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Powerware 9350 Series 685 and 1085 Auxiliary Battery Cabinets

Installation Manual

164201408

Rev. P00 053002

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Summary of Contents for 1085 Series

Page 1: ...Installation Manual Series 685 and 1085 Auxiliary Battery Cabinets 164201408 Rev P00 9350 ...

Page 2: ...binets Observe these precautions when working on or around battery cabinets Remove watches rings or other metal objects Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of batteries or battery cabinets Disconnect the charging source prior to connecting or disconnecting terminals The battery cabinet frame is not referenced to the DC circuit When r...

Page 3: ...stalling wiring These general installation notes apply to either the Series 685 Battery Cabinet or the Series 1085 Battery Cabinet Do not tilt battery cabinets more than 10 during installation The recommended minimum clearance over each battery cabinet is 305 mm 12 in The conduit landing plates are removable to add conduit landing holes as required The conduit landing plates should be removed when...

Page 4: ... term UPS refers only to the UPS cabinet and its internal elements The term UPS system refers to your entire power protection system the UPS cabinet plus battery cabinets that you have installed Read through each installation procedure before you begin it Perform only those procedures that apply to the battery system you are installing NOTE The term Separate refers to battery cabinets that are not...

Page 5: ...llation Plan 9 NOTES 10 3 Connecting to Powerware 9350 30 thru 160 11 The Powerware 9350 UPS with Integral Battery Cabinets 11 Powerware 9350 UPS with Separately Located Battery Cabinets 20 Separate Installation of Series 685 Battery Cabinets 21 Separate Installation of Series 1085 Battery Cabinets 23 Completing the Installation Checklist 27 Installation Checklist for Powerware 9350 30 through 160...

Page 6: ...binet 13 Figure 8 Attaching UPS Base to Series 1085 Base 14 Figure 9 Attaching UPS Base to Series 685 Base 15 Figure 10 Series 685 Battery Cabinet Wiring Detail 17 Figure 11 Series 685 and 1085 Battery Cabinet Hanger Brackets 18 Figure 12 Series 1085 Battery Cabinet Wiring Detail 19 Figure 13 UPS with Separately Located Battery Cabinets 20 Figure 14 Placement of Joining Brackets Two or More Series...

Page 7: ...ery cabinet with respect to the UPS and electrically connecting the battery cabinet to the UPS The information you will use depends on the type of UPS and series of battery cabinet that you purchased Typical Battery Cabinets Series 685 Battery Cabinet Series 1085 Battery Cabinet Figure 1 Typical Battery Cabinets Two basic battery cabinet configurations are possible The UPS and one or more battery ...

Page 8: ...ecifically to your system configuration See Figures 2 and 3 to determine where to find your system installation instructions in this manual UPS Battery Cabinet Figure 2 UPS with Lineup and Match Battery Cabinet For installation instructions refer to The Powerware 9350 UPS with Integral Battery Cabinets section of Chapter 3 Refer to Chapter 2 Unpacking Your Battery Cabinet for unpacking instruction...

Page 9: ...00 053002 UPS Battery Cabinets Figure 3 UPS with Separate Battery Cabinets Attached to Each Other For installation instructions refer to The Powerware 9350 UPS with Separate Battery Cabinets section of Chapter 3 or Chapter 4 Refer to Chapter 2 Unpacking Your Battery Cabinet for unpacking instructions ...

Page 10: ...n other optional cabinets Also describes the UPS Cabinet Control Panel and Monitor Panel and explains the functions of the UPS discusses the standard features of the UPS and optional accessories provides procedures for starting and stopping the UPS and information about maintenance and responding to system events Contact your local Powerware Corporation Field Service office for information about h...

Page 11: ...8 77 F Maximum Relative Humidity 95 noncondensing The Series 685 or Series 1085 Battery Cabinets use convection cooling to regulate internal component temperature Air inlets are in the bottom and top of the cabinets You must allow a minimum clearance of 305 mm 12 in above each cabinet for proper air circulation Additionally a clearance of 915 mm 36 in must be provided in front of the cabinet for c...

Page 12: ...053002 Inspecting and Unpacking Each Cabinet The first task in preparing for installation is inspecting and unpacking each cabinet Cabinets arrive covered with protective packaging material as shown in Figure 4 PLY FOAM CUSHIONS OUTER PACKAGING Figure 4 Cabinet as Shipped with Outer Packaging and Pallet ...

Page 13: ... cutting one corner using a knife blade no longer than 25 mm 1 in 6 Remove the corrugated corner protectors box plastic bag and discard or recycle them in a responsible manner CAUTION IF YOU CAN SEE DAMAGE IN OR ON A CABINET DO NOT INSTALL IT REPORT ANY DAMAGE TO THE CARRIER CONTACT YOUR LOCAL SALES OR SERVICE OFFICE IMMEDIATELY Unloading the Battery Cabinet from the Pallet The battery cabinet is ...

Page 14: ...TIONS ARE NOT CLOSELY FOLLOWED CABINET MAY TIP 4 Turn each jacking bolt consecutively two full turns until the foam cushions clear the floor by approximately 3 mm 1 8 in DANGER RISK OF INSTABILITY TURNING THE JACKING BOLTS UNEVENLY MAY CAUSE THE CABINET TO BECOME UNBALANCED TO PREVENT TIPPING THE CABINET RAISE AND LOWER THE JACKING BOLTS EVENLY DANGER CABINET MAY TIP THE BATTERY CABINET SHOULD ONL...

Page 15: ...cking bolts and discard or recycle them in a responsible manner 8 Remove the hardware labeled 2 in Figure 5 holding the front rear and side supports to the cabinet base Discard or recycle the hardware and support brackets in a responsible manner 9 Replace the doors that were removed in Step 1 The battery cabinet is now ready to be rolled to its final location 10 Repeat Steps 1 through 9 for each c...

Page 16: ..._____________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ______________________________________...

Page 17: ...he term battery cabinet to refer to any battery cabinet There are two different sizes of battery cabinets but the procedure for connecting the cabinets to your UPS system is the same Joining one or more battery cabinets to the UPS One or more battery cabinets separately located from the UPS The Powerware 9350 UPS with Integral Battery Cabinets Use this procedure to attach a Powerware 9350 Series 6...

Page 18: ...acket over this screw hole and the other hole over the hole in the top of the battery cabinet Replace the screw in the hinge and attach the other end of the bracket to the top of the battery cabinet using an M4 10 hex screw from the field kit see Figure 7 8 For Series 1085 Battery Cabinets remove the right hand screw from the top right door hinge of the UPS cabinet and the right hand screw from th...

Page 19: ...acket from kit Screw from kit Existing Screw NOTE When cabinets are properly aligned Cabinet UPS Battery Cabinet Front of 685 Bracket from kit Screw from kit see Figure 9 for Series 685 of UPS Battery Cabinet Battery Cabinet Front of UPS Existing Screw Existing Screw Bracket from kit Front of UPS Front of 1085 Battery Cabinet all cabinet doors will be flush with each other Figure 7 Placement of At...

Page 20: ...S cabinet Hardware is provided on each ground stud 13 Repeat Steps 2 through 12 to attach additional Series 1085 Battery Cabinets to the other side of the first battery cabinet Level the cabinets with the leveling screws 14 Locate the cabinet connecting bracket from the field kit Attach the bracket to the lower right hand side of the Series 685 base using 2 M4 screws 15 Locate the large flat brack...

Page 21: ...se to Series 685 Base 17 Locate the ground wire from the field kit Route the ground wire from the customer ground stud in the battery cabinet under the lower right hand battery tray through the access hole in the side panel of the UPS and attach to customer ground stud in the UPS cabinet Hardware is provided on each ground stud 18 Repeat Steps 2 through 17 to attach additional Series 685 Battery C...

Page 22: ... the unit terminal blocks 4 Wire the UPS to the Battery cabinet by attaching the provided cable from E4 to DC and E5 to DC power interconnection cables provided The provided red and black cables are already cut to length 5 Remove the cable tie securing the battery breaker sensing cable 6 Locate the battery breaker sensing cable in the right hand Battery cabinet Route this connector into the cabine...

Page 23: ...ON BATTERY BREAKER FIXED RIGHT BATTERY POWER CONNECTOR BLACK STRING CONNECTORS RED CONNECTION FOR REMOTE MONITORING CUSTOMER CONNECTION CABINET GROUNDING REMOTE INSTALLATION CABINET TO CABINET TERMINAL LEFT CABINET TO CABINET TERMINAL RIGHT GROUNDING STUD LOCATION 2X GROUNDING STUD LOCATION 2X Figure 10 Series 685 Battery Cabinet Wiring Detail ...

Page 24: ...ttery Cabinets Installation Manual 164201408 Rev P00 053002 HANGER BRACKET LOCATION SECURED WITH SCREWS CABINET TO CABINET EACH SIDE CABLE ACCESS AREA Series 685 Cabinet Series 1085 Cabinet Figure 11 Series 685 and 1085 Battery Cabinet Hanger Brackets ...

Page 25: ...KER FIXED RIGHT BATTERY POWER CONNECTOR BLACK STRING CONNECTORS RED CONNECTION FOR REMOTE MONITORING CUSTOMER CONNECTION CABINET GROUNDING REMOTE INSTALLATION CABINET TO CABINET TERMINAL NOTE COMPRESSION LUGS SHOWN ARE USED FOR REMOTE INSTALLATION ONLY CABINET TO CABINET TERMINAL GROUNDING STUD LOCATION 2X Figure 12 Series 1085 Battery Cabinet Wiring Detail ...

Page 26: ...arately Located Battery Cabinets Use this procedure to wire a separately located Series 685 or Series 1085 Battery Cabinet to any Powerware 9350 UPS cabinet see Figure 14 In this situation the Battery cabinets are remotely loacted from the UPS and are lineup and match with each other Figure 13 UPS with Separately Located Battery Cabinets ...

Page 27: ...Cabinet 1 Bracket from kit Figure 14 Placement of Joining Brackets Two or More Series 685 Battery Cabinets Separate Installation of Series 685 Battery Cabinets 1 Remove the right hand screw from the top door hinge of battery cabinet 1 Align the hole in one flat bracket over this screw hole and the other hole over the hole in the top of battery cabinet 2 Replace the screw in the hinge and attach th...

Page 28: ...wo screws see Figure 15 4 Locate the large flat bracket from the field kit Place the bracket over the stud on the bottom side of battery cabinet 1 lower hinge and over the stud on the bottom side of the cabinet connecting bracket on battery cabinet 2 Attach the bracket with two M8 self locking nuts from the field kit see Figure 15 5 Locate the ground wire from the field kit Route the ground wire f...

Page 29: ...abinet 1 Bracket from kit Figure 16 Placement of Joining Brackets Two or More Series 1085 Battery Cabinets Separate Installation of Series 1085 Battery Cabinets 1 Remove the right hand screw from the top door hinge of battery cabinet 1 Align the hole in one flat bracket over this screw hole and the other hole over the hole in the top of battery cabinet 2 Replace the screw in the hinge and attach t...

Page 30: ...ud on the bottom side of battery cabinet 1 lower hinge and over the stud on the bottom side of battery cabinet 1 lower hinge Attach the bracket with two M8 self locking nuts from the field kit see Figure 17 4 Locate the ground wire from the field kit Route the ground wire from the customer ground stud in battery cabinet 1 under the lower right hand battery tray into the cable access area in batter...

Page 31: ...attery breaker sensing cable 5 Locate the battery breaker sensing cable in the right hand battery cabinet Route this connector into the cabinet to the immediate left and mate with the matching connector in the bottom of that cabinet Connect all battery cabinets together this way 6 Repeat Steps 2 through 5 for each battery cabinet to be joined 7 Route cables from positive and negative terminals in ...

Page 32: ...anger brackets to the top side of the battery cabinets using M4 screws see Figure 11 b Hang the side panel on the hanger brackets and align it with the front and rear of the battery cabinet c Secure the side panel at the bottom using M4 hex head screws 9 Secure all battery cabinets by closing and latching the doors 10 Secure the UPS by reinstalling safety shields and closing and latching the doors...

Page 33: ...st MUST be completed prior to starting up the UPS system for the first time Installation Checklist for Powerware 9350 30 through 160 All packing materials and restraints have been removed from each cabinet Each cabinet in the battery system is placed in its correct location All cabinets are bolted together A ground wire is installed between all cabinets that are bolted together All conduits and ca...

Page 34: ...28 Powerware 9350 Series 685 and 1085 Auxiliary Battery Cabinets Installation Manual 164201408 Rev P00 053002 This Page Intentionally Left Blank ...

Page 35: ...UPS Figure 19 details the same connections in a Powerware 9350 160 UPS NOTE See Table C in Appendix A for sizing wire for separate battery configurations There are no battery cabinet to UPS mechanical attachment requirements for this type of system However individual battery cabinets should be attached and grounded to each other Please refer to later sections of this chapter for instructions on th...

Page 36: ...and doors from the UPS Save covers screws and brackets for later reuse 5 Each battery cabinet in your system will have to be individually connected to terminals E4 and E5 6 Route cables from positive and negative terminals in the bottom of each battery cabinet through conduit top or bottom entry to terminals E4 and E5 of the UPS cabinet See Figure 18 or 19 for location of terminals E4 and E5 Refer...

Page 37: ...zed service personnel Completing the Installation Checklist The final step in installing your battery cabinet is to complete the Installation Checklist This checklist ensures that you have installed all hardware cables and other equipment Completing all items on the checklist will ensure a smooth installation Make a copy of the Installation Checklist before filling it out and retain the original A...

Page 38: ...perly installed Battery cables and harness are terminated on the battery terminals E4 and E5 in the UPS cabinet Internal battery cabinet connections have been completed bus bars plugs etc Air conditioning equipment is installed and operating correctly The area around the installed battery system is clean and dust free It is recommended that the battery cabinet be installed on a sealed concrete pad...

Page 39: ...attern described in this chapter You can install a remote battery disconnect anywhere between the remote DC supply and the UPS according to national and local codes Figure 20 shows the remote battery disconnect enclosure FRONT SIDE ON OFF Figure 20 Remote Battery Disconnect Enclosure The breaker switch on the remote battery disconnect should be set to ON for normal UPS operation when DC power is a...

Page 40: ... at 2 00 VDC per cell Battery cabinets must be installed in accordance with all applicable codes and regulations including the National Electrical Code NEC Article 480 The UPS to battery cable should be sized for a total maximum voltage drop of 1 nominal DC link voltage at maximum current The external wiring specifications are outlined in Table C of Appendix A Tables A and B in this chapter detail...

Page 41: ...al Function E4 1 8 3 0 UPS Battery Contactor K2 E5 1 8 3 0 UPS Battery Contactor K2 Breaker 1 4 300 kcmil Battery Disconnect Breaker 1 4 300 kcmil Battery Disconnect Breaker jumper 1 4 300 kcmil Battery Disconnect jumper Battery Cabinet See Table C Appendix A Stand alone battery cabinet Battery Cabinet See Table C Appendix A Stand alone battery cabinet Table B Battery Cabinet Terminations Battery ...

Page 42: ...ect Circuit Breaker Ratings UPS Model Circuit Breaker Rating DC Voltage 9350 40 125 420 9350 50 125 480 9350 65 175 420 9350 80 200 480 9350 125 350 420 9350 130 350 420 9350 150 350 480 9350 160 350 480 9350 200 600 420 9350 225 600 480 9350 250 800 420 9350 300 800 480 9350 300 900 420 9350 400 1200 420 9350 400 1000 480 9350 500 1200 480 ...

Page 43: ...m The appendix contains these drawings 164201408 1 Series 685 Battery Cabinet 164201408 2 Series 1085 Battery Cabinet 164201408 3 Remote Interface Connections 164201408 4 Series 685 1085 Configurations NOTE Outline diagrams and oneline diagrams for the various UPS models are available in their respective manuals See this manual for more information 164201407 Powerwarer 9350 100 kVA 160 kVA UPS Ins...

Page 44: ...as defined by the NEC for control wiring Install the control wiring in separate conduit from the power wiring The wire should be rated at 24 volts 1 amp minimum 5 Battery voltage is computed at 2 volts per cell as defined by Article 480 of the NEC Rated battery current is computed at 1 8 volts per cell 6 The battery wiring used between the battery and the UPS should not allow a voltage drop of mor...

Page 45: ...42 4 375 1 4I hex 22 6 200 50 40 685 B14 B17 H20 1 or 2 Separate 2 0 3 8I hex 42 4 375 1 4I hex 22 6 200 50 40 1085R B10 1 2 3 or 4 Integral Supplied 3 8I hex 42 4 375 3 8I hex 42 4 375 50 40 1085R B10 1 2 3 or 4 Separate 3 0 3 8I hex 42 4 375 3 8I hex 42 4 375 50 40 1085 B27 B31 B37 B47 H30 H40 H50 1 2 3 or 4 Integral Supplied 3 8I hex 42 4 375 1 4I hex 22 6 200 50 40 1085 B27 B31 B37 B47 H30 H40...

Page 46: ... 2 Separate 2 0 3 8I hex 42 4 375 1 4I hex 22 6 2 80 60 1085R B10 1 Integral Supplied 3 8I hex 42 4 375 3 8I hex 42 4 375 80 60 1085R B10 1 Separate 3 0 3 8I hex 42 4 375 3 8I hex 42 4 375 80 60 1085 B27 B31 B37 B47 H30 H40 H50 1 2 3 or 4 Integral Supplied 3 8I hex 42 4 375 1 4I hex 22 6 200 80 60 1085 B27 B31 B37 B47 H30 H40 H50 1 2 3 or 4 Separate 2 0 3 8I hex 42 4 375 1 4I hex 22 6 200 H20 1 42...

Page 47: ...0 H40 H50 2 3 or 4 Separate 300 kcmil 3 8I hex 42 4 375 3 8I hex 42 4 375 160 160 685 H20 2 Integral Supplied 3 8I hex 42 4 375 3 8I hex 42 4 375 160 160 685 H20 2 Separate 300 kcmil 3 8I hex 42 4 375 3 8I hex 42 4 375 160 160 1085 B27 B31 B37 B47 H30 H40 H50 1 2 3 or 4 Integral Supplied 3 8I hex 42 4 375 3 8I hex 42 4 375 160 160 1085 B27 B31 B37 B47 H30 H40 H50 1 2 3 or 4 Separate 350 kcmil 3 8I...

Page 48: ...binets Installation Manual 164201408 Rev P00 053002 DESCRIPTION DRAWING NO 1 of 2 Series 685 Battery Cabinet elevation SHEET Dimensions are in millimeters inches Series 685 Battery Cabinet 164201408 1 1870 3 73 6 735 8 28 97 685 26 97 without decorative panels ...

Page 49: ...mensions are in millimeters inches Series 685 Battery Cabinet Series 685 Battery Cabinet Series 685 Battery Cabinet plan 164201408 1 201 1 7 92 335 13 19 120 4 72 80 3 15 175 6 89 282 11 1 226 9 8 93 280 4 11 04 148 5 83 75 2 95 735 8 28 97 613 24 14 135 5 32 453 17 83 300 4 11 83 61 4 2 42 141 4 5 57 802 7 31 6 530 20 87 690 27 17 151 5 95 71 2 80 TOP CABLE ENTRY LOCATION COVER SECURED WITH SCREW...

Page 50: ...nets Installation Manual 164201408 Rev P00 053002 DESCRIPTION DRAWING NO 1 of 2 Series 1085 Battery Cabinet elevation SHEET Dimensions are in millimeters inches Series 1085 Battery Cabinet 164201408 2 1870 3 73 6 1135 8 44 72 1085 42 72 without decorative panels ...

Page 51: ...ESS REQUIRED Series 1085 Battery Cabinet plan Dimensions are in millimeters inches 164201408 2 Series 1085 Battery Cabinet Series 1085 Battery Cabinet 335 13 19 120 4 72 80 3 15 175 6 89 282 11 1 61 4 2 42 141 4 5 57 802 7 31 6 151 5 95 71 2 80 229 1 9 02 265 10 43 690 27 27 265 10 43 151 5 95 265 10 43 265 10 43 201 1 7 92 426 9 16 81 480 4 18 91 426 5 16 79 1135 8 44 72 426 5 16 79 1013 39 88 44...

Page 52: ...C11 CB1 ST C12 CB1 AUXILIARY SWITCH N C CB1 AUXILIARY SWITCH COMM CB1 AUXILIARY SWITCH N O CB1 ST CB1 ST TB1 Notes 1 Shunt trip requires 24V 150 VA instantaneous to activate supplied by user 2 Auxiliary switches are rated as follows 240 VAC 15A 125 VDC 0 3A 250 VDC 0 15A 3 Wiring shall be suitable for Class 1 600V wiring methods Note 2 3 4 Note 2 3 4 Note 1 Note 1 4 Torque screw terminals to 20 in...

Page 53: ... E5 E4 E5 Powerware 9350 30 through 160 from the UPS NOTE The term Separate refers to battery cabinets that are not physically attached to the UPS are wired with external contractor supplied wiring and use a single overcurent protection and disconnect device located near the batteries The term Integral refers to battery cabinets that are physically attached to the UPS and the wiring between them i...

Page 54: ...A 12 Powerware 9350 Series 685 and 1085 Auxiliary Battery Cabinets Installation Manual 164201408 Rev P00 053002 This Page Intentionally Left Blank ...

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