Vertiv UL891 Installation and maintenance instructions

UL891 Switchboard
Installer/User Guide

Proprietary and Confidential ©2024 Vertiv Group Corp.
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If you encounter any installation or operational issues with your product, check the pertinent section of this
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and/or end user is responsible for compliance with all applicable laws and
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Vertiv™ UL891 Switchboard Installer/User Guide

TABLE OF CONTENTS
1 Important Safety Instructions 1
2 Introduction 1
2.1 General Information 1
2.2 Product Overview 1
2.3 Design Features and Components 3
2.4 Typical Switchboard Layouts 4
2.5 Typical Customer Connections 5
2.6 Typical Ground Layout 8
2.7 Technical Information 10
2.8 Labels and Markings 10
3 Packaging and Handling 13
3.1 Receiving 13
3.2 Handling 13
3.2.1 Unloading from Truck 13
3.2.2 Unloading off Pallet 14
3.3 Storage 20
4 Installation 21
4.1 Pre-Installation Preparation 21
4.2 Anchoring 21
4.3 Considerations for Installation 23
4.4 Joining Sections 24
4.5 Transformer Close Coupled Connection 26
4.6 Electrical Connections 27
4.6.1 Fish Plates 27
4.6.2 Ground Bus Connection 35
4.6.3 Cable Connections 36
4.6.4 Busway 38
5 Energization 39
5.1 Pre-Energization 39
5.1.1 Pre-Energization Tests 39
6 Maintenance 41
6.1 Setting Up a Maintenance Schedule 41
6.2 Maintenance Inspections 41
7 Torque Table 43
8 Accessories 45
8.1 OHLD Installation 46
8.2 OHLD Operation 47
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Appendices 49
Appendix A: Technical Support and Contacts 49
Appendix B: Submittal Drawings 50
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Vertiv™ UL891 Switchboard Installer/User Guide

1 Important Safety Instructions
All information provided in this instruction manual and additional referenced documentation should be reviewed and
acknowledged by all personnel responsible for the use of the equipment. All models represented in this manual are for
illustrative purposes only, due to the individual specifications associated with each customer. Vertiv will not assume
responsibility for actual use establish by the models.
Proper installation, operation, and maintenance are critical to the performance of the equipment.
Correct operating conditions in terms of input voltage, current and the fault capacities must be ensured at the time of
installing UL891 switchboard.
Refer ANSI C37.20.1 for abnormal operational conditions.
General instructions
•Read all the instructions included in this IUG before working with the equipment.
•Store and keep this IUG to ensure proper commissioning and maintenance to ensure the prolong use of the
equipment.
•Install the switchboard based on the design limitations as given in this IUG. The design limitations are presented
on the main nameplate and should never be installed in applications that exceed the limits presented by the
nameplate.
•Always follow standard safety protocols set forth by your company.
•Turn off all the power sources and de-energized the equipment before removing the covers and opening of
doors of the equipment. All components should be locked out and tagged in line with standard protocol and
ANSI Standard Z244.1 Control of Hazardous Energy – Lockout/Tagout.
•Wear PPEs while working on the switchboard.
•Only Veritv qualified personnel should work on the Switchboard.
•If additional information is needed, please contact your Vertiv representative.
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2 Introduction
2.1 General Information
Vertiv™ UL891 Switchboard range offers a fully customizable solution that improves efficiency, saves space, and enhances
operator safety. The switchboard UL891 is engineered with influence from our proven IEC 60349-1 technology that has been
fully tested and certified to comply with UL891 standards. The Switchboard range also includes power distribution units and
remote power panels.
Features of UL891 Switchboard:
•Fully customized and design for flexibility.
•Type tested arc prevention busbar systems.
•Equipped with Type 1 gasket, and Type 3R enclosures.
•Switchboard ampacity to 6000A.
•Segregation available up to Form 4 type 7 for enhanced user safety and protection.
•Molded case circuit breaker (MCCB) UL489 and air circuit breaker (ACB) UL1066 large selection from main
breaker manufacturers.
•Integration of TVSS, PQM’s, Protective Relays and Controls based on site specific needs.
2.2 Product Overview
Compact
Vertiv manufactures one of the most compact switchboard designs in the North American market. UL891 Switchboard packs
more power into a smaller footprint, with our flexible modular design offering a standard shallow depth of 30.2 in. This
innovative design helps our customer to accommodate the demand for higher power capacity without losing valuable real
estate.
Safe and Reliable
Built and tested with IEC influence, the design of our UL891 Switchboard is focused on achieving the highest standard of
performance reliability and operator safety. Internal segregation as outlined by IEC 61439-2 reduces operator risk by limiting
the propagation of internal arc fault and preserves uptime during maintenance and upgrade operations.
Flexible
Vertiv modular switchboard design facilitates a component agnostic solution, giving the customer more freedom to choose
their preferred components from an extensive range of well known manufacturers. Designs can be customized to fit the most
challenging specifications and site specific needs, while maximizing space and performance.
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Figure 2.1 Typical Switchboard
Figure 2.2 Typical Power Distribution Unit (PDU)
Figure 2.3 Typical Remote Power Panel (RPP)
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2.3 Design Features and Components
Typical switchboards are available with a variety of options. Below shows a typical arrangement with components and
features for a switchboard. PDUs and RPPs use the same typical layouts, but use different components to achieve their
designated goal, such as transformers and panelboards.
Figure 2.4 Rear Internal View
Figure 2.5 Front Internal View
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Sr. No. Item Description
1 Cableway Compartment Designated for customer connections.
2 MCCB Compartment Housing unit for MCCB.
3 MCCB – UL489 fixed mount circuit breaker Equipment designed to break electrical circuit if tripped.
4 ACB – UL1066 draw out circuit breaker Equipment designed to provide protection for overcurrent and short circuits using air.
5 Neutral Busbar Voltage difference to each phase is approximately equal in magnitude and are equally
spaced in phase.
6 Main Busbar Carries the majority of the current.
7 Panel Flange Connection Connection point between switchboard and busway route in a facility.
8 Ground Busbar Ground network for the lineup with taps.
9 Instrument Compartment Designated as the metering and control section.
2.4 Typical Switchboard Layouts
Switchboards provide typical layouts for ACBs and MCCBs within the lineup. Typical layouts include front and rear access,
with single and double stack ACBs in individual sections. See Figure 2.6 below .
Standard MCCB columns with MCCBs stacked on top of each other in individual sections. See Figure 2.7 on the facing page .
MCCB’s use rotary handles for turning the breakers on and off. In a front access only switchboard, there is a cableway for field
termination.
Figure 2.6 Typical ACB Layout
Front Access - Single ACB Front Access -Double ACB Rear Access - Single ACB Rear Access - Double ACB
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Figure 2.7 Typical MCCB Layout
Item Description
1 Line/Load Shrouds
2.5 Typical Customer Connections
Each breaker, either ACB or MCCB, has typical field termination arrangements that are used, unless specified on a per project
basis. Below are the typical field terminations for the different ACBs and MCCBs amperages. Quantities of lug provisions vary
per nominal breaker rating. All lug pads consist of the standard NEMA hole pattern, which is 1.75 in. x 1.75 in. with a clearance
hole for 0.5 in. hardware. The 0.5 in. hardware consists of a bolt, 2 Belleville washers (one on each side of the connection), and
a nut.
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Below are the different typical customer connections.
Figure 2.8 Typical Provision for Front Access and Top Incoming Customer Cable Connections
Figure 2.9 Typical Provision for Front Access and Bottom Incoming Customer Cable Connections
Figure 2.10 Typical Provision for Rear Access and Top Incoming Customer Cable Connections
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Figure 2.11 Typical Provision for Rear Access and Bottom Incoming Customer Cable Connections
Figure 2.12 Typical Provision for Rear Access and Bottom Incoming Customer Cable Connections
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Figure 2.13 Typical Provision for Double Stacked Front/Rear Access and Bottom Incoming Customer Cable
Connections
Figure 2.14 Typical Provision for MCCB Customer Cable Connections
2.6 Typical Ground Layout
The ground is a system that runs the complete length of any switchboard. There are taps periodically throughout each
switchboard for tapping off for field terminations.
Below are typical arrangements of ground cable provisions per switchboard configuration.
Figure 2.15 Typical Ground Dropper Arrangement with Provisions for up to two (2) Compression Lugs
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Figure 2.16 Alternate Ground Dropper Arrangement with Provisions for up to two (2) Compression Lugs
Figure 2.17 Typical Ground Dropper Arrangement with Provisions for up to four (4) Compression Lugs
Figure 2.18 Alternate Ground Dropper Arrangement with Provisions for up to four (4) Compression Lugs
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2.7 Technical Information
Standard
Safety UL891 - Standard for Safety Switchboards
Seismic Requirement IBC 2012 and CBC 2010
Seismic Protection AC156
Test
Certificate
Switchboard is designed, tested, and constructed based on the
standard above ETL File: 103065685CRT
Electrical Data
Rated Voltages
Rated insulation voltage, Vi 2.2 kV
Rated operating voltage, Ve Up to 1000 VAC
System types 3 phase-3 wire, 3 phase-4 wire
Rated frequency 60 Hz
Rated
Ampacities
Rated current Up to 6000 A
Rated short circuit current Up to 100 kA at 600 V and 10 kA at 1000 V
Breakers
MCCB UL489, multiple brands
ACB UL489 or UL1066, multiple brands
Transformer Close coupled to switchboard or internal for PDUs
Busway Available for ratings 800-6000 A
Mechanical
Data
Dimensions
Height in (mm) Up to 94.8 in. (2407 mm)
Width in (mm) Custom per project, no limitation
Depth in (mm) Up to 60.5 in. (1536 mm)
Surface
Protection
Frame Paint finish
Enclosure Paint finish
Enclosure Type Type 1 A and Type 3 R (Front and rear access dependent on project specs)
Plastic
Components Self-extinguishing, flame retardant
Busbars
Standard - tin plated (Silver plated available)
Bus Bracing Up to 100 kA at 600 V
Paint Finish Enclosure Standard - RAL 7035 (Special colors are
available)
Table 2.1 Technical Information
2.8 Labels and Markings
The switchboard comes standard with a master nameplate located on the main incoming section, as well as several other
labels. All nameplates and labels provide information related to the switchboard and electrical data, cautions and warnings to
help the personnel of important information and safety precautions.
Examples of labels that may be found on the switchboard are shown Figure 2.19 on the facing page .
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Figure 2.19 Typical Labels
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3 Packaging and Handling
The switchboard lineup is shipped in single sections or shipping splits. Separation of splits are deemed by the project
engineer and their communication with the customer. Unless otherwise requested, the single sections or splits will be
wrapped and shipped on a pallet to which they are bolted. The standard size of the pallet is the width of the section or split by
the depth of the section plus twelve inches (approximately six inches in the front and rear of the switchboard when centered
on the pallet). Each section is unique to the job, thus the section weights vary. For actual weights and dimensions, consult
equipment shipping documentation.
3.1 Receiving
•Ensure all sections and splits are present when switchboard arrives on site. Notify your Vertiv representative if
any anomalies are found.
•A thorough inspection should be performed to make sure no damages occurred during shipment. If damages did
occur, a qualified technician needs to investigate the gear for proper diagnosis.
•If the damage is from improper handling, contact the carrier and your Vertiv representative.
•All sections are inspected and marked before they leave the facility. It will be clearly marked with what side is the
front, as well as the section or split number.
•A plastic cover should be used to protect the equipment from dust, dirt, moisture, and damage until it is ready for
installation. The switchboard should remain attached to the pallet until it has been moved into its final installation
position.
•All packaging material should be saved until the gear is ready to be installed, especially if there is a delay in the
installation, so that it can be repacked and stored safely. See Storage on page20 if a delay occurs.
3.2 Handling
Most switchboard sections are top and front heavy and should be handled with caution. Before moving or lifting any section,
verify that the equipment that is going to be used to handle the switchboard is within the safe limits of its capacity.
3.2.1 Unloading from Truck
A forklift is the best method for unloading the switchboard.
IMPORTANT! Only trained personnel should drive the forklift and move the switchboard. Make sure the ground is
solid and all operation and safety recommendations are followed while operating the forklift.
NOTE: Be aware of any floors and conditions that could affect stopping and turning. Pay attention to labeling on the
packaging material. Make sure that the forklift being used is rated to work in safe limits for the weight of the
switchboard split being lifted.
1. Lift the switchboard sections from the front or back side.
2. The forks must run all the way through the entire shipping length and extend past the outermost part of the
wooden pallet.
3. A safety strap, belt or leash approved for the purpose of securing the section should be used. Make sure the
position of the strap is adequate in providing stability to the equipment, in a location that will not damage any
components.
4. Slowly lift the equipment to the minimum required height from the floor for safe relocation.
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Figure 3.1 Forklift
Item Description
1 Switchboard
2 Secure switchboard to forklift with safety strap here
3 Forks under entire switchboard
3.2.2 Unloading off Pallet
There are a few methods for unloading the switchboard splits off the pallet and into the proper installation location. Both
lifting methods are applicable for type 1A and type 3R switchboards. The recommended way is by use of lifting bars, lifting
jacks, and lifting skates see section Method 1 on the facing page . The other method uses lifting bars, lifting straps or chains,
and a spreader with a forklift or crane see section Method 2a on page16 and Method 2b on page17 .
NOTE: Vertiv does not provide bars, jacks, skates, straps or spreaders. It is the customers responsibility to purchase
or rent the correctly rated equipment needed to move the panel splits.
The switchboards also need to be unbolted from the pallet first before lifting the panel. There are holes within the plinth of
each panel that allows for a steel bar to go through. The bar is used for lifting the switchboard. A bar of 2 in. diameter and 96
in. length should be used.
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