55°C).
In case the battery is included please refer to Section 3.3.2.
Some important functions of the UPS, such as the customized functions, are defined by parameters
stored in a RAM memory.
A small backup battery located on the Control Unit board supplies the RAM.
If the storage time of the UPS exceeds 1 year, these functions should be verified by an authorized
Service Center before putting the UPS into operation.
3.3.2 Storage of battery
When the delivery includes a maintenance free battery, keep in mind that they are subject to self-
discharge and therefore you must recharge the battery.
The storage time without battery recharge depends on the temperature of the storage site.
The optimal temperature for Battery storage is 68°F (20°C) to 77°F (25°C) and shall never exceed the
range -4°F (-20°C) to 104°F (40°C).
Recharge stored maintenance free battery every:
6 months when the storage temperature is 68°F (20°C)
3 months when the storage temperature is 86°F (30°C)
2 months when the storage temperature is 95°F (35°C)
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3.4 PLACE OF INSTALLATION
3.4.1 UPS location
WARNING !
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.
It is important to have a clean, dust-free environment provided with proper ventilation and air-
conditioning to keep the ambient temperature within the specified operating range.
The recommended air inlet temperature is from 68°F (20°C) to 77°F (25°C) (max. 104°F / 40°C).
Refer to Section 3.5.
Check for sufficient floor load capacity before installing the UPS and the Battery.
Refer to Section 3.1.1.
For Battery installation follow the local codes and the recommendation of the battery supplier.
NOTE !
Temperature is very important for valve-regulated batteries (maintenance free).
Operation at temperatures higher than 77°F (25°C) will reduce battery life.
The SG Series 225 & 300 UPS can radiate radio frequency energy.
Although some RFI filtering is inherent to the UPS there is no guarantee that the UPS will not influence
sensitive devices such as cameras and monitors that are positioned close by.
If interference is expected, the UPS should be moved away from the sensitive equipment.
A single-phase power outlet (120 Vac) should be provided near the UPS for connection of power tools,
test equipment or connectivity devices. This outlet must be grounded.
Positioning of the UPS SG Series 225 & 300
Min.
20" / 500mm
SGS_225-300_S2_UPSdisposition_GE_01
Fig. 3.4.1-1 SG Series 225 & 300 clearances
The rear panel of the UPS may be mounted flush
to a wall or other structure.
Clearance around the front of the unit should be
sufficient to enable free passage of personnel with
the doors fully open, and to allow sufficient airflow
to the door vents.
Check section 110-26(A) of the NEC code for
specific requirements.
Recommended minimum clearance between
ceiling and top of the UPS should be 20” (500 mm)
for proper cooling air exhaust.
In case of additional cabinets (external Batteries or
input, output transformers) these can be placed on
either side of the cabinet.
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Openings for input and output cable connections
SGS_225-300_S2_UPSview top_01US
1,650mm
64.96"
160mm
6.30"
2.76"
40mm
1.58"
70mm
31.50"
21.66"
550mm
800mm
Utility input
Output Load
Battery
Fig. 3.4.1-2 Opening on top of the cabinet for input and output cables
SG Series 225 & 300
openings are provided
on the top and the
bottom of the UPS for
the connection of input
and output cables.
Pay attention to the
position of these
openings, when
choosing the placement
of the UPS.
Utility input
Output Load
6.30"
160mm
1.77"
550mm
21.66"
800mm
31.50"
100mm
3.94"
1,650mm
64.96"
SGS_225-300_S2_UPSviewbottom_01US
45mm
Fig. 3.4.1-3 Opening on the bottom of the cabinet for input and output cables
These openings are
covered with a
protective plate.
Fixing of the UPS cabinet on the floor
The UPS cabinet is free standing and normally does not require to be bolted to the floor.
The UPS cabinet can be fixed however to the floor by bolting it with the supporting blocks to the
floor. See Fig. 3.4.1-4.
62.205"
1580mm
35mm
713mm
28.071"
60mm
2.363"
60mm
2.363"
680mm
26.772"
1.378" 1.378"
35mm
=
Ø 0.47"
Ø 12mm
=
Front side
SGS_225-300_S2_UPS view bottom_02US
Fig. 3.4.1-4 Fixing of the UPS cabinet on the floor
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UPS
3 - 4 - 5 - 6
SGS_225-300_S2_RPAdisposition_GE_01US
UPS 1
UPS 2
Fig. 3.4.1-5 RPA system disposition
In case of parallel system, try to place the UPS modules in sequence of their numbers (marked on
the packing).
If the units are positioned “side by side”, the side panels must be mounted on all units.
3.4.2 Battery location
Batteries require a well-ventilated room with controlled temperature to obtain reliable operation.
The battery can be install immediately adjacent to the UPS (left or right side) or remotely from the UPS.
If the battery is installed remotely from the UPS, a wall mounted DC disconnect device must be installed
within line-of-site to both the UPS and the battery.
The optimal room temperature for Battery storage is 68°F (20°C) to 77°F (25°C) and shall never exceed
the range -4°F (-20°C) to 104°F (40°C).
The life of valve-regulated batteries will be reduced by 50% for each additional 18°F (10°C) that the
battery ambient temperature is above 77°F (25°C).
The battery system associated with larger UPS is usually either rack mounted or installed in multiple
battery cabinets.
Installation and assembly must be made according to the local standards and battery system
manufacturer‘s recommendations.
The battery circuit breaker or battery fuse box must be mounted as near as possible to the battery.
NOTE !
Battery installation and connection must be performed by QUALIFIED SERVICE
PERSONNEL ONLY.
Read all safety instructions before proceeding with the installation.
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3.5 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.
A suitable ventilation or cooling system must be installed to extract the heat from the UPS room.
NOTE !
Do not put anything on the top of the cabinet.
Air filtration systems could be required when the UPS operates in a dirty environment.
Contact your Dealer or the nearest Service Center for appropriate solutions.
In order to prevent overheating of the UPS, the available air intake flow rate must exceed the total air
exhaust flow rate requirement of the UPS system.
The below table indicates the heat dissipation at full load at PF = 0.9 lag. and charged battery, up to
3,280 ft (1,000 m) altitude, for cooling air 77°F (25°C) to 86°F (30°C).
Losses Cooling air flow
UPS rating with options
BTU / hr kW CFM m3/ h
SG Series 225 with 5th filter 82,902 15.5 2,661 4,521
SG Series 225 in eBoost™ Operation Mode 9,898 2.9 498 846
SG Series 300 with 5th filter 73,721 21.6 3,709 6,300
SG Series 300 in eBoost™ Operation Mode 12,287 3.6 618 1,050
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3.6 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.
If delivered in a wooden crate, remove the cabinet from the pallet with care, because of the heavy
weight of the equipment.
White color =without any anomaly
Red color =anomaly evidence
Fig. 3.6-1 ShockWatch device
The package of the SG Series 225 & 300 is
equipped with ShockWatch (indicator for shock),
and TiltWatch (indicator for overthrow) on the
outside.
These devices indicate an eventual shock or
overthrow during transport.
Whenever these devices show a possible
anomaly, the UPS shall not be commissioned
before consulting a “Service Center”.
Fig. 3.6-2 TiltWatch device
NOTE !
Take care not to damage the UPS when moving by forklift.
A damaged UPS must never be installed or connected to Utility or Battery!
In case of any damage sustained during the transport, immediately inform the
shipping agent!
A detailed report of the damage is necessary for any indemnity claim.
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, use only environmentally friendly
material.
UPS packing materials must be recycled in compliance with all applicable
regulations.
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3.7 ELECTRICAL WIRING
WARNING !
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
NOTE !
Ensure that the AC and DC external isolators are OFF and locked out to prevent their
inadvertent operation.
Do not apply power to the equipment prior to the commissioning by a QUALIFIED
SERVICE ENGINEER.
Before any other input connection, connect and check the grounding wire.
The UPS has available input terminations for the Rectifier and Bypass.
The unit may be powered from a common input source or dual input (option) sources if desired.
Common Input Rectifier & Bypass
The same power source is to be used for both Bypass Supply and Rectifier Input (input F3).
Bear in mind that when the Utility Fuses are opened there is a supply failure to the Rectifier as well as
to the Bypass and Manual Bypass.
In this case, the interconnection links BR1, BR2 and BR3 on the input terminals or bus
bars MUST REMAIN CONNECTED. See Fig. 3.8.3-3.
Dual Input Configuration Rectifier & Bypass (option)
The Bypass and Rectifier inputs are to be powered from different Utility supplies (F1 and F2 inputs).
In this case, when the Rectifier Input Fuses are opened, the Bypass and the Manual Bypass are
supplied by the other source.
In this case, REMOVE the interconnection links BR1, BR2 and BR3 on the input
terminals or bus bars. See Fig. 3.8.3-3.
Dual Input Configuration Rectifier & Bypass (option) Common Input Rectifier & Bypass
Fig. 3.7.1-1 Dual Input Configuration Rectifier & Bypass (option) Fig. 3.7.1-2 Common Input Rectifier & Bypass
1 = Rectifier
2 = Inverter
3 = Automatic Bypass
4 = Manual Bypass Q2 (option)
6 = Load
5 = Utility input
7 = Battery
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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.
Output load configuration may be such that one phase may carry a load current at 100% of that
phases maximum current rating while the other two phases run at 0% or any combination in between.
Ensure that the load does not consist of any equipment that may require high starting currents such as
electric motors, laser printers, etc.
This may cause the UPS to occasionally go into Bypass due to overload conditions
To choose the correct input fuses or circuit breaker, consider the available short-circuit current of the
system up-stream.
Choose the correct fuse or breaker using current data shown in the chart and the appropriate NEC
code.
The ratings indicated in the following chart do not consider any line voltage drop.
In case of optional input transformer the input protective devices should be sized to allow the
transformer magnetization inrush current.
Caution when using four-pole circuit breakers as protection.
A potential problem exists for situations with non-linear loads:
The neutral current could be greater than the phase currents.
The three-phase Utility power supply must be symmetrical with respect to ground, due to the existence
of voltage surge protection devices inside the UPS.
NOTE !
If you use ELCB breaker (Earth Limiting Circuit Breaker) to protect the input
connections, consider the high leakage current generated by the noise suppression
capacitors.
If these ELCB breakers are strictly necessary, we suggest using the largest type
suitable for non-linear current and for delayed operations.
To ensure coordination when the UPS is configured for Separate Bypass and Rectifier Inputs, special care
must be taken in choosing the fuse or circuit breaker ratings installed in the output distribution circuits.
Protective devices on the output of the UPS should be coordinated with the Bypass Input circuit
protection.
Due to the relatively low short circuit capability of the UPS inverter, a short circuit in the load will cause
an immediate transfer to Bypass.
The largest fuse or circuit breaker in the output distribution should be rated at no more than 60% of the
rating of the protective device supplying the Bypass line.
If circuit selectivity is required while the load is fed from the inverter (Bypass Utility not available), the
largest fuse or circuit breaker should be rated at no more than 20% of the UPS output current rating.
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3.7.3 Battery over current protection and wire sizing
NOTE !
• 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.
• The remote rack mounted batteries are to be used then DC over current
protection must be provided by others.
• Choose an appropriate DC fuse or circuit breaker using the current data in the
chart below.
• Minimum battery cable requirement is based on the current data below.
• The maximum available fault current from the battery supply is: 20kA.
• The minimum breaker voltage rating is 540V.
The AC values below are current ratings per phase.
These maximum and nominal ratings should be considered when choosing the appropriate AC
over current protection device.
NEC (National Electric Code) Section 210-20 a rules must be applied.
DC current rating is the nominal battery discharge current which the UPS allows.
(See Fig. 3.7.1-1 and 3.7.1.2)
AC Input Rectifier AC Input AC Input
Bypass DC Input
F1 F3
UPS rating
Nom. Max. F2 Nom. Max. F4
SG Series 225 338 A 380 A 271 A 338 A 380 A 444 A
SG Series 300 451 A 490 A 361 A 451 A 490 A 592 A
Size of Branch Circuit Over current Protection - All Models: - "CAUTION - To reduce the risk of fire,
only connect UPS to a circuit provided with (See below) maximum amperes branch circuit over
current protection in accordance with the NEC (National Electric Code), NSI / NFPA 70
AC Input Rectifier AC Input Bypass AC Input DC Input
UPS rating F1 F2 F3 F4
SG Series 225 450 A 350 A 450 A 600 A
SG Series 300 600 A 500 A 600 A 700 A
WIRING
Wire sizing according to
NEC Section 210-20 (a) Table 310-16
Use 75°C (167°F) 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
Refer to torque specifications table for torque requirements
UPS rating Rectifier Input Bypass Input DC Input AC Output GND
SG Series 225 2 x 500 kcmil 2 x 500 kcmil 2 x 750 kcmil 2 x 500 kcmil 350 kcmil
SG Series 300 2 x 750 kcmil 2 x 500 kcmil 2 x 750 kcmil 2 x 500 kcmil 350 kcmil
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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
Eart7h (Directly Buried), Based on Ambient Temperature of 30°C (86°F).
Temperature Rating of Conductor (See table 310-13)
Size 60°C (140°F) 75°C (167°F) 90°C (194°F) 60°C (140°F) 75°C (167°F) 90°C (194°F)
AWG
or
kcmil
Types
TW, UF
Types
FEPW, RH, RHW,
THHW, THW,
THWN, XHHW,
USE, ZW
Types
TBS, SA, SIS, FEP,
FEPB, MI, RHH,
RHW-2, THHN,
THHW, THW-2,
THWN-2, USE-2,
XHH, XHHW,
XHHW-2,ZW-2
Types
TW, UF
Types
RH, RHW,
THHW,
THW, THWN,
XHHW, USE
Types
TBS, SA, SIS,
THHN, THHW,
THW-2,
THWN-2, RHH,
RHW-2, USE-2,
XHH, XHHW,
XHHW-2,
ZW-2
COPPER ALUMINIUM or COPPER-CLAD ALUMINIUM
18 --- --- 14 --- --- ---
16 --- --- 18 --- --- ---
14 20 20 25 --- --- ---
12 25 25 30 20 20 25
10 30 35 40 25 30 35
8 40 50 55 30 40 45
6 55 65 75 40 50 60
4 70 85 95 55 65 75
3 85 100 110 65 75 85
2 95 115 130 75 90 100
1 110 130 150 85 100 115
1/0 125 150 170 100 120 135
2/0 145 175 195 115 135 150
3/0 165 200 225 130 155 175
4/0 195 230 260 150 180 205
250 215 255 290 170 205 230
300 240 285 320 190 230 255
350 260 310 350 210 250 280
400 280 335 380 225 270 305
500 320 380 430 260 310 350
600 355 420 475 285 340 385
700 385 460 520 310 375 420
750 400 475 535 320 385 435
800 410 490 555 330 395 450
900 435 520 585 355 425 480
1000 455 545 615 375 445 500
1250 495 590 665 405 485 545
1500 520 625 705 435 520 585
1750 545 650 735 455 545 615
2000 560 665 750 470 560 630
CORRECTION FACTORS
Ambient
Temp. (°C)
For ambient temperatures other than 30°C (86°F), multiply the allowable ampacities shown above by the appropriate factor
below
21 - 25 1.08 1.05 1.04 1.08 1.05 1.04
26 - 30 1.00 1.00 1.00 1.00 1.00 1.00
31 - 35 0.91 0.94 0.96 0.91 0.94 0.96
36 - 40 0.82 0.88 0.91 0.82 0.88 0.91
41 - 45 0.71 0.82 0.87 0.71 0.82 0.87
46 - 50 0.58 0.75 0.82 0.58 0.75 0.82
51 - 55 0.41 0.67 0.76 0.41 0.67 0.76
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