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August 26, 2013© S&C Electric Company Instruction Sheet 653-503

S&C PureWave® UPS System750 kW and 1000 kW, 208 Volt—600 Volt

InstallationTable of Contents

Section Page Section Page

IntroductionQualified Persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Read This Instruction Sheet . . . . . . . . . . . . . . . . . . . . . . 2Retain This Instruction Sheet . . . . . . . . . . . . . . . . . . . . . 2Proper Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Document Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Safety InformationUnderstanding Safety Alert Messages . . . . . . . . . . . . . .4Following Safety Instructions . . . . . . . . . . . . . . . . . . . . .4Replacement Instructions and Labels . . . . . . . . . . . . . .4Hazard Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Operator Training Requirements . . . . . . . . . . . . . . . . . .6Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Personal Protective Equipment (PPE) . . . . . . . . . . . . . .8Insulated Hand Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .8Emergency Eye Wash Stations . . . . . . . . . . . . . . . . . . . .8Recommended Emergency Response Equipment

and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Release of Hazardous Materials . . . . . . . . . . . . . . . . . . .9Fire Protection and Extinguishers . . . . . . . . . . . . . . . . . .9Disconnect Means . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Equipment OverviewSystem Bay Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 10Opening the Door of a Bay . . . . . . . . . . . . . . . . . . . . . . 11

InstallationStorage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Concrete Pad Specifications . . . . . . . . . . . . . . . . . . . . . 12Apron for Forklift Access (without Battery Module

Roller Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Apron for Forklift Access (with Battery Module

Roller Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Shimming the Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Set the Center Shipping Split (Switchgear

and Control Bays) . . . . . . . . . . . . . . . . . . . . . . . . . . 15Set the Left Shipping Split (Two Battery Bays) . . . . . . . 16Set the Right Shipping Split (Battery Bay/s) . . . . . . . . 18Secure, Seal, and Ground the Enclosure . . . . . . . . . . 19Door Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19PCM Guide Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Connect the Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Battery Bay Interconnects . . . . . . . . . . . . . . . . . . . . . . 22User Input and Output Connections . . . . . . . . . . . . . . 25Electrical-Connection Inspection . . . . . . . . . . . . . . . . . 30Battery Modules (with Rollers) . . . . . . . . . . . . . . . . . . . 31Battery Modules (without Rollers) . . . . . . . . . . . . . . . . 32Completing the Installation . . . . . . . . . . . . . . . . . . . . . 34Pre-Startup Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2 S&C Instruction Sheet 653-503

Introduction

The following information must be read and understood before installing or operating the S&C PureWave® UPS System. In addition, please also review the “Safety Information” section prior to working with the equipment.

Qualified Persons WARNINGThe equipment covered by this publication must be installed, operated, and maintained by qualified persons who are knowledgeable in the installation, operation and mainte-nance of electric power distribution equipment, along with the associated hazards . A qualified person is one who is trained and competent in:

• The skills and techniques necessary to distinguish exposed live parts from non-live parts of electrical equipment .

• The skills and techniques necessary to determine the proper approach distances corresponding to the voltage to which the qualified person will be exposed .

• The proper use of the special precautionary techniques, personal protective equipment, insulating and shielding materials, and insulated tools for working on or near exposed energized parts of electrical equipment .

These instructions are intended only for such qualified persons . They are not intended to be a substitute for adequate training and experience in safety procedures for this type of equipment .

Read this Instruction Sheet

Read this instruction sheet thoroughly and carefully before installing or operating your S&C PureWave UPS System. Familiarize yourself with the safety information and precautions on pages 4 through 9. The latest version of this publication is available online in PDF format at sandc.com/Support/Product-Literature.asp

Retain this Instruction Sheet

This instruction sheet is a permanent part of your S&C PureWave System. Designate a location where you can easily retrieve and refer to it.

Proper Application CAUTIONThe equipment covered in this publication must be selected for a specific application . The application must be within the ratings furnished for the equipment . Ratings for this equip-ment are listed on a ratings label on the front of the equipment .

The PureWave UPS System is a battery storage system capable of delivering ac power to critical loads and serving the power quality needs of the user. It is an immediate response, high capacity, standby power system which operates as both a voltage source and a current source to protect sensitive electrical and electronic equipment from the adverse affects of voltage sags or swells, momentary power interruptions, and frequency deviations occurring on the utility system.

Document Purpose This instruction sheet provides the information necessary to install a PureWave UPS System.

S&C Instruction Sheet 653-503 3

Warranty The warranty and/or obligations described in S&C’s standard conditions of sale, as set forth in Price Sheet 150, plus the special warranty provisions set forth below, are exclusive. The remedies provided in the former for breach of these warranties shall constitute immedi-ate purchaser’s or end user’s exclusive remedy and a fulfillment of all seller’s liability. In no event shall seller’s liability to immediate purchaser or end user exceed the price of the specific product which gives rise to immediate purchaser’s or end user’s claim. All other warranties whether express or implied or arising by operation of law, course of dealing, usage of trade or otherwise, are excluded. The only warranties are those stated in Price Sheet 150, and THERE ARE NO EXPRESS OR IMPLIED WARRANTIES OF MERCHANT-ABILITY OR FITNESS FOR A PARTICULAR PURPOSE. ANY EXPRESS WARRANTY OR OTHER OBLIGATION PROVIDED IN PRICE SHEET 150 IS GRANTED ONLY TO THE IMMEDIATE PURCHASER AND END USER, AS DEFINED THEREIN. OTHER THAN AN END USER, NO REMOTE PURCHASER MAY RELY ON ANY AFFIRMATION OF FACT OR PROMISE THAT RELATES TO THE GOODS DESCRIBED HEREIN, ANY DESCRIP-TION THAT RELATES TO THE GOODS, OR ANY REMEDIAL PROMISE INCLUDED IN PRICE SHEET 150.

SPECIAL WARRANTY PROVISIONS: The standard warranty contained in seller’s stan-dard conditions of sale, as set forth in Price 150, applies to S&C PureWave UPS Systems except that the first paragraph of said warranty is replaced by the following:

(1) General: Seller warrants to purchaser for a period of 24 months after startup of the system, or 30 months after the date of shipment, whichever occurs first, that the equip-ment delivered will be of the kind and quality specified in the contract description and will be free of defects of workmanship and material. Should any failure to conform to this warranty appear under proper and normal use within 24 months after startup of the system, or 30 months after the date of shipment, which ever occurs first, the seller agrees, upon prompt notification thereof and confirmation that the equipment has been stored, installed, operated, and maintained in accordance with recommen-dations of the seller and standard industry practice, to correct the nonconformity by repairing any damaged or defective parts of the equipment.

Replacement parts provided by seller under the warranty for the original equipment will be covered by the original-equipment warranty for its duration. Replacement parts purchased separately will be covered by the warranty contained in seller’s standard conditions of sale, as set forth in Price Sheet 150.

Seller further warrants that the batteries in each battery module will perform within their rating for either of the following”

(a) 60 months after startup of the system or 66 months after date of shipment, provided that, during any storage periods, battery charge is maintained in accordance with the operation and maintenance manual requirements, or

(b) A total discharge from each battery module of no less than 625 megajoules, whichever occurs first.

Introduction


Understanding Safety-Alert Messages

There are several types of safety alert messages which may appear throughout this instruction sheet as well as on labels and tags attached to the PureWave UPS System. It is important that you recognize these messages and the importance of the various signal words, as explained below.

DANGER“DANGER” identifies the most serious and immediate hazards which will likely result in serious personal injury or death if instructions, including recommended precautions, are not followed .

WARNING“WARNING” identifies hazards or unsafe practices which can result in serious personal injury or death if instructions, including recommended precautions, are not followed .

CAUTION“CAUTION” identifies hazards or unsafe practices which can result in minor personal injury or product/property damage if instructions, including recommended precautions, are not followed .

NOTICE“NOTICE” identifies important procedures or requirements that, if not followed, can result in product/property damage .

Following Safety Instructions

If you do not understand any portion of this instruction sheet and need assistance, contact your nearest S&C Sales Office or S&C Authorized Distributor. Their tele- phone numbers are listed on S&C’s website sandc.com Or call S&C Headquarters at (773) 338-1000; in Canada, call S&C Electric Canada Ltd. at (416) 249-9171.

NOTICE

Read this instruction sheet thoroughly and carefully before installing or operating your S&C PureWave UPS System .

Replacement Instructions and Labels

If you need additional copies of this instruction sheet, contact your nearest S&C Sales Office, S&C Authorized Distributor, S&C Headquarters, or S&C Electric Canada Ltd.

It is important that any missing, damaged, or faded labels on the equipment be replaced immediately. Replacement labels are available by contacting your nearest S&C Sales Office, S&C Authorized Distributor, S&C Headquarters, or S&C Electric Canada Ltd.

Safety Information


Safety Information

Hazard Notification There are a number of potential hazards associated with the PureWave UPS System:

• High-voltage ac and dc electricity—Potentially lethal voltages are present inside the equipment. High-voltage dc electricity is present even if utility power is not connected. Hazardous voltages may also be present in all interconnecting components and lines.

To maintain safety, padlocks should be used on all doors of the equipment. The doors, fitted with high-quality padlocks, will provide protection to inadvertent contact with high-voltage circuits.

• Corrosive liquid and sulfuric acid vapors from cracked or leaky batteries—Lead-acid batteries contain electrolyte, consisting of a solution of 36% sulfuric acid and 64% water by weight. Sulfuric acid (H2SO4 aqueous) is a colorless, odorless liquid which can form a mist during battery charging or emergency releases caused by explosion or fire. Exposure to sulfuric acid mist or vapor severely irritates eyes, respiratory tract, and skin. Repeated exposure to high concentrations through inhalation of mist may also cause erosion of teeth. Splashes in eyes or on skin will cause severe burns. Sulfuric acid will concentrate if not removed from contaminated clothing or skin; the concentrated acid has a severe dehydrating action and destroys tissue.

Contact of sulfuric acid with some metals may form corrosive sulfur dioxide fumes and flammable hydrogen gas. Toxic gases such as sulfur dioxide, carbon monoxide, and sulfuric acid fume may be released during decomposition. Water applied directly to sulfuric acid causes heat and splattering.

The combined volume of sulfuric acid contained in the 48 batteries of each battery module is approximately 78 gallons (293 liters). Each of the five vertically stacked trays within the battery module provides acid containment. The trays are designed to contain electrolyte that may be released by the rupture of batteries. Reference the bat-tery material safety data sheet shipped with the system for more battery information.

• Fire and explosion hazard from hydrogen gas generated during the battery charging cycle—During charging, hydrogen (H2)—a colorless, odorless, and tasteless gas which is non-toxic under normal conditions—may be released. Hydrogen can cause asphyxiation in confined spaces by displacing oxygen. It is also a severe fire and explosion hazard when exposed to heat, flame, or oxidizers. The explosive range for hydrogen is very wide, with the lower explosive limit (L.E.L.) at 4.1 percent by volume and the upper explosive limit (U.E.L.) at 74.2 percent.

Hydrogen Gas Ventilation—Hydrogen gas generated during charging cycles is collected from each individual battery through a length of chemical-resistant tubing. The hydrogen gas is removed from the system through natural ventilation and is vented directly to the outside of each battery bay.

DANGEROpen flame and temperatures above 300°F can ignite hydrogen vented from the Pure-Wave UPS System enclosure . Sources of such flame and heat should be kept at a minimum of five feet from the enclosure .

• Decomposition of materials during fire—in the event of a fire, structural components of the equipment can degrade. Degradation of the enclosure structure, the module, acoustical foam panel lining, and battery cases will generate carbon monoxide gas, acid vapors, mist, and, possibly, hydrogen cyanide gas and vapors.

• System alarm sensors will detect the smoke and/or change in temperature of the container’s internal environment. The system will operate in bypass mode, isolating power circuitry other than the bypass breaker.


Safety Information

Operator Training Requirements

All personnel exposed to the potential hazards associated with the PureWave UPS System must be properly trained to minimize the risk of injury and equipment damage. Personnel should be assessed for retraining on a regular basis, and will receive retraining when pro-cedures or systems change, routine inspections or observations indicate personnel are not following safe work practices, and/or personnel have not performed a task involving the equipment within a year.

As a minimum, all personnel exposed to the potential hazards associated with the PureWave UPS System should be trained in the following:

• Right-to-know

• Lockout/tagout

• System operation

• Fire extinguisher training

• Personal protective equipment (PPE)

• High-energy awareness training

Personnel working on or in the vicinity of the PureWave UPS System should know, follow, and be trained according to the safe working practices outlined in the following regulations and standards, at a minimum:

• Electric Power Generation Transmission and Distribution (29 CFR 1910.269)

• Electrical-Safety-Related Work Practices (29 CFR 1910.331 through 1910.335)

• Standard for Electrical Safety Requirements for Employee Workplaces (NFPA 70E)

• Recommended Practice for Maintenance, Testing, and Replacement of Vented Lead-Acid Batteries for Stationary Applications (ANSI/IEEE 450-1995).

The following personal safety precautions should be emphasized in the operator train-ing program, at a minimum.

• The requirement that only qualified individuals may work on or near exposed electrical contacts, or components with differences in potential in excess of 50 volts.

• The need to wear 100% natural fiber clothing or flame-resistant apparel.

• The need to not wear conductive articles (e.g., rings, watches, etc.).

• Use of properly insulated hand tools.

• The need to keep sources of heat, sparks, or flame away from the hydrogen ventilation system, located behind the top-left corner of each battery bay door.

• The need to ensure unobstructed egress from the work area.

• The material safety data sheet for sulfuric acid (Ref. 29 CFR 1910.1200).

• Training in the proper use of emergency fire extinguishers (Ref. 29 CFR 1910.157).

• Training in the selection and use of personal protective equipment, as may be required for operation and maintenance or emergency response (Ref. 29 CFR 1910 Subpart I).

• Training in hazardous waste management.

• Use of proper personal protective equipment. Personnel should know how and when to use personal protective equipment appropriate for the situation, e.g., insulated rubber gloves, safety glasses with side shields, face shields, hard hats, etc.

• Right-to-know training, including training on lead-acid batteries.

• Use of the buddy system, i.e., not to work alone in potentially hazardous situations


Safety Information

Battery Safety Battery handling and servicing should be performed or supervised by authorized person-nel who are knowledgeable of batteries and the required precautions.

CAUTION1 . DO NOT dispose of batteries in a fire as an explosion may occur .

2 . Lead-acid batteries can present a risk of fire because they generate hydrogen gas . The following procedures should be followed:

a . DO NOT SMOKE near batteries .

b . DO NOT allow sources of flame or sparks in the battery area . Discharge static electricity from your body before touching batteries by first touching a grounded metal surface .

3 . DO NOT open or mutilate the batteries . Released electrolyte is harmful to skin and eyes .

4 . When replacing batteries, replace with the same type and number of batteries or battery packs . Torque the terminals to the value specified .

5 . A battery can present the risk of electrical shock and high short-circuit current . The following precautions should be observed when working on batteries:

a . Remove watches, rings, and other metal objects .

b . Use tools with insulated handles .

c . Wear rubber gloves and boots .

d . Do not lay tools or metal parts on top of batteries .

e . Disconnect the charging source prior to connecting or disconnecting battery terminals .

f . Determine if the battery has been inadvertently grounded . If it is grounded, remove the source of the ground . Contact with any part of a grounded battery can result in electrical shock . The likelihood of such shock will be reduced if such grounds are removed during installation and maintenance .

6 . Instructions for internally mounted batteries:

a . Instructions shall carry sufficient information to enable the replacement of the battery with a suitable recommended type;

b . Safety instructions to allow access by a service person shall be stated in the installation/service handbook;

c . If batteries are to be installed by a service person, instructions for interconnections including terminal torques shall be provided .

7 . Electrolyte is a dilute sulfuric acid that is harmful to skin and eyes . It is electrically conductive and corrosive . The following procedures should be observed:

a . Wear full eye protection and protective clothing .

b . If electrolyte contacts skin, wash it off immediately with water .

c . If electrolyte contacts eyes, flush thoroughly and immediately with water . Seek medical attention .

d . Spilled electrolyte should be washed down with a suitable acid neutralizing agent . Use a solution of approximately one pound (500 grams) bicarbonate of soda to approximately one gallon (4 liters) of water . Add bicarbonate of soda solution until the evidence of reaction (foaming) has ceased . The resulting liquid should be flushed with water and the area dried .


Safety Information

Personal Protective Equipment (PPE)

All personal protective equipment (PPE) must conform to the regulations established by 29 CFR 1910 Subpart I. The following PPE is the minimum that must be made available to personnel performing maintenance on the PureWave UPS System:

• Safety glasses with side shields and splash protection.

• Head protection appropriate for environments with electrical hazards.

• Insulated rubber gloves. The class of insulation is dependent on the specific application, given the voltages present. (Class 0 gloves are adequate to voltages up to 1000 Vac.)

• Insulated rubber sleeves. The class of insulation is dependent on the specific application, given the voltages present.

The PPE must be maintained according to manufacturer’s instructions and properly used.

It is the responsibility of the immediate purchaser or end user to identify any further needs for personal protective equipment based on the specific needs of the site.

Insulated Hand Tools Insulated hand tools are required when working on or around energized equipment. Only use tools that are properly rated for the energy present. Tool inventories should be kept to ensure that all tools that enter the system enclosure are removed prior to energizing the system.

Emergency Eye Wash Stations

The PureWave UPS System contains lead-acid, maintenance-free batteries. Check with the local municipality planning and development agency for emergency eye wash and emergency shower requirements. Inspect and maintain this equipment according to the manufacturer’s recommendations and local, state, and federal regulations.

Recommended Emergency Response Equipment and Procedures

The following equipment should be maintained at the site, ready to use in response to an emergency situation:

• Emergency eye wash and quick-drench shower located nearby the PureWave UPS System, maintained in accordance with the manufacturer’s recommendations and state, local, and federal regulations.

• Three portable fire extinguishers approved for use in electrical fires and fires involving sulfuric acid or lead acid batteries.

• Appropriate chemical protective equipment and approved full-face air-purifying respirators with combination acid gas, organic vapor, and HEPA cartridges (magenta/yellow), for clean-up of low-risk sulfuric acid spills;

• Sulfuric acid spill control and clean-up materials—absorbent pillows, lime, crushed limestone, sodium bicarbonate, or soda ash.

• High-voltage-rated emergency rescue poles.

The immediate purchaser or end user should develop policies and procedures for han-dling emergency situations. It is the responsibility of the immediate purchaser or end user to develop a site-specific emergency action plan for response to such situations.


Release of Hazardous Materials

CAUTIONUnqualified personnel must not attempt clean-up of any hazardous material released . Serious personal injury can occur.

Prior to responding to the release of any hazardous material, qualified personnel should:

• Be trained in the cleanup of that material,

• Be trained in the use and limitations of the proper personal protective equipment for the cleanup of that material,

• Have completed right-to-know training .

Refer to the battery material safety data sheet shipped with the system for more informa-tion on cleanup and disposal of hazardous materials .

Fire Protection and Extinguishers

The PureWave UPS System senses fire or the potential for fire in three different ways . Smoke detectors monitor the system for smoke and will disable the system if smoke is detected. Two thermocouples inside the system enclosure sense internal temperature and will disable the system if the temperature exceeds 64°C.

Fire extinguishers should be kept oh hand and maintained for initial response to electri-cal fires and fires involving sulfuric acid or batteries. Refer to the battery material safety data sheet shipped with the system for further information. Proper training, placement, and maintenance of the fire extinguishers are essential for ensuring their functionality and proper use.

Disconnect Means The PureWave UPS System may be placed in bypass by closing the bypass circuit breaker. See Figure 2. An external disconnect means, if required, must be provided by others.

Safety Information


System Bay Overview The PureWave UPS System consists of three to four battery bays, a switchgear bay, and a control bay. See Figure 1.

Battery Bay

Battery Bay

Battery Bay

Battery Bay

(Catalog Number

91100 only)

Control Bay

Switchgear bay

Figure 1. PureWave® UPS System.

The switchgear bay houses the user input/output connections and circuit breakers. The user connections are located behind the left door. Guard doors, located behind the left door, prevent accidental contact with the power terminals. The input isolation breaker, bypass breaker, and output isolation breaker are located behind the right door. See Figure 2.

Guard doors

AC terminals

Neutral bus(located behind phase conductors) Ground bus

I/O connections

Input breaker

Enabled/disabled selector switch and reset push button(not visible in photo)

Bypass breaker

Output breaker

Output AC terminalsFigure 2. Interior of switchgear bay.

The control bay houses the system controls, power electronic switch (PES), monitor-ing computer, Ethernet connection, and phone line connection. The liquid crystal display (LCD) is located on the outside of the control bay. See Figure 3.

Liquid-crystal display

Figure 3. Interior of control bay.

Equipment Overview


Equipment Overview

Each battery bay houses a battery module, power conversion module (PCM), and HVAC control panel. The battery module is located behind the left door. The power conversion module and HVAC control panel are located behind the right door. See Figure 4 .

HVAC control panel

Power conversion module

Battery module

Figure 4. Interior of battery bay.

Opening the Door of a Bay

DANGERNever enter any of the bays. Potentially lethal voltages are present inside. High-voltage dc is present even if utility power in not connected .

Never enter any of the PureWave UPS System bays. The system can be operated using the system controls.

To open a door, remove the padlock from the security cover located over the center bolt. Loosen the three bolts (top, center, and bottom) which secure the door, so they detach from the enclosure (the bolts will not completely detach from the door). Swing the door open approximately 90 degrees or 135 degrees, then engage the lock-bar at the bottom of the door to prevent accidental closure. See Figure 5.

Figure 5. Engaging door-lock bar.


Installation

NOTICEThe equipment must be installed in a restricted-access location to prevent unauthorized/improper handling .

Storage If necessary, the PureWave UPS System can be temporarily stored outdoors prior to installation and commissioning. The system should be left in the packaging material in which it was shipped.

The maximum ambient temperature for storing the system is 113°F (45°C). If the sys-tem is to be stored longer than two months, the batteries will need to be charged prior to commissioning. Contact your nearest S&C Sales Office for battery charging information.

Concrete Pad Specifications

The concrete pad on which the system will be placed should be sized to accommodate the unit and its external mounting brackets. The pad should be poured with a maximum pitch of ½ degree and have a flatness within a ⅛ inch .

The pad should extend beyond the edge of the enclosure by an adequate amount, to prevent the pad from cracking or breaking when the bolts are installed to anchor the system to the pad. Please refer to S&C Drawing #902064 for the 1000-kW UPS and S&C Drawing #902063 for the 750-kW UPS for more information.

The system is designed to meet Seismic Zone 4 requirements when installed appropri-ately. If a higher seismic rating is required for the installation, the pad must be designed accordingly. The concrete pad must have a minimum compressive strength of 2000 pounds per square inch for a Seismic Zone 4 rating.


Apron for Forklift Access (without Battery Module Roller Option)

A level apron of concrete or asphalt should extend at least 12 feet in front of the Pure-Wave UPS System to facilitate installation and removal of the battery modules using a forklift. The apron should be flush with the concrete pad (base of the unit). See Figure 6.

Compacted road gravel can also be utilized for the apron. If compacted road gravel is utilized, the apron must extend at least 16 feet in front of the PureWave UPS System.

The area in front of the system must remain clear of permanent obstacles such as walls, parking posts, etc.

Minimumaprondepth

Apron for forklift access12 ft.

Notes:1) Apron must be of adequate size to provide forklift access to power module as shown .2) Apron must be concrete, asphalt, or compacted road gravel .

Figure 6. Clearance requirements for battery installation and removal (without Battery Module Roller Option).

Installation


Apron for Forklift Access (with Battery Module Roller Option)

A level apron of concrete, asphalt, or compacted road gravel should extend at least 6 feet in front and to the right of the system, to facilitate installation and removal of the battery modules using a forklift. The apron should be flush with the concrete pad (base of unit).

6 ft.

Notes:1) Apron must be of adequate size to provide forklift access to power module as shown .2) Apron must be concrete, asphalt, or compacted road gravel .3) Apron should be flush with UPS base .

Figure 7. Clearance requirements for battery installation and removal (with Battery Module Roller Option).

Packing The PureWave UPS System is shipped fastened to wooden skids, thus sealing the bottom of the system to prevent entry of water, debris, and rodents during shipment and storage. The system should be left on the skids until just prior to installation. A lifting bar must be provided for installation.

The battery modules are shipped separately and are wrapped with protective material. The battery modules should remain wrapped until ready for installation. The battery mod-ules may be stored for up to two months in a restricted area with an ambient temperature between -30°F and +113°F (-35°C to +45°C) protected from rain or snow.

• Left shipping split: two battery bays.

• Center shipping split: switchgear bay and control bay.

• Right shipping split: two battery bays for Catalog Number 911000, one battery bay for Catalog Number 910750.

Inspection Examine the shipment for external evidence of damage as soon after receipt as possible, preferably before removal from the carrier’s conveyance. Check the bill of lading to make sure that all shipping skids, crates, and containers listed thereon are present.

If there is visible loss and/or damage:

1. Notify the delivering carrier immediately.

2. Ask for a carrier inspection.

3. Note condition of the shipment on all copies of the delivery receipt.

4. File a claim with the carrier.

If concealed damaged is discovered:

1. Notify the delivering carrier within 15 days of receipt of shipment.

2. Ask for a carrier inspection.

3. File a claim with the carrier.

Also notify S&C Electric Company in all instances of loss and/or damage.

Installation


Installation

Shimming the Pad Shims may need to be placed on the pad to ensure that the PureWave UPS System sections are level with each other and provide proper door alignment. Place shims on the pad per the following procedure:

1. Use a laser-level beam to find the high spot of the pad at the flatness-location lines shown in S&C Drawing #902194.

2. Add shims at the mounting hole locations as necessary to bring all shim locations to the same height as the high spot. A tolerance of ± 0 .125” (3 mm) between all shim locations is recommended.

Set the Center Shipping Split (Switchgear and Control Bays)

WARNINGObserve standard lifting practices as well as the general instructions below . Failure to follow these precautions can result in serious personal injury or equipment damage.

Equipment weight: Center shipping split (switchgear and control bays): 9,200 lbs. (4,173 kg.).

1. Make sure that the lifting eye-bolts are parallel to the lifting direction of the slings and that the lifting hooks are completely engaged in the eye bolts before lifting the enclosure. See Figure 8.

Figure 8. Hoisting diagram for center shipping split.

2. Use 11-foot or longer hoist slings of equal length at each of the four lifting locations to prevent overstressing the enclosure during lifting.

3. Arrange the hoist slings to distribute the lifting forces equally between the eye bolts.


Installation

WARNINGMake sure that the doors are closed while lifting . The doors contribute to the structural integrity of the system . The enclosure may be damaged if the system is lifted while the doors are open .

4. Avoid sudden starts and stops.

5. Apply a resilient closed-cell foam gasket (included with the shipment) to the bottom flange of the enclosure. The gasket should be recessed sufficiently to allow for grout and caulk after the unit is set on the pad. The gasket prevents the bottom of the enclosure from being scratched and isolates the enclosure from the alkalinity of the concrete pad.

6. Set the switchgear/control bay over the stub-up areas on the pad.

7. Clean the sides of the switchgear bay and control bay with isopropyl alcohol, then apply gasket material (included with the shipment) to each surface. The edge of the gasket material should be flush with the outside edge of the enclosure. The gasket provides a watertight seal between the bays. See Figure 9.

Gasket material

Figure 9. Gasket material applied to side of enclosure.

Set the Left Shipping Split (Two Battery Bays)

Equipment weight: Left shipping split (two battery bays) without batteries installed: 6,000 lbs. (2722 kg).

WARNINGObserve standard lifting practices as well as the general instructions below . Failure to follow these precautions can result in serious personal injury or equipment damage.


Installation

Using the same precautions described above, set the left battery-bay shipping split on the pad, to the left of the switchgear/control bay. See Figure 10. The T-shaped holes punched in the right side of the left battery-bay shipping split correspond with holes in the left side of the switchgear/control bay split. The enclosures must be set so that the holes in the roof and base of the split are directly aligned. Insert bolts in the roof and/or base holes, to facilitate alignment. Adequate pressure should be applied to the shipping splits to compress the gasket material, providing a watertight seal.

Install shipping split covers as shown on S&C Drawing #902064 for the 1000-kW UPS and S&C Drawing #902063 for the 750-kW UPS.

Caulk the seams between the bays as an additional precaution to prevent water ingress into the enclosure.

Figure 10. Hoisting diagram for left and right shipping splits.

Attach the battery bays to the switchgear/control bay.

Attach the inter-module fastening clips to the side walls. There are six clip locations between the switchgear bay and left battery bay split. Insert the inter-module fastening clips into the holes and tighten securely. See Figures 11 and 12.

Figure 11. Hole for inter-module

fastening clip.Figure 12. Inter-module fastening clip.


Installation

Attach the fastening bolts, washers, and nuts for the bay roofs and the bases. There are two holes on the sides of the roof and the bases. See Figures 13 and 14.

Figure 13. Inter-module fastening bolt locations in bay roof.

Figure 14. Inter-module fastening bolt locations in bay base.

Set the Right Shipping Split (Battery Bay/s)

Equipment weight of 1000-kW PureWave UPS System right shipping split (two battery bays) without batteries installed: 6,000 lbs. (2,722 kg).

Equipment weight of 750-kW PureWave UPS System right shipping split (one battery bay) without batteries installed: 3,000 lbs. (1,361 kg)

Using the same precautions described above for the center and left shipping splits, set the right battery-bay shipping split on the pad, to the right of the switchgear/control bay. See Figure 10. The T-shaped holes punched in the left side of the right battery-bay shipping split correspond with holes in the right side of the switchgear/control bay split. The enclosures must be set so that the holes in the roof and base of the split are directly aligned. Insert bolts in the roof and/or base holes, to facilitate alignment. Adequate pressure should be applied to the shipping splits to compress the gasket material, providing a watertight seal.

Repeat the assembly steps described above for attaching the left shipping split, to attach the right shipping split.

Install shipping split covers as shown on S&C Drawing #902064 for the 1000-kW UPS and S&C Drawing #902063 for the 750-kW UPS.

Caulk the seams between the bays as an additional precaution to prevent water ingress into the enclosure.


Installation

Secure, Seal, and Ground the Enclosure

A mounting bracket is provided at each corner of the enclosure. Drill an appropriate hole in the concrete pad at each mounting bracket location. Bolt the enclosure to the pad using four 5/8-diameter anchors. See Figure 15.

Figure 15. Mounting bracket.

Gaps between the base and the pad should be filled with grout to prevent entry of insects and debris into the system enclosure. The grout should be recessed sufficiently to permit the application of a bead of caulk between the enclosure and the pad.

Apply a bead of butyl caulk around the outer edge of the bottom flange (where it meets the pad), to provide a seal which prevents the entry of insects and debris into the system enclosure as well as secondary containment of electrolyte.

Remove the wire ties which secure the grounding conductors. Ground the enclosure by feeding the loose end of each grounding conductor through the hole located in the side of the base near the front of the enclosure, and into the adjacent shipping split. Attach a copper lug to the loose end of the grounding conductor. Then attach the lug to the welded stud.

Door Alignment The doors of the system might have misaligned during shipment. If the doors are not aligned properly, the door bolts may cross-thread while securing the doors closed. To align a door:

1. Loosen the three door bolts and open the door.

2. Verify that the centerline of the middle door bolt is aligned with the centerline of its threaded fastener.

3. If the door bolt is not aligned with the threaded fastener, slightly loosen the six nuts which attach the door hinge hardware to the door stile (inside the enclosure behind the hinges). Loosen the bolts just enough to permit a floor jack or lever to be applied.

4. Use the floor jack or lever to align the centerline of the center door bolt with the centerline of its threaded fastener.

5. Confirm that the top and botton door bolts are aligned with their corresponding fasteners. If necessary, adjust the door with the floor jack or lever.

6. Re-tighten the six nuts that attach the door hinge hardware, to a torque of 24 to 28 ft.-lbs.

7. Confirm that all three door bolts are aligned with their corresponding threaded fasteners.


Installation

PCM Guide Rail A guide rail is located in each battery bay, above the power conversion module. See Figure 16. The module slides in this rail for servicing. Two retaining bolts, located at the front of the rail slot, were tightened at the factory to prevent the module from sliding during shipment. See Figure 17.

NOTICEDo not install the battery module until the two bolts, located at the front end of the PCM rail slot, have been loosened . The rear bolt cannot be accessed after the battery module has been installed .

PCM guide rail

Figure 16. PCM guide rail location in the battery bay.

Figure 17. Retaining bolts at front end of rail slot.


Installation

Connect the Bus Using the bus sections included with the shipment, connect the bus of the switchgear bay to the bus of the left battery bay. See Figures 18, 19, and 20. There are two bolt holes on either end of each bus section; both bolt-holes should be used to connect the bus. The bus should be connected from back to front as follows:

C-Phase

B-Phase

A-Phase

Ground

Cap Neutral

Figure 18. Bus in left battery bay split.

Connect the bus of the control bay to the bus of the right battery bay in the same manner.

Figure 19. Bus in switchgear bay.


Installation

Figure 20. Bus in switchgear bay, after connection.

Battery Bay Interconnects

A wire bundle is located in the switchgear bay (in the top-left corner). Another wire bundle is located in the control bay (behind the control panel). See Figure 21.

Figure 21. Wire bundle in switchgear bay.

Carefully feed the wire bundles through the square feed-through holes. See Figure 22. Each wire bundle includes two sets of wires. The short set goes to the near battery bay and the long set goes to the far battery bay. The wire bundles must be handled carefully to prevent damage to the fiber-optic cables. Fiber-optic cables must not be pinched, bent, or rolled tightly. Dress the cables with wire ties in/near the channel at the top front of the bays, behind the top edge of the door.

Figure 22. Wire bundle feed-through hole.


Installation

The cable ends are marked for connections to TB1 and TB2. Make the appropriate con-nections in each of the battery bays. TB1 is located behind the HVAC control panel in each battery bay. TB2 is located inside the HVAC control panel of each battery bay.

Two white transformer neutral conductors are included in each wire bundle. In each of the battery bays, connect the white transformer neutral wires to the first bus located behind the horizontal beam at the top of each battery bay. A label identifies the connector on each I-beam. See Figures 23 and 24.

Transformer neutral connector (located directly behind beam)

Figure 23. Location of transformer neutral connection.

Transformer neutral connector

Figure 24. Transformer neutral connector (viewed by looking straight up).


Installation

For each PCM, connect the fiber-optic cables to the PCM as labeled. Connect the 9-pin connector to the PCM. See Figure 25.

Figure 25. PCM connections.

In each battery bay, feed the thermocouple wire along the front edge of the battery bay enclosure, utilizing the wire-tie holders and wire ties.


Installation

User Input and Output Connections

Remove the current transformer hold-in bolts, which prevent the current transformers from moving during shipment, from the output ac terminals in the switchgear bay. See Figure 26.

Current transformer hold-in bolt locations

Figure 26. Current transformer hold-In bolt locations in switchgear bays.

Prepare the user connections in the switchgear bay. See Figure 27.

Control connections

Output ac terminals

Input ac terminals

Neutral bus

Figure 27. User connections in switchgear bay.


Installation

Using a compression lug, attach the ground bus of the PureWave UPS System to the system ground in accordance with the user’s standard grounding practice and any appli-cable code requirements.

Refer to Table 1 for recommended power conductor sizes and terminals for a 750-kW system. Immediate purchaser or end user has final responsibility for sizing of conductors.

Table 1. Recommended power conductor sizes and terminals for a 750-kW system.

Temperature Rating, °C①

Solid Copper Conductors Aluminum or Copper-Clad Conductors

Wire Size and Type

Crimp Tool Lug and Die②

Wire Size and Type


75

Three 600 kc-mil

75°C, THHW,

THWN, or XHHW

Lug: T&B 54921BE

Die: 15611

Code 94

Three 900 kc-mil

75°C, THHW,

THWN, or XHHW

Lug: 58926BE

Die: 15504

Code 1154

90

Three 500 kc-mil

90°C, THHW,

THWN, or XHHW

Lug: T&B 54918BE

Die: 15506

Code 87

Three 750 kc-mil

90°C, THHW,

THWN, or XHHW

Lug: 54922BE

Die: 15515CK

Code 106

① With no derating for voltage drop or more than three current-carrying conductors in the raceway .

② Torque ½-inch Grade 5 hardware to 60 lb .-ft .

Refer to Table 2 for ratings of a 750-kW system.

Table 2. Power and current ratings of 750-kW system.

Voltage kVA kW Current (Amperes)

208 406 406 1128

240 469 469 1128

380 750 750 1128

400 782 750 1128

415 811 750 1128

440 860 750 1128

480 938 750 1128

575 938 750 942

600 938 750 903

690 938 750 785


Installation

Refer to Table 3 for recommended power conductor sizes and terminals for a 1000-kW system. Immediate purchaser or end user has final responsibility for sizing of conductors.

Table 3. Recommended power conductor sizes and terminals of 1000-kW system, assuming 90° C “wet” rating of cable.

Temperature Rating, °C①

Solid Copper Conductors Aluminum or Copper-Clad Conductors

Wire Size and Type


Wire Size and Type


75

Four 600 kc-mil

75°C, THHW,

THWN, or XHHW

Lug: T&B 54921BE

Die: 15611

Code 94

Four 900 kc-mil

75°C, THHW,

THWN, or XHHW

Lug: 58926BE

Die: 15504

Code 1154

90

Four 500 kc-mil

90°C, THHW,

THWN, or XHHW

Lug: T&B 54918BE

Die: 15506

Code 87

Four 750 kc-mil

90°C, THHW,

THWN, or XHHW

Lug: 54922BE

Die: 15515CK

Code 106

① With no derating for voltage drop or for more than three current-carrying conductors in the raceway .

② Torque ½ inch Grade 5 hardware to 60 lb .-ft .

Refer to Table 4 for ratings of a 1000-kW UPS.

Table 4. Power and current ratings for 1000-kW system.

Voltage kVA kW Current (Amperes)

208 542 542 1504

240 625 625 1504

380 1000 1000 1504

400 1042 1000 1504

415 1081 1000 1504

440 1146 1000 1504

480 1250 1000 1504

575 1250 1000 1255

600 1250 1000 1203

690 1250 1000 1046


Installation

Refer to Table 5 for recommended control conductor sizes and terminals for 750-kW and 1000-kW systems.

Refer to Table 6 for TB1 and TB2 contact specifications.

Terminate the neutral conductors to the neutral bus.

Terminate the input phase conductors to the utility-source input (upper) terminals.

Terminate the output phase conductors to the load output (lower) terminals.

Terminate the applicable control wires including the phone line and/or Ethernet con-nections. The Ethernet connection requires a Category 5 cable with RJ45 connector. The phone line requires a standard dial-up phone line. The protection panels, located behind the control panel in the control bay, must be removed to access the control conductor conduits.

Table 5. Recommended control conductor sizes and terminals.

Input/Output Contact Wire Size, AWG Connector Type①

All Except Transfer Signal 14T&B RB864

Sta-kon

Transfer Signal 10T&B RC864

Sta-kon

① Thomas & Betts Hydraulic Crimp Tool WT145C, ERG-2001, WT145A or WT145S . Torque #8 hardware to 20 lb-in .

Table 6. Solid-state contact specifications for TB1 and TB2.

Parameter Value

Operating Voltage RangeTB1: 24-280 Vac

TB2: 12-140 Vac

Current Rating 3 amperes

UL Motor Load Rating 1 .5 amperes

One-Cycle Surge 80 amperes peak

Peak Repetitive Voltage 500 volts

Isolation Input-to-Output 4,000 volts RMS

Minimum Load Current 20 milliamperes

Operating Frequency 25-65 Hz

Turn-On Time 1/2-cycle maximum-zero voltage

Turn-Off Time 1/2-cycle maximum-zero current

DV/DT—Off State 200 volts/microsecond

DV/DT—Communicating Snubbed for rated 0 .5 power factor load

Output Voltage Drop, Maximum Peak 1 .6 volts

Off-State Leakage @ Nominal Voltage, 60 HzTB1—2 .5 milliamperes

TB2—5 milliamperes


Installation

Phone connection

Ethernet connection

Figure 28. Location of phone and ethernet connections in control bay.

Figure 29. Control panel open (with protection panels removed).


Installation

Figure 30. User signal connections in switchgear bay.

Seal all conduit entrances on the outside of the enclosure with RTV and on the inside of the enclosure with expansive foam to prevent water entry.

Electrical-Connection Inspection

Perform a “point-to-point” check of all field-installed cables and wiring to verify that the system is wired, labeled, and terminated correctly. Note any problems found and the corrective actions applied.

Check all field-installed fiber-optic cables and connections to the power conversion modules. Verify that the fibers of each cable are flush with the cable connector, that the cable is fully engaged in mating connector, and is labeled and terminated. Note any problems found and corrective actions applied.

Check all factory and field-bolted electrical connections inside the PureWave UPS System and verify that they are torqued to the proper tightness. Torque to following requirements:

Table 7. Hardware torque specifications.

Bolt Size Grade 5 Hardware Torque, Ft.-Lbs.

Stainless-Steel Hardware

½–13 Coarse Thread 55 45

⅜–16 Coarse Thread 25 20


Installation

Battery Modules (with Rollers)

Each battery bay contains internal rollers to simplify installation of the battery modules. See Figure 31.

Figure 31. Internal battery rollers.

To install a battery module:

1. Assemble and install the battery module roller support frame. See Figure 32.

Figure 32. Battery module roller support frame.


Installation

2. Carefully set the battery module on the battery support frame.

3. Install the front battery module hold-down bolt and nuts.

4. Attach the grounding strap which is located on the front-left corner of the battery module, to the stud located at the bottom-left inside corner of the enclosure.

S&C personnel will make all connections between the battery module and the power conversion module during commissioning.

Battery Modules (without Rollers)

Unpack the battery modules. perform the following for each battery module.

1. Remove the front battery-module hold-down rods and nuts from the battery bay. See Figure 33.

2. Carefully set the battery module in the battery bay with a forklift. The v-grooves in the back of the battery module base should mate with the rear hold-down rods and bolts.

Battery module hold-down locations

Figure 33. Battery module hold-down locations.


Installation

3. Install the front battery-module hold-down rods and nuts. See Figure 34.

4. Attach the grounding strap which is located on the front-left corner of the battery module, to the stud located at the bottom-left inside corner of the enclosure. See Figure 35.

S&C personnel will inspect the battery modules and make all connections between the battery module and the PCM during commissioning.

Figure 34. Installed battery module hold down and nut.

Battery module grounding strap

Figure 35. Power module grounding strap.


Installation

Completing the Installation

1. Prior to shipment from the factory, a piece of protective tape was applied to the bottom edge of each door to protect the door gasket. Remove the protective tape.

2. Close and lock all doors of the PureWave UPS System.

3. Wipe down the exterior of the enclosure with a clean, damp cloth. Re-finish any scratches or abrasions with S&C touch-up finish and red-oxide primer, which are available in aerosol spray cans. No other finish or primer is approved. The area to be touched up should be cleaned to remove all oil and grease. Sand the area, removing any traces of rust that may be present, and make sure that all edges are feathered before applying the primer.

Pre-Startup Checklist A pre-startup checklist will be provided to the immediate purchaser or end user. The checklist must be reviewed by the installing contractor. The document must be signed and faxed to S&C’s Power Systems Services Division at (414) 423-8766 prior to S&C’s Field Service personnel being dispatched to the job site for commission-ing. If a pre-startup checklist is required, contact S&C’s Power Systems Services at (414) 423-8776.

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