s&c purewave ups system instructions for installation

S&C ELECTRIC COMPANYSpecialists in Electric Power Switching and Protection

Instructions for Installation

S&C PureWave UPS™ System250 kW and 500 kW, 208 Volt—600 Volt

Instruction Sheet 653-501 July 18, 2005

Supersedes Instruction Sheet 653-501 dated 12-1-03 ©2005

Section Page Section Page

INTRODUCTIONQualified Persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Read this Instruction Sheet . . . . . . . . . . . . . . . . . . . . . .3Proper Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Document Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

SAFETY INFORMATIONUnderstanding Safety-Alert Messages . . . . . . . . . . . . .4Following Safety Instructions . . . . . . . . . . . . . . . . . . . .4Replacement Instructions and Labels . . . . . . . . . . . . . .4Hazard Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . .5High Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Sulfuric Acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Acid Volume/Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . .6Hydrogen Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Decomposition of Materials During Fire . . . . . . . . . . .6Operator Training Requirements . . . . . . . . . . . . . . . . . .7

Training Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Safety Equipment, Precautions, and Practices . . . . . .9Personal Protective Equipment (PPE) . . . . . . . . . . . . .9Recommended Emergency Response Equipment . . .9Individual Safety Precautions . . . . . . . . . . . . . . . . . . .10Disconnect Means . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Entering the System Enclosure . . . . . . . . . . . . . . . . . .11Insulated Hand Tools . . . . . . . . . . . . . . . . . . . . . . . . . .13Emergency Wash Stations . . . . . . . . . . . . . . . . . . . . . .13Emergency Procedures and Equipment . . . . . . . . . . .14Fire Protection Systems . . . . . . . . . . . . . . . . . . . . . . . .14Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Releases of Hazardous Material . . . . . . . . . . . . . . . . .14Quarterly and Annual Inspections . . . . . . . . . . . . . . . .14Hydrogen Detection (Optional) . . . . . . . . . . . . . . . . . .14

TABLE OF CONTENTS

IMPORTANT SAFETY INSTRUCTIONSSAVE THESE INSTRUCTIONSThis publication contains important instructions for installation and maintenance of PureWave UPS System Catalog Numbers 910250 and 910500.

653-501 2

Section Page Section Page

INSPECTION AND HANDLINGPacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Lead-Acid Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . .15Handling 250-kW System with or Without Battery

Module Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Handling 500-kW System with Battery

Modules Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Handling 500-kW System Without Battery

Modules Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

INSTALLATIONStorage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Concrete Pad Specifications . . . . . . . . . . . . . . . . . . . .18Apron for Forklift Access (without battery

module roller option) . . . . . . . . . . . . . . . . . . . . . . . .18Apron for Forklift Access (with battery

module roller option) . . . . . . . . . . . . . . . . . . . . . . . .19Access to Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Air Conditioner Installation Instructions

for 60-Hz Systems . . . . . . . . . . . . . . . . . . . . . . . . . . .22Air Conditioner Installation Instructions

for 50-Hz Systems . . . . . . . . . . . . . . . . . . . . . . . . . . .23Door Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24Completing the Installation . . . . . . . . . . . . . . . . . . . . .24Pre-startup Checklist . . . . . . . . . . . . . . . . . . . . . . . . . .24

CABLE TERMINATIONSConduit Requirements . . . . . . . . . . . . . . . . . . . . . . . . . .25Input and Output Power and Control Connections . .25

ETHERNET AND TELEPHONE MODEM CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

TABLE OF CONTENTS

653-5013

INTRODUCTION

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

• The skills and techniques necessary to distinguish exposed live parts from nonlive 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 equip-ment, 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

Thoughly and carefully read this instruction sheet before installing or operating your S&C PureWave UPS System. Familiarize yourself with “SAFETY INFORMATION” on page 4.

Proper Application NOTICEThe equipment in this publication must be selected for a specific application. The application must be within the ratings furnished for the equipment. Ratings for this equipment are listed on a ratings label at the front of the system.

The PureWave UPS System is a battery storage system capable of delivering voltage to critical loads and serving the power quality needs of the utility and its customers.

The PureWave UPS System is an immediate response, high capacity, standby power system, which operates as both a voltage source and a current source. Catalog Number 910250 is capable of delivering up to 313 kVA (at 480 V) and Catalog Number 910500 is capable of delivering up to 625 kVA (at 480 V) of clean power 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’s power grid.

Document Purpose This instruction sheet provides all of the information necessary to install the PureWave UPS System, referred to as a PureWave UPS System in this document.

653-501 4

Understanding Safety-Alert Messages

There are several types of safety-alert messages which may appear throughout this instruction sheet as well as on labels attached to the PureWave UPS System. Familiarize yourself with these types of messages and the importance of the various signal words, as explained below.

Ç 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.

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

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

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 telephone numbers are listed on S&C’s website www.sandc.com. Or call S&C Headquarters at (773) 338-1000; in Canada, call S&C Electric Canada Ltd. at (416) 249-9171.

NOTICE

Thoroughly and carefully read this instruction sheet before installing 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

653-5015

SAFETY INFORMATION

Hazard Identification

The following is a list of potential hazards associated with the PureWave UPS System:

• High-voltage ac and dc electricity,

• Corrosive liquid (battery electrolyte; i.e., sulfuric acid) and sulfuric acid vapors from cracked or leaky batteries,

• Fire and explosion hazard from hydrogen gas generated during the battery charging cycle, and

• Hazardous fumes or vapors resulting from decomposition of system components or materials due to combustion (fire).

High Voltages Potentially lethal voltages are present inside the PureWave UPS System. High-voltage dc is present even without utility power connected. Hazardous voltages should also be expected in all interconnecting components and lines.

To maintain safety, the user should use padlocks on each of the battery module bay doors and the PCS compartment door (the front doors). The door and the use of the padlock provide protection to inadvertent contact with high-voltage circuits.

Sulfuric Acid Lead acid batteries contain electrolyte. Electrolyte consists of a solution of 36% sulfuric acid and 64% water by weight. Sulfuric acid (H2SO4aqueous) 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 vapors severely irritates the eyes, respiratory tract, and skin. Repeated exposure to high concentrations through inhalation of mist may also cause erosion of the teeth. Splashes in the eyes or on the 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, vapors, and fumes such as sulfur dioxide, carbon monoxide, and sulfuric acid fume may be released during decomposition. Water applied directly to sulfuric acid causes evolution of heat and splattering. Reference the battery material safety data sheet shipped with the system for further information.

Figure 1. Lead-acid battery.

653-501 6

SAFETY INFORMATION

Acid Volume/Capacity

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. Each tray is designed to contain the electrolyte of four batteries.

Figure 2. Battery module configuration.

Hydrogen Gas Precautions—Under charging conditions, hydrogen (H2), a colorless, odorless, and tasteless gas which is non-toxic under normal conditions may be released. It may however, cause asphyxiation in confined spaces by displacing oxygen and is 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.

Ç DANGEROpen flame or heat above 300°F can ignite any hydrogen being vented from the system enclosure. Keep such flame and heat a distance of at least five feet from the enclosure.

Decomposition of Materials During Fire

Under normal operating conditions the structural components of the system can be considered safe. In the case of fire, however, these structural components can degrade. Degradation of the enclosure structure, the module, acoustical foam panel lining, and battery cases during fire will generate carbon monoxide gas, acid vapors, and mist, and possibly hydrogen cyanide gas and vapors.

In the case of fire, the systems alarm sensors will detect the smoke or change in tempera-ture of the containers internal environment. Once the system has detected the likelihood of a fire the system will shut down. Additional information on smoke and fire detection can be found under “Smoke, Fire, and Hydrogen Detection” on page 19.

653-5017

SAFETY INFORMATION

Operator Training Requirements

All personnel exposed to the risks associated with the PureWave UPS System must be properly trained in order to minimize the risk of injury to personnel and equipment. Personnel should be assessed for retraining on a regular basis and will receive retraining when procedures or systems change, when routine inspections or observations indicate workers are not following safe work practices, and when operators have not performed a task within one year.

Training Programs Areas of Training—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

• PureWave UPS System operation

• Fire extinguisher training

• Personal protective equipment (PPE)

• High-energy awareness training.

Standards and Regulations—Personnel working on or in the vicinity of the system should know, follow, and be trained according to the safe working practices outlined in the following regulations and standards as 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).

Battery Safety Servicing of batteries should be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.

When replacing batteries, replace with the same number of Deka 7T31 batteries.

Ç CAUTIONDO NOT dispose of batteries in a fire. They may explode.

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

1. DO NOT SMOKE when near batteries.2. DO NOT cause flame or spark in battery area.

Discharge static electricity from body before touching batteries by first touching a grounded metal surface.

653-501 8

SAFETY INFORMATION

Ç�CAUTIONDo not open or mutilate the batteries. Released electrolyte is harmful to the skin and eyes. It may be toxic.

Ç�CAUTIONA battery can present a risk of electrical shock and high short-circuit current. The following precautions should be observed when working on batteries:

1. Remove watches, rings, or other metal objects.

2. Use tools with insulated handles.

3. Wear rubber gloves and boots.

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

5. Disconnect charging source prior to connecting or disconnecting battery terminals.

6. Determine if the battery is 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.

Ç�CAUTIONThe electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. It is electrically conductive and corrosive. The following procedures should be observed:

1. Wear full eye protection and protective clothing.

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

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

4. Spilled electrolyte should be washed down with a suitable acid neutralizing agent. A common practice is to use a solution of approximately one pound (500 grams) bicar-bonate of soda to approximately one gallon (4 liters) of water. The bicarbonate of soda solution should be added until the evidence of reaction (foaming) has ceased. The resulting liquid should be flushed with water and the area dried.

653-5019

SAFETY INFORMATION

Safety Equipment, Precautions, and Practices

The PureWave UPS System instruction sheet must be available to all operators and other employees. If doors to the electrical controllers or panels to the system enclosure must be opened, refer to the instruction sheet for procedures for guarding against electric shock. Lockout and tagout procedures should be developed and implemented (in accordance with 29 CFR 1910.147).

All enclosure doors should be padlocked when authorized personnel are not present to prevent injury to persons unaware of the risks associated with the system.

Personal Protective Equipment (PPE)

All personal protective equipment must conform to the regulations established by 29 CFR 1910 Subpart I. The following list of personal protective equipment is the minimum equipment that must be made available to personnel performing maintenance. The equipment must be maintained according to manufacturer’s instructions and properly used inside the PureWave UPS System area.

• Safety glasses with side shields and splash protection.

• Head protection appropriate for environments with electrical hazards.

• Insulated rubber gloves. Class of insulation is dependent on the specific application given the voltages present.

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

It is the responsibility of the user/owner to identify any further needs for personal pro-tective equipment based on the specific needs of the site.

Recommended Emergency Response Equipment

Keeping the following equipment maintained and ready for use at the site is recommended for response to emergency situations.

• Emergency eye wash and quick-drench shower located nearby the PureWave UPS System area (maintained according to manufacturer’s recommendations and state, local, and federal regulations pertaining to such equipment).

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

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

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

• High-voltage-rated emergency rescue poles.

653-501 10

SAFETY INFORMATION

Individual Safety Precautions

The following minimum list of personal safety precautions are to be emphasized in the training program.

• Only qualified employees may work on or near exposed electrical contacts or components with differences in potential in excess of 50 volts.

• Wear 100% natural fiber clothing or flame resistant apparel.

• Do not wear conductive articles (e.g. rings, watches, etc.).

• Use properly insulated hand tools.

• Keep heat, sparks, or flame away from the hydrogen ventilation system.

• Ensure unobstructed egress from the work area.

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

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

• Receive training in the selection and use of personal protective equipment which may be required for operations and maintenance or emergency response (Ref. 29 CFR 1910 Subpart I).

• Receive training in hazardous waste management.

• Use the proper personal protective equipment. Personnel should be trained when and how to use the personal protective equipment required for the situation (i.e. insulated rubber gloves, safety glasses with side shields, face shields, hard hats, etc.).

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

• Use the buddy system. Do not work alone in potentially hazardous situations.

Disconnect Means The UPS system may be placed in bypass via the bypass switchgear located behind the side door. An external disconnect means shall be provide by others.

653-50111

SAFETY INFORMATION

Entering the System Enclosure

The system enclosure shall never be entered while the system is active. Normal operation can be accomplished without entering the enclosure.

The side door provides access to the bypass switchgear, enabled/disabled switch, reset push button switch, and customer connections. The front right door provides access to the optional monitoring computer (no monitor included), control system, power electronic switch, and ac filter capacitor. In addition, an emergency disable switch (red mushroom switch), reset push button, and CPC connector are located behind the front right door.

The left door of the battery bay provides access to the battery module, the right door of the battery bay provides access to the power conversion module.

To open a door, remove the padlock from the security cover located over the center bolt. There are three bolts (top, center, and bottom) securing the door closed. Loosen the three bolts so they detach from the enclosure (the bolt will not completely detach from the door). The door will now open. Once the door is opened approximately 90 degrees or 135 degrees, engage the lock-bar at the bottom of the door to prevent the door from being accidentally closed. See Figure 6.

To close a door, disengage the lock-bar by lifting the lock-bar and returning it to its storage location. Swing the door closed. Tighten the three bolts to secure the door and install the padlock.

High-voltage dc is always present because of the nature of batteries and proper safe-guards should always be used. Proper insulating equipment should always be used to protect personnel from electric shock.

Ç WARNINGPotentially lethal voltages are present inside the system enclosure. High-voltage dc is present even without utility power connected.

Figure 3. Door latch.

653-501 12

Always use extreme caution when accessing the internal components of the system enclosure, high ac and dc voltages are present inside the enclosure. Voltages to 600 Vdc and 208 Vac should be expected under normal operating conditions.

Physical entry into the PureWave UPS System should never be attempted while in the enabled state or when the modules are on-line. Technicians may access the PureWave UPS System control panel and the monitoring computer through the front right door of the system. Again, voltages of up to 600 Vdc and 690 Vac should be expected under normal operating conditions inside the container.

Ç WARNINGDo not enter the system enclosure unless trained, certified, and authorized to do so by S&C. Potentially lethal voltages are present inside the system enclosure. High-voltage dc is present even without utility power connected.

Figure 4. Inside the system side door.

SAFETY INFORMATION

653-50113

SAFETY INFORMATION

Figure 5. Inside the battery and PCM bay.

No attempt to enter the PureWave UPS System should be made without verifying that all sources of hazardous energy have been removed. In order to ensure that no voltages are present in the PureWave UPS System, the shutdown procedure must be used.

Insulated Hand Tools

Insulated hand tools are required when working on or around any energized equipment. Use only properly rated tools 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 Wash Stations

The PureWave UPS System houses 48 lead-acid maintenance free batteries. Check with local municipality planning and development agency for emergency eye wash and emergency shower requirements. Inspect and maintain this equipment according to manufacturer’s recommendations and local, state, and federal regulations.

653-501 14

SAFETY INFORMATION

Emergency Procedures and Equipment

The owner should develop policies and procedures for handling emergency situations. It is the responsibility of the owner to develop site-specific emergency action plans for response to such situations.

Fire Protection Systems

The system senses fire or the potential for fire in three different ways. An optional hydrogen detector monitors the level of hydrogen in the enclosure and will disable the system if the amount exceeds 0.8% by volume. An optional smoke detector monitors the system for smoke and will disable the system when smoke is detected. Two thermo-couples inside the system enclosure sense internal temperature and will shut the system down if the temperature exceeds 64°C. See “Smoke, Fire, and Hydrogen Detection” on the next page for more information.

Fire Extinguishers Fire extinguishers to handle electrical fires and fires involving sulfuric acid or batteries should be kept on hand and maintained for initial fire emergency response. Reference the battery material safety data sheet shipped with the system, for further information regarding the composition of the unit. Proper training, placement, and maintenance are essential to ensuring the functionality and proper use of fire extinguishers.

Releases of Hazardous Material

No attempt should be made to respond to the release of hazardous materials by unqualified personnel. Prior to responding to the release of any hazardous material personnel should:

• Be trained in the clean up of that material,

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

• Have completed right-to-know training.

Reference the battery material safety data sheet shipped with the system for more information on clean up and disposal of hazardous materials.

Quarterly and Annual Inspections

After the PureWave UPS System is started and the unit is on line, inspection and maintenance should be scheduled on a regular basis to ensure the proper operation of the system. See the “Maintenance” section of Instruction Sheet 653-502 for checklists of inspection and maintenance items.

Hydrogen Detection (Optional)

An optional gas detector in the PureWave UPS System senses the presence of free hydrogen. Hydrogen created by the charging of batteries is evacuated from the system by a forced flow hydrogen evacuation system. Should the exhaust ventilation system fail and hydrogen collect inside the system enclosure, the combustible-gas detector will detect the accumulation of hydrogen and shutdown the system.

Hydrogen in concentrations of more than 0.8% by volume inside the system enclo-sure will activate the sensor and automatically disable the PureWave UPS System by switching to the bypass state. The control computer will sound an audible alarm inside the system enclosure and a “HYDROGEN IN CONTAINER” alarm will be displayed on the LCD display. The monitoring computer will log the event and an alarm contact will activate. If a report-by-exception alarm system is in use (such as ADT), the alarm monitoring service will then notify the appropriate personnel.

653-50115

INSPECTION AND HANDLING

Packing The PureWave UPS System is shipped fastened to a wooden skid such that the bottom of the system is sealed to prevent water, debris, or rodents from entering the unit during shipping and storage. The unit should be left on the skid until just prior to installation on the pad.

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 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.

Lead-Acid BatteriesÇ WARNING

Lead-acid batteries generate hydrogen gas.

To prevent a fire:

• DO NOT SMOKE near batteries.

• DO NOT allow sparks or flames near batteries.

• Discharge static electricity before touching batteries by first touching a grounded metal surface.

653-501 16


Handling 250-kW System with or Without Battery Module Installed

Ç WARNING

When handling an enclosure with an overhead hoist, observe standard lifting practices as well as the gen-eral instructions below. Failure to follow these precautions can result in serious personal injury or equipment damage.

Note: PureWave UPS Model 910250 weighs 9,200 lbs. (4,185 kg).

1. Ensure that the lifting eye-bolts are parallel to the lifting direction of the slings and that the lifting hooks are completely engaged in the eyebolts before lifting the enclosure.

2. Use 8-foot (245 cm) 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 so as to distribute the lifting forces equally between the eyebolts. See Figure 6.

4. Avoid sudden starts or stops.

Handling 500-kW System with Battery Modules Installed

Ç WARNING


Note: PureWave UPS Model 910500 weighs 15,600 lbs. (7,090 kg).


2. Use 11-feet (335 cm) or longer hoist slings of equal length, at each of the four lifting locations, to prevent overstressing the enclosure during lifting.


4. Avoid sudden starts or stops.

Figure 6. Hoisting diagram for 250-kW system.

Figure 7. Hoisting diagram for 500-kW system with battery modules Installed.

653-50117


Handling 500-kW System Without Battery Module Installed

Ç WARNING


Note: PureWave UPS Model 910500 weighs 9,000 lbs (4,077 kg) when the battery modules are not installed.


2. Use 11-feet (335 cm) or longer hoist slings of equal length, at each of the four lifting locations, to prevent overstressing the enclosure during lifting.


4. Avoid sudden starts or stops.Figure 8. Hoisting diagram for 500-kW system without battery modules installed.

653-501 18

INSTALLATION INSTALLATION

StorageIf necessary, the PureWave UPS System can be temporarily stored outdoors prior to being installed and placed into ser-vice. Protection is required only for the bottom of the unit. The PureWave UPS System should be left on the original pallet and the plastic under the unit should be left intact.

The maximum ambient temperature for storing the PureWave UPS System is 104°F (40°C). If the PureWave UPS System is to be stored longer than two months the batteries will need to be charged. Contact your nearest S&C Sales Office for battery charging information.

Concrete Pad SpecificationsThe concrete pad on which the PureWave UPS 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 ¹⁄₂ degree and should have a flatness within ¹⁄₄ 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 Hilti bolts are installed to bolt the PureWave UPS System to the pad.

The PureWave UPS System is designed to meet Seismic Zone 4 requirements when installed appropriately. If seismic ratings are required for the installation, the pad must be designed accordingly. The concrete pad must have a mini-mum compressive strength of 2000 psi (pounds per square inch) if a seismic zone 4 rating is required.

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 PureWave 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 9.

12 ft.

PureWave UPS

Battery module

Forklift

Minimumapron depth

Apron for forklift access

Notes:

1) Apron must be of adequate size to provide forklift access to battery module as shown.

2) Apron must be concrete, asphalt, or compacted road gravel.

Figure 9. Clearance requirements for battery removal and installation without battery module roller option.

653-50119


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 per-manent obstacles such as walls, parking posts, etc.

Apron for Forklift Access (with battery module roller option)A level apron of concrete, asphalt, or compacted road gravel should extend at least 5 feet in front of the PureWave UPS system and to the right to facilitate installation and removal of the battery modules using a forklift. The apron should be flush with the concrete pad (base of unit). See Figure 10.

PureWave UPS

Apron for forklift access

Notes:

1) Apron must be of adequate size to provide forklift access to battery module as shown.

2) Apron must be concrete, asphalt, or compacted road gravel.

3) Apron should be flush with UPS base.

Battery module Forklift

5 ft.

Figure 10. Clearance requirements for battery removal and installation with battery module roller option.

653-501 20

INSTALLATION

1. Place the PureWave UPS System on the pad.

2. Bolt the enclosure to the concrete pad utilizing ⁵⁄₈ diameter 4 embed Hilti Kwik Bolt II anchors. Bolt the enclosure at the mounting bracket location at each corner of the PureWave UPS System. Drill holes in the concrete pad as required. See Figure 11 for mounting bracket.

If a seismic rating is required for the installa-tion, Hilti Kwik Bolt anchors must be installed at each mounting bracket location. There is a mounting bracket located at each corner of each enclosure section of the PureWave UPS System.

Figure 11. Mounting bracket.

653-50121


Access to InteriorTo open a door: Remove the padlock from the security cover located over the center bolt. There are three bolts (top, center, and bottom) securing the door closed. Loosen the three bolts so they detach from the enclosure (the bolt will not completely detach from the door). The door will now open. Once the door is opened approximately 90 degrees or 135 degrees, engage the lock-bar at the bottom of the door hinge to prevent the door from being acciden-tally closed.

To close a door: Disengage the lock-bar by lifting the lock-bar and returning it to its storage location. See Figure 12. Swing the door closed. Tighten the three bolts to secure the door and install the padlock.

Grounding1. Connect the cable concentric-neutral ground

wires to the grounding system as appropri-ate.

2. Using a compression or box-type lug, attach the ground bar of the PureWave UPS System to the system ground in accordance with the user’s standard grounding practice and any applicable code requirements. See Figure 13.

Use the equivalent of 4/0 copper (or cable sized in accordance with the user’s stan-dard practice) in either a single or multiple connection to realize the maximum momen-tary rating of the switchgear. For a multiple connection, cables smaller than 1/0 copper or equivalent should not be used.

Figure 13. Attach system ground to one of the available ground bar bolt locations (located behind side door) using a compression or box-type lug.

Figure 12. Push down on lock-bar with foot to unlock.

653-501 22


Some applications may require that the PureWave UPS System be shipped without the air conditioner installed. In such cases the air conditioner(s) will need to be installed during the PureWave UPS System installation. Fol-lowing are installation instructions for the air conditioner.

Air Conditioner Installation Instructions for 60-Hz Systems1. Attach the four air-conditioner mounting

clamps to the air conditioner as shown. Removing the air-conditioner cover screws will enable the clamps to be slid under the cover more easily. Replace the air-condi-tioner cover screws after the clamps are installed.

2. Set the clamp spacers over the air-condi-tioner mounting studs.

3. Lift the air conditioner over the mounting area on top of the PureWave UPS System and connect the electrical cable.

4. Set the air conditioner in place over the mounting studs as shown.

5. Secure the air conditioner with the ⁵⁄₁₆ flat washer, lock-washer, and hex nuts. Figure 14. Air conditioner (60 Hz), expanded view.

Figure 15. Air conditioner (60 Hz), final view.

653-50123


Air Conditioner Installation Instructions for 50-Hz Systems1. Attach the adapter plate to the bottom of

the air conditioner as shown utilizing the ¹⁄₄–20 flat-head screws.

2. Apply a bead of caulk completely around the perimeter of the bottom of the adapter plate to provide a seal between the adapter plate and the roof of the UPS. Use Dow Corning RTV Sealant, 732 Multi Purpose Sealant, 100% Silicone Rubber Caulk, or equivalent.

3. Lift the air conditioner over the mounting area on top of the PureWave UPS System and connect the electrical cable.

4. Set the air conditioner in place over the mounting studs as shown.

5. Secure the air conditioner with the ⁵⁄₁₆ flat washer, lock-washer, and hex nuts.

Figure 16. Air conditioner (50 Hz), expanded view.

Figure 17. Air conditioner (50 Hz), final view.

653-501 24

Figure 18. S&C touch-up finish and red-oxide primer.

INSTALLATION CABLE TERMINATIONS

Door AdjustmentThe doors of the PureWave UPS System may move out of alignment during shipment. If the doors are not aligned properly the door bolts may become cross-threaded while securing the door closed. Follow the procedure below to align the doors:

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

2. Visually verify if the centerline of the middle door bolt is aligned with the centerline of the corresponding threaded fastener.

3. If the door bolt is not in alignment with the threaded fastener carefully loosen the six nuts (5/16” – 18) that are affixing the door hinge hardware to the front door stile (inside the enclosure behind the hinges).

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

5. Confirm that the top and bottom door bolts are in alignment with their corresponding fasteners. Make adjustments with the floor jack or lever if required.

6. Re-tighten the six nuts that are affixing the door hinge hardware to 24 – 28 ft/lbs.

7. Re-confirm that all three door bolts are aligned with the corresponding threaded fasteners.

Completing the Installation1. Close and lock all doors of the PureWave

UPS System.

2. Wipe down the exterior of the enclosure with a clean, damp cloth. Refinish any scratches or abrasions with S&C touch-up finish and red-oxide primer, which are available in aero-sol spray cans. See Figure 20. Order Catalog Number 9999-080 for light gray finish, and 9999-061 for red-oxide primer. 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 primer.

Pre-startup ChecklistA Pre-startup checklist will be provided that needs to be reviewed by the installing contrac-tor. 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 Technicians being dispatched to the job site for commissioning. If a pre-startup checklist is required, contact S&C’s Power Systems Services at 414-423-8776.

653-50125

Conduit RequirementsThe size and quantity of conduits required are based on the options ordered with the PureWave UPS System.

Input and Output Power and Control Connections1. Open the door to access the customer

connections. The door is located on the right side of the PureWave UPS System. See Figure 22 on page 29 for a 250-kW system. See Figure 24 on page 31 for a 500-kW system.

2. Refer to Table 1 for recommended power conductor sizes and terminals for a 250-kW system. Refer to Table 2 for recommended power conductor sizes and terminals for a 500-kW system. Refer to Table 3 for ratings of Model 910250 and Table 4 for ratings of Model 910500. Refer to Table 5 on page 26 for recommended control conductor sizes and terminals for both systems. Refer to Table 6 on page 26 for TB1-TB2 contact specifications.

INSTALLATION CABLE TERMINATIONS

TABLE 1. Recommended Power Conductor Sizes and Terminals for 250-kW, 480-V System1 (per phase)

Temperature Rating, °C2

Solid Copper Conductors Aluminum or Copper-Clad Conductors

Wire Size and Type Crimp Tool3 Lug and Die Wire Size and Type Crimp Tool3 Lug and Die

75Two 350 kc mil 75°C, THHW, THWN, or XHHW

Lug: T&B 54872BE Die: 15514

Two 500 kc mil 75°C, THHW, THWN, or XHHW

Lug: T&B 60273 Die: 15505

90Two 250 kc mil 90°C, THHW, THWN, or XHHW

Lug: T&B 54868BE Die: 15510

Two 400 kc mil 90°C, THHW, THWN, or XHHW

Lug: T&B 60629 Die: 15536

1 Assuming 90C° “wet” rating of cable.

2 With no derating for voltage drop or for more than three current-carry-ing conductors in the raceway.

3 Thomas & Betts Hydraulic Crimp Tool 13100A. Torque ¹⁄₂-inch Grade 5 hardware to 60 lb-ft.

TABLE 2. Recommended Power Conductor Sizes and Terminals for 500-kW, 480-V System1 (per phase)

Temperature Rating, °C2

Solid Copper Conductors Aluminum or Copper-Clad Conductors

Wire Size and Type Crimp Tool3 Lug and Die Wire Size and Type Crimp Tool3 Lug and Die

75Four 350 kc mil 75°C, THHW, THWN, or XHHW

Lug: T&B 54872BE Die: 15514

Four 250 kc mil 90°C, THHW, THWN, or XHHW

Lug: T&B 60273 Die: 15505

90Four 250 kc mil 90°C, THHW, THWN, or XHHW

Lug: T&B 54868BE Die: 15510

Four 400 kc mil 90°C, THHW, THWN, or XHHW

Lug: T&B 60629 Die: 15536

1 Assuming 90C° “wet” rating of cable.

2 With no derating for voltage drop or for more than three current-carry-ing conductors in the raceway.

3 Thomas & Betts Hydraulic Crimp Tool 13100A. Torque ¹⁄₂-inch Grade 5 hardware to 60 lb-ft.

TABLE 3. System Ratings for Model 910250

Voltage, VacSystem Rating, kVA

(kW)Current, Amperes

208 135 (135) 376

240 156 (156) 376

380 250 (250) 376

400 261 (250) 376

415 271 (250) 376

440 287 (250) 376

480 313 (250) 376

575 313 (250) 314

600 313 (250) 301

TABLE 4. System Ratings for Model 910500

Voltage, VacSystem Rating, kVA

(kW)Current, Amperes

208 271 (271) 752

240 313 (313) 752

380 500 (500) 752

400 521 (500) 752

415 541 (500) 752

440 573 (500) 752

480 625 (500) 752

575 625 (500) 628

600 625 (500) 601

653-501 26

CABLE TERMINATIONS

TABLE 5. Recommended Control Conductor Sizes and Terminals

Input/Output Contact Wire Size, AWG Connector

Type1

All Except Transfer Signal 14 T&B RB864

Sta-kon

All Except Transfer Signal 10 T&B RC864

Sta-kon

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

3. Terminate the input phase connections to the utility-source input (upper) terminals. See Figure 19.

4. Terminate the output phase connections to the load output (lower) terminals. See Figure 19.

5. Terminate the applicable control connections including the phone line and/or Ethernet connection. The Ethernet connection requires a Category 5 cable with RJ45 connector. The phone line requires a standard dial-up phone line.

Ç CAUTIONSeal all conduit entrances on the outside with RTV and on the inside with expansive foam, to prevent water from entering the enclosure.

TABLE 6. Solid-State Contact Specifications for TB1 and TB2

Operating Voltage Range

TB1TB2

24-280 Vac12-140 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 Time¹⁄₂-cycle maximum-zero

voltage

Turn-Off Time¹⁄₂-cycle maximum-zero

current

DV/DT—Off State 200 volts/microsecond

DV/DT—CommunicatingSnubbed for rated 0.5

power factor load

Output Voltage Drop Maximum Peak

1.6 volts

Off-State Leakage @ Nominal Voltage—60 Hz

TB1—2.5 milliamperes TB2—5 milliamperes

Figure 19. Input and output connections.

Input terminals

Output terminals

Neutral

Ground

653-50127

ETHERNET AND TELEPHONE MODEM CONNECTIONS

The PureWave UPS System can be remotely monitored through its Ethernet and/or tele-phone modem connection points. Refer to Figure 20.

NOTICECommunication cables from the PureWave UPS System must be installed in a separate conduit, per NEC requirements.

Figure 20. Monitoring computer connections.

Ethernet connector for monitoring computer

Phone line connector for monitoring computer

653-501 28

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

Figure 21. PureWave UPS Model 910250.

DRAWINGS DRAWINGS

653-50129

DRAWINGS DRAWINGS

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��


653-501 30

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

� ��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��


DRAWINGS DRAWINGS

653-50131

DRAWINGS DRAWINGS

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��


653-501 32

Prin

ted

in U

.S.A

.

DRAWINGS

The overall scope of connections to the PureWave UPS System is shown in Figure 26. The optional transfer switch and alarm contacts

are discussed in the PureWave operation and maintenance manual supplied with the unit.

Figure 25. Electrical connections.

s&c purewave ups system instructions for installation

Documents