Table of Contents
- Important Safety Instructions — SAVE THESE INSTRUCTIONS
- Specifications
- Mechanical Assembly
- Floor Mounting
- Connect Input and PE Cables in Single Systems
- Connect Input and PE Cables in Parallel Systems
- Connect PE Cable in TNC System
- Connect the Communication Cables
- Install an External Battery
- Install a Battery Circuit Breaker Kit for Third Party Battery Cabinets (Option)
- Battery Circuit Breaker Enclosure (Option)
- Install the Battery Temperature Monitor (Option)
- Install the Synchronization Module (Option)
- Install an External Bypass
- Install Marine UPS Adaptation Voltage Transformer
- Install Isolation Transformer (Option)
APC G55TUPU80HXS User Manual
Displayed below is the user manual for G55TUPU80HXS by APC which is a product in the Uninterruptible Power Supplies (UPSs) category. This manual has pages.
Related Manuals
Galaxy 5500 / Galaxy 5500 Marine
20 - 120 kVA 400 V
Installation
06/2018
www.schneider-electric.com
Legal Information
The Schneider Electric brand and any registered trademarks of Schneider Electric
Industries SAS referred to in this guide are the sole property of Schneider Electric
SA and its subsidiaries. They may not be used for any purpose without the owner's
permission, given in writing. This guide and its content are protected, within the
meaning of the French intellectual property code (Code de la propriété
intellectuelle français, referred to hereafter as "the Code"), under the laws of
copyright covering texts, drawings and models, as well as by trademark law. You
agree not to reproduce, other than for your own personal, noncommercial use as
defined in the Code, all or part of this guide on any medium whatsoever without
Schneider Electric's permission, given in writing. You also agree not to establish
any hypertext links to this guide or its content. Schneider Electric does not grant
any right or license for the personal and noncommercial use of the guide or its
content, except for a non-exclusive license to consult it on an "as is" basis, at your
own risk. All other rights are reserved.
Electrical equipment should be installed, operated, serviced, and maintained only
by qualified personnel. No responsibility is assumed by Schneider Electric for any
consequences arising out of the use of this material.
As standards, specifications, and designs change from time to time, please ask for
confirmation of the information given in this publication.
20 - 120 kVA 400 V
Table of Contents
Important Safety Instructions — SAVE THESE
INSTRUCTIONS.........................................................................................5
Safety Precautions .....................................................................................6
Electrical Safety....................................................................................8
Periodical Check...................................................................................9
Battery Safety.......................................................................................9
Electromagnetic Compatibility..............................................................10
Specifications ............................................................................................ 11
Input........................................................................................................ 11
Output ..................................................................................................... 11
Bypass ....................................................................................................12
Environment.......................................................................................13
Batteries ..................................................................................................14
Recommended Circuit Breakers and Cable Sizes .......................................15
Transformers............................................................................................19
Battery Circuit Breaker Enclosure ..............................................................21
Mechanical Assembly ..............................................................................23
Clearance Dimensions..............................................................................23
Remove Battery Protection........................................................................25
Remove Battery Protection from the UPS .............................................25
Remove Battery Protection from the External Battery Cabinet ................25
Install the Top Entry Option........................................................................26
Install the IP32 Option...............................................................................28
Floor Mounting ..........................................................................................29
Connect Input and PE Cables in Single Systems ................................30
Single Utility/Mains Systems......................................................................30
Dual Utility/Mains Systems ........................................................................30
Frequency Converter ................................................................................31
Connect Input and PE Cables in Parallel Systems..............................33
Overview .................................................................................................33
Single Utility/Mains Systems......................................................................33
Dual Utility/Mains Systems ........................................................................34
Redundant Parallel System .................................................................34
Parallel System with External Bypass ...................................................34
Frequency Converter ................................................................................36
Connect PE Cable in TNC System.........................................................37
Connect the Communication Cables .....................................................38
Overview of the Communication Cables .....................................................38
Connect Dry Contact Communication Card ................................................40
Connect Network Management Card .........................................................42
Example of Communication Card Connection .............................................42
Add or Change Communication Cards .......................................................42
Connect General Shutdown or Remote Emergency Power Off .....................44
Connect Parallel Communication Cables....................................................44
Redundant Parallel System .................................................................44
Parallel System with External Bypass ...................................................45
990–5233E–001 3
20 - 120 kVA 400 V
Install an External Battery........................................................................47
Lock Battery Cells on Shelves for Marine UPS ............................................47
Connect the Battery Cables.......................................................................47
Install An Empty Battery Cabinet................................................................49
Install Battery Circuit Breaker Kit ..........................................................49
Install Shelves and Battery Cells ..........................................................50
Connect the Battery Remote Control .......................................................... 51
Install a Battery Circuit Breaker Kit for Third Party Battery
Cabinets (Option)......................................................................................53
Battery Circuit Breaker Enclosure (Option)...........................................56
Install Battery Circuit Breaker Enclosure.....................................................58
Install the Battery Temperature Monitor (Option) .................................60
Install the Synchronization Module (Option) .........................................61
Overview of the Synchronization Module ....................................................61
Mount the Synchronization Module to the Wall ............................................61
Recommended Cable Sizes ......................................................................62
Connect Cables to the Synchronization Module for Single UPS....................62
Connect Cables to the Synchronization Module in a Parallel System ............63
Input and Output Contacts.........................................................................65
Install an External Bypass .......................................................................66
Install 150 kVA External Bypass Cabinet ....................................................66
TNS...................................................................................................66
TNC...................................................................................................67
Install 400 kVA External Bypass Cabinet ....................................................68
TNS...................................................................................................68
TNC...................................................................................................69
Install Marine UPS Adaptation Voltage Transformer...........................70
Install Isolation Transformer (Option).....................................................71
Transformer Configuration Options in Single Systems .................................72
Transformer Configuration Options in Parallel UPS System .........................74
Install Input Isolation Transformer ..............................................................75
Install Output Isolation Transformer............................................................79
4 990–5233E–001
Important Safety Instructions — SAVE THESE
INSTRUCTIONS 20 - 120 kVA 400 V
Important Safety Instructions — SAVE THESE
INSTRUCTIONS
Read these instructions carefully and look at the equipment to become familiar with
it before trying to install, operate, service or maintain it. The following safety
messages may appear throughout this manual or on the equipment to warn of
potential hazards or to call attention to information that clarifies or simplifies a
procedure.
The addition of this symbol to a “Danger” or “Warning” safety
message indicates that an electrical hazard exists which will result in
personal injury if the instructions are not followed.
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages with this symbol
to avoid possible injury or death.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
Failure to follow these instructions will result in death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
Failure to follow these instructions can result in injury or equipment
damage.
NOTICE
NOTICE is used to address practices not related to physical injury. The safety
alert symbol shall not be used with this type of safety message.
Failure to follow these instructions can result in equipment damage.
Please Note
Electrical equipment should only be installed, operated, serviced, and maintained
by qualified personnel. No responsibility is assumed by Schneider Electric for any
consequences arising out of the use of this material.
A qualified person is one who has skills and knowledge related to the construction,
installation, and operation of electrical equipment and has received safety training
to recognize and avoid the hazards involved.
990–5233E–001 5
20 - 120 kVA 400 V
Important Safety Instructions — SAVE THESE
INSTRUCTIONS
Safety Precautions
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
All safety instructions in this document must be read, understood and followed.
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Read all instructions in the Installation Manual before installing or working on this
UPS system.
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Do not install the UPS system until all construction work has been completed
and the installation room has been cleaned.
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• The product must be installed according to the specifications and
requirements as defined by Schneider Electric. It concerns in particular the
external and internal protections (upstream breakers, battery breakers,
cabling, etc.) and environmental requirements. No responsibility is assumed
by Schneider Electric if these requirements are not respected.
• After the UPS system has been electrically wired, do not start up the system.
Start-up must only be performed by Schneider Electric.
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
The UPS system must be installed according to local and national regulations.
Install the UPS according to:
• IEC 60364 (including 60364–4–41- protection against electric shock, 60364–
4–42 - protection against thermal effect, and 60364–4–43 - protection against
overcurrent), or
• NEC NFPA 70, or
• Canadian Electrical Code (C22.1, Part 1)
depending on which one of the standards apply in your local area.
Failure to follow these instructions will result in death or serious injury.
6 990–5233E–001
Important Safety Instructions — SAVE THESE
INSTRUCTIONS 20 - 120 kVA 400 V
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Install the UPS system in a temperature controlled indoor environment free of
conductive contaminants and humidity.
• Install the UPS system on a non-flammable, level and solid surface (e.g.
concrete) that can support the weight of the system.
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
The UPS is not designed for and must therefore not be installed in the following
unusual operating environments:
• Damaging fumes
• Explosive mixtures of dust or gases, corrosive gases, or conductive or radiant
heat from other sources
• Moisture, abrasive dust, steam or in an excessively damp environment
• Fungus, insects, vermin
• Salt-laden air or contaminated cooling refrigerant
• Pollution degree higher than 2 according to IEC 60664-1
• Exposure to abnormal vibrations, shocks, and tilting
• Exposure to direct sunlight, heat sources, or strong electromagnetic fields
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Do not drill or cut holes for cables or conduits with the gland plates installed and
do not drill or cut holes in close proximity to the UPS.
Failure to follow these instructions will result in death or serious injury.
WARNING
HAZARD OF ARC FLASH
Do not make mechanical changes to the product (including removal of cabinet
parts or drilling/cutting of holes) that are not described in the Installation Manual.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
NOTICE
RISK OF OVERHEATING
Respect the space requirements around the UPS system and do not cover the
product’s ventilation openings when the UPS system is in operation.
Failure to follow these instructions can result in equipment damage.
NOTICE
RISK OF EQUIPMENT DAMAGE
Do not connect the UPS output to regenerative load systems including
photovoltaic systems and speed drives.
Failure to follow these instructions can result in equipment damage.
990–5233E–001 7
20 - 120 kVA 400 V
Important Safety Instructions — SAVE THESE
INSTRUCTIONS
Electrical Safety
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH
• Electrical equipment must be installed, operated, serviced, and maintained
only by qualified personnel.
• The UPS system must be installed in a room with restricted access (qualified
personnel only).
• Apply appropriate personal protective equipment (PPE) and follow safe
electrical work practices.
• Turn off all power supplying the UPS system before working on or inside the
equipment.
• Before working on the UPS system, check for hazardous voltage between all
terminals including the protective earth.
• The UPS contains an internal energy source. Hazardous voltage can be
present even when disconnected from the utility/mains supply. Before
installing or servicing the UPS system, ensure that the units are OFF and that
utility/mains and batteries are disconnected. Wait five minutes before
opening the UPS to allow the capacitors to discharge.
• A disconnection device (e.g. disconnection circuit breaker or switch) must be
installed to enable isolation of the system from upstream power sources in
accordance with local regulations. This disconnection device must be easily
accessible and visible.
• The UPS must be properly earthed/grounded and due to a high leakage
current, the earthing/grounding conductor must be connected first.
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
In systems where backfeed protection is not part of the standard design, an
automatic isolation device (backfeed protection option or other device meeting
the requirements of IEC/EN 62040–1 or UL1778 5th Edition – depending on
which of the two standards apply to your local area) must be installed to prevent
hazardous voltage or energy at the input terminals of the isolation device. The
device must open within 15 seconds after the upstream power supply fails and
must be rated according to the specifications.
Failure to follow these instructions will result in death or serious injury.
When the UPS input is connected through external isolators that, when opened,
isolate the neutral or when the automatic backfeed isolation is provided external to
the equipment or is connected to an IT power distribution system, a label must be
fitted at the UPS input terminals, and on all primary power isolators installed
remote from the UPS area and on external access points between such isolators
and the UPS, by the user, displaying the following text (or equivalent in a language
which is acceptable in the country in which the UPS system is installed):
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Risk of Voltage Backfeed. Before working on this circuit: Isolate the UPS and
check for hazardous voltage between all terminals including the protective earth.
Failure to follow these instructions will result in death or serious injury.
8 990–5233E–001
Important Safety Instructions — SAVE THESE
INSTRUCTIONS 20 - 120 kVA 400 V
Periodical Check
WARNING
HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH
• Limited lifetime components, such as capacitors, fans, electronic boards,
batteries, etc., must be checked periodically by qualified personnel.
• Battery trip control must be done periodically by qualified personnel.
This periodical check is recommended every 6 months and required every
12 months.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
Battery Safety
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Battery circuit breakers must be installed according to the specifications and
requirements as defined by Schneider Electric.
• Servicing of batteries must only be performed or supervised by qualified
personnel knowledgeable of batteries and the required precautions. Keep
unqualified personnel away from batteries.
• Disconnect charging source prior to connecting or disconnecting battery
terminals.
• Do not dispose of batteries in a fire as they can explode.
• Do not open, alter, or mutilate batteries. Released electrolyte is harmful to the
skin and eyes. It may be toxic.
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Batteries can present a risk of electric shock and high short-circuit current. The
following precautions must be observed when working on batteries
• Remove watches, rings, or other metal objects.
• Use tools with insulated handles.
• Wear protective glasses, gloves and boots.
• Do not lay tools or metal parts on top of batteries.
• Disconnect the charging source prior to connecting or disconnecting battery
terminals.
• Determine if the battery is inadvertently grounded. If inadvertently grounded,
remove source from ground. Contact with any part of a grounded battery can
result in electric shock. The likelihood of such shock can be reduced if such
grounds are removed during installation and maintenance (applicable to
equipment and remote battery supplies not having a grounded supply circuit).
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
When replacing batteries, always replace with the same type and number of
batteries or battery packs.
Failure to follow these instructions will result in death or serious injury.
990–5233E–001 9
20 - 120 kVA 400 V
Important Safety Instructions — SAVE THESE
INSTRUCTIONS
CAUTION
RISK OF EQUIPMENT DAMAGE
Batteries must not be stored more than six months due to the requirement of
recharging. If the UPS system remains de-energized for a long period, we
recommend that you energize the UPS system for a period of 24 hours at least
once every month. This charges the batteries, thus avoiding irreversible
damage.
Failure to follow these instructions can result in injury or equipment
damage.
Electromagnetic Compatibility
NOTICE
RISK OF ELECTROMAGNETIC DISTURBANCE
This is a product Category C3 according to IEC 62040-2. This is a product for
commercial and industrial applications in the second environment - installation
restrictions or additional measures may be needed to prevent disturbances. The
second environment includes all commercial, light industry, and industrial
locations other than residential, commercial, and light industrial premises directly
connected without intermediate transformer to a public low-voltage mains
supply. The installation and cabling must follow the electromagnetic compatibility
rules, e.g.:
• the segregation of cables,
• the use of shielded or special cables when relevant,
• the use of grounded metallic cable tray and supports.
Failure to follow these instructions can result in equipment damage.
10 990–5233E–001
Specifications 20 - 120 kVA 400 V
Specifications
Input
UPS rating 20 kVA 30 kVA 40 kVA 60 kVA 80 kVA 100 kVA 120 kVA
Input voltage (V) 380 - 400 - 415
Input voltage range permitted by the
standard according to the curve below
(V)
250 to 470 for a standard UPS
342 to 470 for a UPS with backfeed protection
Input frequency (Hz) 45 to 65
Rated current1
Normal AC input (A)
32 45 57 87 115 143 171
Maximum input current (A) for 400 V 33 46 58 88 116 145 173
Input current (A) for 400V, overload=
1.25 In limited to 10 min.
39 56 72 108 145 181 217
Input current (A) for 400V, overload=1.5
In limited to 1 min.
47 68 87 130 174 217 260
THDI < 6% at full load
< 8% at 25–75% load
Maximum short circuit withstand (kA) 20 30
Input fuse ratings (A) 80 80 80 125 160 315 315
Power Supplied as a Function of Input Voltage
Output
UPS rating 20 kVA 30 kVA 40 kVA 60 kVA 80 kVA 100 kVA 120 kVA
Overload capacity 125% for 10 minutes
150% for 1 minute
220% for 0.1 second
Voltage tolerance (V) 380, 400, 415 ± 3%
Rated output current 29 44 58 87 116 145 174
Output current limitation (A) 190 240 360 480
Output frequency 50 Hz or 60 Hz
THDU ≤ 1% phase to phase, ≤ 1.5% phase to neutral for linear loads
≤ 2.5% phase to phase, ≤ 3.5% phase to neutral for non-linear loads
990–5233E–001 11
1. Rated currents with battery float charging. normal AC input voltage = U, AC bypass input = U, load = 400 V / P load = PN / load cos phi =
0.9
20 - 120 kVA 400 V Specifications
UPS rating 20 kVA 30 kVA 40 kVA 60 kVA 80 kVA 100 kVA 120 kVA
Output fuse rating 80 80 80 125 160 315 315
Crest factor 6.55 4.41 3.27 2.75 3.12 3.33 2.77
Permissible UPS Overloads as a Function of Time
Bypass
UPS rating 20 kVA 30 kVA 40 kVA 60 kVA 80 kVA 100 kVA 120 kVA
Connection type 3PH+N
Input voltage (V) 380 to 443
Input frequency (Hz) 46 to 54
12 990–5233E–001
Specifications 20 - 120 kVA 400 V
Environment
Operating Temperatures
The operating temperature range is 0 to 40 °C, however optimal operation is 20 to
25 °C.
Battery backup time is adversely affected by high and low temperatures. It is
significantly reduced at temperatures under 10 °C.
Above 25 °C, battery service life is reduced by 50% for every 10 °C temperature
increase. Above 40 °C, battery manufacturers no longer guarantee operation due
to the risk of thermal runaway.
Losses calculated with maximum current → V=380 and RL load; cosf: 0.9 @ 100%
load
Heat Dissipation
UPS rating 20 kVA 30 kVA 40 kVA 60 kVA 80 kVA 100 kVA 120 kVA
Losses (kW) 1.61 2.03 2.68 4.26 4.86 6.90 8.41
Heat dissipation
(BTU/hr)
5493 6928 9146 14539 16587 23549 28362
Recommended air throughput (m³/h) 1332 2556
990–5233E–001 13
20 - 120 kVA 400 V Specifications
Batteries
Battery type: Sealed lead-acid or vented lead acid.
DC Power Levels for Battery Sizing with Output Power Factor = 0.9
UPS rating 20 kVA 30 kVA 40 kVA 60 kVA 80 kVA 100 kVA 120 kVA
DC power in
KW
Load 25 % 6.3 8.6 10.9 15.6 20.6 25.2 29.8
Load 50 % 10.9 15.6 20.3 29.7 34.9 48.5 58.1
Load 75 % 15.6 22.6 29.7 44.2 58.9 72.5 87.1
Load 100 % 20.3 29.7 39.4 58.6 78.4 97 116.8
DC Power Levels for Battery Sizing with Output Power Factor = 0.8
UPS rating 20 kVA 30 kVA 40 kVA 60 kVA 80 kVA 100 kVA 120 kVA
DC power in
KW
Load 25 % 5.8 7.8 9.9 14.1 18.5 22.6 26.8
Load 50 % 9.9 14.1 18.2 26.6 33.1 43.4 51.7
Load 75 % 14.1 20.3 26.6 39.4 52.4 64.5 77.3
Load 100 % 18.2 26.6 35.0 52.2 69.6 86.0 103.5
Maximum Current at End of Discharge
UPS rating 20 kVA 30 kVA 40 kVA 60 kVA 80 kVA 100 kVA 120 kVA
Battery (A) 68 101 134 201 268 338 402
Load (A) 29 44 58 87 116 145 174
14 990–5233E–001
20 - 120 kVA 400 V Specifications
Recommended Upstream Circuit Breaker
UPS Rating 20 kVA 30 kVA 40 kVA 60 kVA 80 kVA 100 kVA 120 kVA
Dual utility/
mains
system –
Input
C60L - 50A C60L - 63A NSX 100F 3P-
TM80D
NSX 160F 3P-
TM125D
NSX 160F 3P-
TM160D
NSX 250F 3P-
TM200D
NSX 250F 3P-
TM250D
Dual utility/
mains
system –
Bypass
NSX 100F 4P-
TM100D
NSX 100F 4P-
TM100D
NSX 100F 4P-
TM100D
NSX 160F 4P-
TM125D
NSX 160F 4P-
TM160D
NSX 250F 4P-
TM250D
NSX 250F 4P-
TM250D
Single utility/
mains
system
NSX 100F 4P-
TM100D
NSX 100F 4P-
TM100D
NSX 100F 4P-
TM100D
NSX 160F 4P-
TM125D
NSX 160F 4P-
TM160D
NSX 250F 4P-
TM250D
NSX 250F 4P-
TM250D
WARNING
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Place a label with the following text on each upstream circuit breaker: “Isolate
the Uninterruptible Power Supply (UPS) before working on this circuit”.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
NOTICE
RISK OF EXPLOSION, ARC FLASH OR VOLTAGE OUTAGE
For Installation design, consider:
• the above recommended upstream circuit breaker for discrimination with the
UPS internal fuses.
• Icw = 20 kA for 20 to 60 kVA UPS when using the recommended upstream
circuit breaker.
• Icw = 30 kA for 80 to 120 kVA UPS when using the recommended upstream
circuit breaker.
Failure to follow these instructions can result in equipment damage.
Recommended Downstream Circuit Breaker
UPS rating 20-30-40 kVA 60 kVA 80 kVA 100-120 kVA
Downstream
circuit breaker
C60N C120N NSX100
Trip unit C 16A B 25A C 20A B 32A C 25A B 50A C 32A B 63A TMG 63A
N type curve for the downstream circuit breaker can be replaced by H or L type
curve, depending on the installation. The indicated protection ensures
discrimination for each output circuit downstream of the UPS, whether supplied via
the input or the bypass source.
NOTE: If these downstream protection recommendations are not followed, it
can result in a break in power longer than 20 ms in all the output circuits if a
short circuit occurs on an output circuit.
Earth-Leakage Current
UPS earth-leakage current is 1A.
16 990–5233E–001
Specifications 20 - 120 kVA 400 V
Fuses
Time/Current Curves for UPS Input and Output Fuses
Recommended Cable Sizes
NOTE: Cables length must be less than 100 meters.
UPS rating 20 kVA 30 kVA 40 kVA 60 kVA 80 kVA 100 kVA 120 kVA
Dual utility/
mains
system –
Input (mm²)
10 16 16 25 50 50 70
Dual utility/
mains
system –
Bypass
(mm²)
16 16 16 25 50 70 70
Single utility/
mains
system –
Input &
bypass (mm²)
16 16 16 25 50 70 70
Output (mm²) 16 16 16 25 50 70 70
Battery (<15
m) (mm²)
16 25 35 70 95 2 x 50 2 x 70
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Use power cables of equal resistance, equal length, and equal size for the same
function.
Failure to follow these instructions will result in death or serious injury.
990–5233E–001 17
20 - 120 kVA 400 V Specifications
NOTE: Cable sizes are determined for copper conductors (for aluminium
conductors, increase the size by 30%). Size calculations also take into account
a voltage of 400 V and grouping of four cables.
Terminal hole diameter: 6.5 mm (8.5 mm for 120 kVA).
PE cables (Protective Earth) cables connect to the earthing terminal. Hole
diameter: 6.5 mm (8.5 mm for 120 kVA).
18 990–5233E–001
Specifications 20 - 120 kVA 400 V
Transformers
Marine UPS Adaptation Voltage Transformer Specifications
UPS Rating 60 kVA 80 kVA 120 kVA
Transformation 440V to
400V
690V to
400V
440V to
400V
690V to
400V
440V to
400V
690V to
400V
Topology Dyn11 Dyn11 Dyn11
Primary Voltage (V) 440 +/- 5% 690 +/- 5% 440 +/- 5% 690 +/-
5%
440 +/- 5% 690 +/- 5%
Current (A) 81 52 108 69 162 103
Cable sizes (mm2)235 35 95 35 95 95
Secondary Voltage (V) 400
Current (A)387 116 174
Cable sizes (mm2)235 35 95
Frequency (Hz) 50/60
Efficiency > 97.3% at 40 °C > 97.7% at 40 °C > 98.5% at 40 °C
Overload 110% for 2 hours
Inrush current < 5 x In
Isolation Transformer Specifications
UPS Rating 40 kVA 60 kVA 120 kVA
Voltage (V) 380–400–415 +/- 5%
Frequency (Hz) 50
Efficiency > 97% at 75 °C > 96% at 75 °C > 97% at 75 °C
Overload 110% for 1 hour
Inrush current < 12 Inom 915 A at 380 V < 12 Inom 1095 A at 380 V < 12 Inom 2005 A at 380 V
Power dissipation 1.88 KW / 450 cal/.s 2.61 KW / 624 cal/.s 4.38 KW / 1047 cal/.s
The isolation transformer is DYN05 type. It can be connected to AC input and AC
bypass sources (upstream) and load output (downstream) of a Galaxy 5500 UPS.
The isolation transformer can setup galvanic isolation from upstream power,
network power supply to downstream power absorber. A 3 meter cable is provided
with the transformer to connect it to the UPS, limiting the installation distance
between the UPS and the transformer to under 3 meters.
990–5233E–001 19
2. The suggested cable sizes are for 1000R02V type copper cables less than 100 meters long and for a voltage drop of less than 3%.
3. Full load
20 - 120 kVA 400 V Specifications
NOTE: The current values given in the table below are for nominal utility/mains
voltages and rated load.
The transforming ratio is equal to 1.
UPS Rating 40 kVA 60 kVA 120 kVA
Line current for various
utility/mains voltages (A)
380 V 61 91 182
400 V 58 87 173
415 V 56 84 166
Transformer inrush current (max) 12 x Inom 12 x Inom 11 x Inom
Vector group DYN11 DYN5 DYN5
Cable sizes4(mm2)Power cables 35 35 70
PE cables 16 16 35
20 990–5233E–001
4. The suggested cable sizes are for 1000R02V type copper cables less than 100 meters long and for a voltage drop of less than 3%.
Specifications 20 - 120 kVA 400 V
Battery Circuit Breaker Enclosure
The recommended cable sizes are applicable to U1000R02V type copper cables.
They are calculated in relation to permissible temperature rises and take into
account a maximum line voltage drop of 1 % for a maximum cable length of 25 m.
For greater cable lengths, sizes will be chosen to keep the voltage drop within 1%.
UPS Rating 20 – 120
kVA
100-120 kVA
Runtime ≤ 10 mn > 10 mn
Weight (kg) Enclosure without insulation monitor 15 35
Enclosure with insulation monitor 17 37
WARNING
HAZARD OF FIRE
• Protect the battery circuit with a DC circuit breaker equipped with an
undervoltage coil (MN 24 VDC).
• The DC breaker must be rated. The undervoltage coil must be wired to the
UPS as shown in the connection diagrams below.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
Standard Battery Circuit Breaker Offer
UPS rating 20 kVA 30 kVA 40 kVA 60 kVA 80 – 120
kVA
Maximum battery backup
time at full load5
≤ 30 mn ≤ 15 mn > 15 mn to
≤ 30 mn
≤ 15 mn > 15 mn to
≤ 30 mn
≤ 5 mn > 5 mn to ≤
30 mn
≤ 30 mn
Configuration Internal
batteries
Internal
batteries
External
batteries
Internal
batteries
External
batteries
Internal
batteries
External
batteries
External
batteries
QF1
circuit
breaker
Type NSX160S
DC 3P
NSX160S
DC 3P
NSX400S
DC 3P
NSX160S
DC 3P
NSX400S
DC 3P
NSX160S
DC 3P
NSX400S
DC 3P
NSX400S
DC 3P
Trip unit TM100D TM100D MP1 TM250D MP1 TM250D MP1 MP1
Magnetic
setting (A)
800 800 800 1250 800 1250 800 800
Thermal
setting
1 1 -1-1- -
990–5233E–001 21
5. For other values, consult the after sales department at Schneider Electric or your local agency.
20 - 120 kVA 400 V Specifications
Circuit Breaker Specifications
UPS rating 20 kVA 30 kVA 40 kVA 60 kVA 80 kVA 100 kVA 120 kVA
Requirements • It must be a DC current circuit breaker (Power pole and tripping).
• DC rating must be higher than 500 VDC.
• Breaking capacity must be higher than maximum battery short circuit current.
Mandatory fitted equipment • 24 VDC Undervoltage coil tripping
• Auxiliary dry contact
Current
setting6
Rated
discharge
battery
current (A)
68 101 134 201 268 338 402
Maximum
magnetic
current
Magnetic current setting (lsd) must be less than 50% of maximum battery short circuit current7
Minimum
magnetic
setting (A)8
95.2 141.1 187.6 281.4 375.2 473.2 562.8
NOTE: Due to discharge time limited to battery backup time, circuit breaker
can be overloaded according to battery supplier specifications.
22 990–5233E–001
6. Rated discharge battery current based on nominal load with a power factor of 0.9
7. According to circuit breaker supplier specifications.
8. Including 20% of circuit breaker trip uncertainty. Magnetic must trip below 40 ms for 50% of maximum battery short circuit current.
Mechanical Assembly 20 - 120 kVA 400 V
Mechanical Assembly
NOTE: Not applicable for Galaxy 5500 Marine, see Galaxy 5500 Marine
receiving and unpacking manual.
Clearance Dimensions
UPS with external batteries
NOTE: The clearance dimensions given above are published for airflow and
service access only. Consult with the local safety codes and standards for
additional requirements in your local area.
990–5233E–001 23
Mechanical Assembly 20 - 120 kVA 400 V
Remove Battery Protection
Remove Battery Protection from the UPS
The cardboard protecting the batteries must always be removed once the cabinet
is installed in its final location.
1. Remove the ties holding the cardboard.
2. Remove the cardboard.
3. Remove the struts.
Remove Battery Protection from the External Battery Cabinet
The cardboard protecting the batteries must always be removed once the cabinet
is installed in its final location.
1. Remove the battery support upright.
2. Remove the ties holding the cardboard (1000 mm external battery cabinet).
3. Remove the cardboard protecting the batteries.
990–5233E–001 25
20 - 120 kVA 400 V Mechanical Assembly
4. Remove the ties holding the batteries.
Install the Top Entry Option
NOTE: Tightening torque for all operations is 6.5 Nm.
1. Remove the two screws on the top edges of the UPS left side panel.
2. Install the cable fastening bar using the M5 spacers, the washers, and the M5
screws.
3. Install the panel brackets and spacers.
26 990–5233E–001
20 - 120 kVA 400 V Mechanical Assembly
Install the IP32 Option
NOTE: Not applicable for Galaxy 5500 Marine, see Galaxy 5500 Marine
receiving and unpacking manual.
NOTE: The IP32 option will add 200 mm to the height of the cabinet.
1. Install the protection cover on top of the UPS.
2. Install the posts. The longer posts must be positioned in the front.
3. Install the roof.
4. Install the side deflectors.
28 990–5233E–001
Floor Mounting 20 - 120 kVA 400 V
Floor Mounting
WARNING
HAZARD OF OVERHEATING
Do not remove the cabinet feet as they are required to ensure sufficient
ventilation.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
The measurements include the cabinet side (panels and door).
990–5233E–001 29
20 - 120 kVA 400 V Connect Input and PE Cables in Single Systems
Connect Input and PE Cables in Single Systems
Single Utility/Mains Systems
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
PE cables must be connected first.
Failure to follow these instructions will result in death or serious injury.
1. Fold the dust protection cover as shown on the cover.
2. Remove the protection cover in the bottom of the cabinet.
3. Connect the AC input cables to the bypass terminals and to the UPS earthing
terminal.
4. Connect cables from the input terminals to the bypass terminals.
5. Connect the AC output cables to the output terminals and to the UPS earthing
terminal.
6. Fasten the cables to the cabinet.
7. Reinstall the protection cover for power terminals. Tightening torque is 2 Nm.
8. Unfold the dust protection cover.
Dual Utility/Mains Systems
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
PE cables must be connected first.
Failure to follow these instructions will result in death or serious injury.
30 990–5233E–001
Connect Input and PE Cables in Single Systems 20 - 120 kVA 400 V
1. Fold the dust protection cover as shown on the cover.
2. Remove the protection cover in the bottom of the cabinet.
3. Connect the AC bypass cables to the bypass terminals and to the UPS
earthing terminal.
4. Connect the AC input cables to the input terminals.
5. Connect the AC output cables to the output terminals and to the UPS earthing
terminal.
6. Fasten the cables to the cabinet.
7. Reinstall the protection cover for power terminals. Tightening torque is 2 Nm.
8. Unfold the dust protection cover.
Frequency Converter
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
PE cables must be connected first.
Failure to follow these instructions will result in death or serious injury.
1. Fold the dust protection cover as shown on the cover.
2. Remove the protection cover in the bottom of the cabinet.
3. Connect the AC input neutral cable to the AC bypass neutral terminal.
4. Connect the AC input cables to the input terminals and to the UPS earthing
terminal.
5. Connect the AC output cables to the output terminals and to the UPS earthing
terminal.
990–5233E–001 31
20 - 120 kVA 400 V Connect Input and PE Cables in Single Systems
6. Connect the bypass neutral terminal to the output neutral terminal.
7. Fasten the cables to the cabinet.
8. Reinstall the protection cover for power terminals. Tightening torque is 2 Nm.
9. Unfold the dust protection cover.
32 990–5233E–001
Connect Input and PE Cables in Parallel Systems 20 - 120 kVA 400 V
Connect Input and PE Cables in Parallel Systems
Overview
Single Utility/Mains Systems
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
PE cables must be connected first.
Failure to follow these instructions will result in death or serious injury.
1. Fold the dust protection cover as shown on the cover.
2. Remove the protection cover in the bottom of the cabinet.
3. Connect the AC input cables to the bypass terminals and to the UPS earthing
terminal for each UPS.
4. Connect cables from the input terminals to the bypass terminals for each UPS.
5. Connect the AC output cables to the output terminals and to the UPS earthing
terminal of UPS1.
6. Connect cables from the output terminals of UPS1 to the output terminals of
UPS2.
7. Fasten the cables to the cabinet.
8. Reinstall the protection cover for power terminals. Tightening torque is 2 Nm.
9. Unfold the dust protection cover.
990–5233E–001 33
20 - 120 kVA 400 V Connect Input and PE Cables in Parallel Systems
Dual Utility/Mains Systems
Redundant Parallel System
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
PE cables must be connected first.
Failure to follow these instructions will result in death or serious injury.
1. Fold the dust protection cover as shown on the cover.
2. Remove the terminal protection cover in the bottom of the cabinet.
3. Connect the AC input cables to the input terminals and to the UPS earthing
terminal for each UPS.
4. Connect the AC bypass cables to the bypass terminals and to the UPS
earthing terminal for each UPS.
5. Connect the AC output cables to the output terminals and to the UPS earthing
terminal for UPS1.
6. Connect cables from output terminals of UPS1 to output terminals of UPS2.
7. Fasten the cables to the cabinet.
8. Reinstall the protection cover for power terminals. Tightening torque is 2 Nm.
9. Unfold the dust protection cover.
Parallel System with External Bypass
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
PE cables must be connected first.
Failure to follow these instructions will result in death or serious injury.
1. Fold the dust protection cover as shown on the cover.
2. Remove the protection covers in the bottom of the cabinets.
3. Connect the AC input cables to the input terminals and to the UPS earthing
terminal of each UPS.
4. Connect the AC bypass input cables to the bypass terminals and to the UPS
earthing terminal of the external bypass.
5. Connect the bypass terminals of the UPSs to the bypass terminals of the
external bypass using cables with equal lengths and sizes.
34 990–5233E–001
Connect Input and PE Cables in Parallel Systems 20 - 120 kVA 400 V
6. Connect the AC output cables to the output terminals and to the earthing
terminal of the external bypass.
7. Connect the output terminals of the UPSs to the output terminals of the
external bypass using cables with equal lengths and sizes.
8. Fasten the cables to the cabinet.
9. Reinstall the protection covers for power terminals. Tightening torque is 2 Nm.
10. Unfold the dust protection cover.
990–5233E–001 35
20 - 120 kVA 400 V Connect Input and PE Cables in Parallel Systems
Frequency Converter
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
PE cables must be connected first.
Failure to follow these instructions will result in death or serious injury.
1. Fold the dust protection cover as shown on the cover.
2. Remove the protection cover in the bottom of the cabinet.
3. Connect the neutral cable of AC input to the neutral terminal on the bypass
terminals.
4. Connect the AC input cables to the input terminals and to the UPS earthing
terminal.
5. Connect the input terminal of UPS1 to the input terminal of UPS2.
6. Connect the bypass neutral terminal of UPS1 to the bypass neutral terminal of
UPS2.
7. Connect the AC output cables to the output terminals of UPS1.
8. Connect the output terminals of UPS1 to the output terminals of UPS2.
9. Connect bypass neutral terminal to output neutral terminal on both UPSs.
10. Fasten the cables to the cabinet.
11. Reinstall the protection cover for power terminals. Tightening torque is 2 Nm.
12. Unfold the dust protection cover.
36 990–5233E–001
Connect PE Cable in TNC System 20 - 120 kVA 400 V
Connect PE Cable in TNC System
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
PE cables must be connected for single UPSs, parallel UPSs and external
bypasses.
Failure to follow these instructions will result in death or serious injury.
1. Fold the dust protection cover as shown on the cover.
2. Remove the protection cover in the bottom of the cabinet.
3. Connect the AC input PEN cable to the UPS bypass earthing terminal.
4. Connect the AC output PEN cable to the UPS output earthing terminal.
5. Connect the UPS bypass earthing terminal to the bypass neutral terminal with
the supplied cable.
6. Connect the UPS output earthing terminal to the output neutral terminal with
the supplied cable.
7. Fasten the cables to the cabinet.
8. Reinstall the protection cover for power terminals. Tightening torque is 2 Nm.
9. Unfold the dust protection cover.
990–5233E–001 37
20 - 120 kVA 400 V Connect the Communication Cables
Connect the Communication Cables
Overview of the Communication Cables
Overview of Communication Cables in Single Systems
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Run the communication cables separately from the power cables to ensure
sufficient isolation. If any risk of contact with the power cables exists, reinforce
the insulation of the communication cables.
Failure to follow these instructions will result in death or serious injury.
A. Network management card (SELV)
B. Optional communication cards (SELV or LV)
C. Dry contact communication card (SELV)
D. External battery circuit breaker cables (SELV)
E. General shutdown cable (SELV)
38 990–5233E–001
Connect the Communication Cables 20 - 120 kVA 400 V
Overview of Communication Cables in Parallel Systems
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Run the communication cables separately from the power cables to ensure
sufficient isolation. If any risk of contact with the power cables exists, reinforce
the insulation of the communication cables.
Failure to follow these instructions will result in death or serious injury.
A. Network management card (SELV)
B. Optional communication cards (SELV or LV)
C. Dry contact communication card (SELV)
D. External battery circuit breaker cables (SELV)
E. General shutdown cable (SELV)
F. External bypass cable (ELV), CAN cables (SELV) and exchange-current
cables (SELV)
990–5233E–001 39
20 - 120 kVA 400 V Connect the Communication Cables
Connect Dry Contact Communication Card
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Isolate and tagout/lockout all power sources for the dry contact communication
card (also known as SECI) before making connections. Never connect SELV
(safety extra low voltage) and non-SELV circuits to the different outputs of the
same card.
Failure to follow these instructions will result in death or serious injury.
NOTE: Only one dry contact communication card can be installed in a UPS.
Characteristics of output contacts:
• Permissible voltage: 250 V AC, 30 V DC
• Permissible current: 2 A
• Cable: 4 x 0.93 mm², Ø 6.6 mm +/- 0.3 mm
Pin Description
6 Low battery warning
5 Load on battery power
4 Load on automatic bypass
3 Load on UPS
2 Battery inoperable
1 General alarm
Characteristics of input contacts:
• Switched voltage: 5 V DC
• Consumption: 10 mA
• Cable: 4 x 0.34 mm², Ø 5 mm +/- 0.5 mm
Pin Description
A UPS OFF
B UPS ON
1. Remove the cover fastened by the screws.
2. Run the communication cables through the cable entry holes.
3. Connect the communication cables to the input contacts.
40 990–5233E–001
Connect the Communication Cables 20 - 120 kVA 400 V
4. Connect the communication cables to the output contacts.
5. Reinstall the cover and fasten it with the screws.
6. Tighten the screws to lock the cables.
7. Indicate the location of the power sources on the labels.
8. Install the card in its slot.
9. Fasten the card with two screws.
990–5233E–001 41
20 - 120 kVA 400 V Connect the Communication Cables
Connect Network Management Card
Follow the instructions in the network management card installation manual 990-
3194.
Example of Communication Card Connection
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
If a SELV source is used, isolate the communication card from the power source
to ensure the safety of personnel working on the installation.
Failure to follow these instructions will result in death or serious injury.
Add or Change Communication Cards
1. Open the UPS door. The cardholder for optional communication cards is
placed on the inside of the door.
42 990–5233E–001
20 - 120 kVA 400 V Connect the Communication Cables
Connect General Shutdown or Remote Emergency Power Off
Pressing the general shutdown button causes UPS shutdown and opening of the
battery circuit breaker (When the opening of the bypass static switch is disabled
through customization settings, then the installer must make sure that the source
disconnection will be managed at upstream level). A Remote Emergency Power
Off (REPO) is applicable to installations where pressing the button also causes the
AC input source and AC bypass source circuit breakers to open. In parallel
systems, there must be a single general shutdown button with a separate contact
for each UPS unit.
To locate the terminals in the cabinet, see Overview of the Communication
Cables, page 38
1. Remove the wire jumper from the terminal block.
2. Connect the general shutdown (Normally Closed) contact to XMB06 terminals
1 and 2 (SELV).
3. Fasten the cable.
Connect Parallel Communication Cables
Redundant Parallel System
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
De-energize the UPSs before connecting the cables.
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
A maximum of two UPSs can be installed in parallel.
Failure to follow these instructions will result in death or serious injury.
NOTE: The supplied cables (10 m) limit the distance between the two UPSs to
approximately six meters.
To locate the terminals in the cabinet, see Overview of the Communication
Cables, page 38
1. Connect a communication cable from XMS02 of UPS1 to XMS02 of UPS2.
2. Connect a communication cable from XMS03 of UPS1 to XMS03 of UPS2.
3. Install a blue terminator in connector XMS06 of UPS1.
4. Connect a communication cable from XMS07 of UPS1 to XMS06 of UPS2.
44 990–5233E–001
Connect the Communication Cables 20 - 120 kVA 400 V
5. Install a red terminator in connector XMS07 of UPS2.
6. Install the supplied protection cover over the communication cables.
Parallel System with External Bypass
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
De-energize the UPSs before connecting the cables.
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
A maximum of two UPSs can be installed in parallel. (Four UPSs can be present
in redundancy parallel system).
Failure to follow these instructions will result in death or serious injury.
NOTE: The supplied cables (10 m) limit the distance between the two UPSs to
approximately six meters.
To locate the terminals in the cabinet, see Overview of the Communication
Cables, page 38
1. Connect the communication cables to XMS02 and XMS03 terminals as
shown, creating a loop between all the UPSs.
2. Connect the communication cables to XMS06 and XMS07 terminals as
shown, creating a loop between all the UPSs.
3. Install a blue terminator in connector XMS06 of UPS1.
4. Install a red terminator in connector XMS07 of UPS4.
990–5233E–001 45
20 - 120 kVA 400 V Connect the Communication Cables
5. Connect the external bypass terminals 1,3,5 as shown.
6. Connect the external bypass terminals 1,2,4,6 to XMS04 and XMS05
terminals of the UPSs as shown, using maximum size 2.5 mm² cables.
7. Install the supplied protection cover over the communication cables.
46 990–5233E–001
Install an External Battery 20 - 120 kVA 400 V
Install an External Battery
Lock Battery Cells on Shelves for Marine UPS
CAUTION
FOR INSTALLATION ON SHIP – RISK OF ELECTRICAL DISCONNECTION
Install wedges as shown below.
Failure to follow these instructions can result in injury or equipment
damage.
Rear wedges are already mounted on the shelves.
Depending on battery cells configuration, some provided wedges remain unused.
Shelf types
Top View, Wedges Filled in Grey Color
UPS power
rating
Number of shelves to mount by shelf type
A B C D E
20 - 30 kVA 3 1 0 0 0
40 – 60 kVA 0 0 3 1 0
80 – 100 kVA90 0 3 1 4
120 kVA90 0 6 2 0
1. Install the battery cells on the shelves according to the documentation
supplied by the battery vendor.
2. Mount the back wedge (20 - 30 kVA only).
3. Mount the sides wedges.
4. Mount the front wedges.
Connect the Battery Cables
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Connect PE cables to the battery cabinet and the UPS first.
Failure to follow these instructions will result in death or serious injury.
990–5233E–001 47
9. Two battery cabinets.
Install an External Battery 20 - 120 kVA 400 V
Install An Empty Battery Cabinet
Install Battery Circuit Breaker Kit
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• It is mandatory to protect the battery circuit with a circuit breaker equipped
with an undervoltage coil (MN 24V DC).
• Circuit breaker type and rated must be compliant with specifications given.
See Battery Circuit Breaker Enclosure, page 21
Failure to follow these instructions will result in death or serious injury.
NOTE: Please contact Schneider Electric when selecting the battery circuit
breaker. In systems with several battery cabinets, only one circuit breaker is
necessary. Temperature sensors must be installed to obtain the battery
warranty and to optimize battery lifetime.
1. Fasten the circuit breaker plate (four screws).
2. Fasten the XR1 terminals.
3. Fasten the temperature sensor.
4. Fasten the protection cover after connecting the batteries to the battery circuit
breaker. Tightening torque is 6.5 Nm.
990–5233E–001 49
20 - 120 kVA 400 V Install an External Battery
Install Shelves and Battery Cells
NOTE: Assembly of the battery cabinet must be carried out by certified
personnel (standard EN 62040-1).
NOTE: The minimum clearance between the top of the battery cells and the
next shelf above them is 150 mm.
1. Fasten the angle supports (six screws per support).
2. Position the shelves individually.
3. Fasten the shelves individually with two screws in each angle.
4. Install the battery cells on each shelf, fasten and interconnect them per shelf.
5. Interconnect all the battery assemblies from the different shelves and then
connect the overall battery assembly to the battery circuit breaker.
50 990–5233E–001
Install an External Battery 20 - 120 kVA 400 V
Connect the Battery Remote Control
WARNING
RISK OF EQUIPMENT DAMAGE
The maximum size for the communication cables (SELV) is 2.5 mm² and the
total length must be less than 100 meters.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
1. Connect the external battery cabinet connector XR1 to UPS connector
XMB07, as shown.
990–5233E–001 51
Install a Battery Circuit Breaker Kit for Third Party Battery
Cabinets (Option) 20 - 120 kVA 400 V
Install a Battery Circuit Breaker Kit for Third Party
Battery Cabinets (Option)
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
This battery circuit breaker kit contains an undervoltage coil (MN 24 VDC) which
is mandatory for all external battery cabinets. This battery circuit breaker is for
installations with third party batteries.
Failure to follow these instructions will result in death or serious injury.
1. Mount the fixing bar onto the battery cabinet.
2. Position the battery circuit breaker on the fixing bar and fasten with 2 screws.
3. Bolt the support plate for the connector XR1 to the front upright of the cabinet.
Bottom View of the Battery Cabinet
4. Attach XR1 to the support plate.
990–5233E–001 53
20 - 120 kVA 400 V
Install a Battery Circuit Breaker Kit for Third Party Battery
Cabinets (Option)
5. Connect the battery circuit breaker to XR1. The connecting cables (2.5 m) are
supplied (N° 51031630).
6. Connect XR1 to the ATIZ board.
Side View of the Battery Cabinet
7. The terminals 1 to 4 of the XR1 terminal block must be connected to the UPS
to provide the functions for automatic opening of battery circuit breaker QF1
(in case of emergency shutdown) and detection of the battery circuit breaker
position for the UPS. Details of these connections are given in the installation
manuals of these units.
8. Place the QF1 protection cover over the circuit breaker and its connections.
Side View of the Battery Cabinet
54 990–5233E–001
20 - 120 kVA 400 V Battery Circuit Breaker Enclosure (Option)
Battery Circuit Breaker Enclosure (Option)
Overview
The circuit breaker enclosure must be located as close to the batteries as possible.
The enclosure is mounted to a vertical wall by means of four M8 screws using the
fastening lugs placed in the vertical or horizontal position.
The enclosure door is closed by two lock knobs with a key (405 type) on one of the
knobs.
The enclosure with insulation controller has the same characteristics as the
standard version (except for dimensions), with the insulation controller being
located in the upper part of the enclosure door.
Cables are fed through the bottom of the enclosure via a 315 x 90 mm opening.
20–120 kVA Battery Circuit Breaker Enclosure with up to 10 Minutes Runtime
56 990–5233E–001
Battery Circuit Breaker Enclosure (Option) 20 - 120 kVA 400 V
100–120 kVA Battery Circuit Breaker Enclosure with More Than 10 Minutes
Runtime
Connection Diagrams
• The size of the power cables is given in the tables above.
• The recommended size of auxiliary cables is 1 mm2(terminal acceptance
capacity: 2.5 mm2).
• Make sure that the auxiliary cables and power cables do not follow the same
path.
• Power cables and auxiliary cables are not supplied.
990–5233E–001 57
20 - 120 kVA 400 V Battery Circuit Breaker Enclosure (Option)
Connection Points
UPS rating 20 – 120 kVA 100 – 120 kVA
Battery backup time ≤ 10 min > 10 min
connection to UPS 25 x 5 mm copper terminal
8.2 mm diameter holes
32 x 8 mm copper terminal
12.2 mm diameter holes
battery 32 x 10 mm copper terminal
12.2 mm diameter holes
earth 50 x 5 mm copper terminal, or
8 mm threaded rod
Install Battery Circuit Breaker Enclosure
1. Drill appropriate holes in a wall and mount the battery circuit breaker
enclosure to the wall as close to the batteries/battery cabinet(s) as possible.
2. Open the door of the battery circuit breaker enclosure.
3. Connect the PE terminal to PE.
4. Connect B- and B+ terminals to the battery B- and B+ terminals.
58 990–5233E–001
20 - 120 kVA 400 V Install the Battery Temperature Monitor (Option)
Install the Battery Temperature Monitor (Option)
1. Install the temperature monitor in the battery cabinet.
2. Connect the temperature monitor to the XMD3 connector in the UPS, and
pass the cable through the ferrite three times.
60 990–5233E–001
20 - 120 kVA 400 V Install the Synchronization Module (Option)
1. Mark the four mounting hole locations on the wall. You can either use the
horizontal or the vertical mounting brackets. Drill holes in each of the four
marked locations and install plugs.
2. Place the synchronization module enclosure against the wall lining up with the
holes and fasten the synchronization module enclosure to the wall with four
screws.
Recommended Cable Sizes
A 12m long Sub D9/Sub D15 (XF1/XF2 to XFSY4/XFSY5) cable is supplied for
each UPS.
You can make a longer cable (maximum length is 150 m) using the pinout diagram
below connecting only the 4 twisted wires shown.
Connection Cable length Recommended cable
XF1/XF2 to XFSY4/XFSY5 < 20 m Unshielded twisted pair cable
AWG24
XF1/XF2 to XFSY4/XFSY5 > 20 m Unshielded twisted pair cable
AWG18
XR1 – XR3 All Unshielded cable 1.5 mm²
Connect Cables to the Synchronization Module for Single UPS
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
The synchronization module must be earthed at one point only.
Failure to follow these instructions will result in death or serious injury.
62 990–5233E–001
Install the Synchronization Module (Option) 20 - 120 kVA 400 V
1. Connect power cables from UPS 1 to the synchronization module according to
the illustration above.
2. Connect power cables from UPS 2 to the synchronization module according to
the illustration above.
3. Connect the supplied 12 m Sub D9/Sub D15 cable from terminal XFSY5 on
the SYNIN board in UPS 1 to XF2 on the COSS board in the synchronization
module.
4. Connect the supplied 12 m Sub D9/Sub D15 cable from terminal XFSY5 on
the SYNIN board in UPS 2 to XF1 on the COSS board in the synchronization
module.
Connect Cables to the Synchronization Module in a Parallel
System
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
The synchronization module must be earthed at one point only.
Failure to follow these instructions will result in death or serious injury.
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20 - 120 kVA 400 V Install the Synchronization Module (Option)
1. Connect power cables between all UPS units in Group 1 and connect them to
the synchronization module.
2. Connect the supplied 12 m Sub D9/Sub D15 cables between the SYNIN
boards in the UPS units, and connect Sub D9/Sub D15 cable from the last
UPS in the row to the COSS board in the synchronization module.
3. Connect Group 2 to the synchronization module according to the procedures
in step 1 and 2 above.
64 990–5233E–001
Install the Synchronization Module (Option) 20 - 120 kVA 400 V
Input and Output Contacts
Characteristics
The Phase in tolerance,Major malfunction,UPS 1 controlled, and UPS 2
controlled relay contacts have a breaking capacity of 30 W maximum (on resistive
load) for 2 A maximum current.
Permissible voltage: SELV only.
The contacts are represented in unactuated state.
Outputs
XM1 terminals 1–6 UPS 1 controlled
XM1 terminals 7–12 UPS 2 controlled
XM2 terminals 1–6 Phase within tolerance
XM2 terminals 7–12 Major alarm
Inputs
XM3 terminals 7–8 UPS supplied by utility/mains
XM3 terminals 9–10 UPS supplied by generator set
990–5233E–001 65
20 - 120 kVA 400 V Install an External Bypass
Install an External Bypass
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
The combined UPS power of all the installed UPS cabinets must not exceed the
available bypass power.
Failure to follow these instructions will result in death or serious injury.
Install 150 kVA External Bypass Cabinet
TNS
1. Prepare the external bypass cabinet for cables by clearing the cable running
entries.
2. Connect the external bypass cabinet to earth.
3. Connect the bypass cables from the terminals (N, L1, L2, L3) in the external
bypass cabinet to the bypass terminals (N, L1, L2, L3) on the UPSs.
4. Connect the bypass cables from the AC bypass source to the terminals (N, L1,
L2, L3) in the external bypass cabinet.
5. Connect the load cables from the load to the terminals (N, L1, L2, L3) in the
external bypass cabinet.
66 990–5233E–001
Install an External Bypass 20 - 120 kVA 400 V
6. Connect the AC output cables from output terminals (N, L1, L2, L3) in the
UPSs to the terminals (N, L1, L2, L3) in the external bypass cabinet.
NOTE: Connection of the communication cables is shown in Parallel
System with External Bypass, page 34.
TNC
1. Prepare the external bypass cabinet for cables by clearing the cable running
entries.
2. Connect the external bypass cabinet to earth and neutral (PEN).
3. Connect the bypass cables from the terminals (L1, L2, L3) in the external
bypass cabinet to the bypass terminals (L1, L2, L3) on the UPSs.
4. Connect the bypass cables from the AC bypass source to the terminals (L1,
L2, L3) in the external bypass cabinet.
5. Connect the load cables from the load to the terminals (L1, L2, L3) in the
external bypass cabinet.
6. Connect the AC output cables from the output terminals (L1, L2, L3) in the
UPSs to the terminals (L1, L2, L3) in the external bypass cabinet.
NOTE: Connection of the communication cables is shown in Parallel
System with External Bypass, page 34.
990–5233E–001 67
20 - 120 kVA 400 V Install an External Bypass
Install 400 kVA External Bypass Cabinet
TNS
1. Prepare the external bypass cabinet for cables by clearing the cable running
entries.
2. Connect the external bypass to earth.
3. Connect the bypass cables from the terminals (N, L1, L2, L3) in the external
bypass cabinet to the bypass terminals (N, L1, L2, L3) on the UPSs through
the top cable entry.
4. Connect the bypass cables from the AC bypass source to the terminals (N, L1,
L2, L3) in the external bypass cabinet.
5. Connect the load cables from the load to the terminals (N, L1, L2, L3) in the
external bypass cabinet.
6. Connect the AC output cable from output terminals (N, L1, L2, L3) in the UPSs
to the terminals (N, L1, L2, L3) in the external bypass cabinet.
NOTE: Connection of the communication cables is shown in Parallel
System with External Bypass, page 34.
68 990–5233E–001
Install an External Bypass 20 - 120 kVA 400 V
TNC
1. Prepare the external bypass cabinet for cables by clearing the cable running
entries.
2. Connect the external bypass cabinet to earth.
3. Connect the bypass cables from the terminals (PEN, L1, L2, L3) in the
external bypass cabinet to the bypass terminals (PEN, L1, L2, L3) on the
UPSs through the top cable entry.
4. Connect the bypass cables from the AC bypass source to the terminals (PEN,
L1, L2, L3) in the external bypass cabinet.
5. Connect the load cables from the load to the terminals (PEN, L1, L2, L3) in the
external bypass cabinet.
6. Connect the AC output cables from output terminals (PEN, L1, L2, L3) in the
UPSs to the terminals (N, L1, L2, L3) in the external bypass cabinet.
NOTE: Connection of the communication cables is shown in Parallel
System with External Bypass, page 34.
990–5233E–001 69
20 - 120 kVA 400 V Install Marine UPS Adaptation Voltage Transformer
Install Marine UPS Adaptation Voltage Transformer
For transformer specifications, see Transformers, page 19.
WARNING
HAZARD OF OVERHEATING
• Do not cover the transformer ventilation openings when the transformer is in
operation.
• Do not remove the transformer feet.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
Install the transformer according to the documentation supplied by the transformer
vendor.
70 990–5233E–001
Install Isolation Transformer (Option) 20 - 120 kVA 400 V
Install Isolation Transformer (Option)
For transformer specifications, see Transformers, page 19.
NOTE: A transformer cabinet can only be placed to the right of the UPS
cabinet.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH
Do not install different transformer sizes that belong to different vector groups in
the same UPS installation.
Failure to follow these instructions will result in death or serious injury.
990–5233E–001 71
20 - 120 kVA 400 V Install Isolation Transformer (Option)
Transformer Configuration Options in Single Systems
For Single Transformer Connected to Input
Upstream: TT, TN or IT system
Downstream: with neutral distributed
Dual Utility/Mains System
Single Utility/Mains System
Dual Utility/Mains System
For Single Transformer Connected to Output
Upstream: TT, TN system
Downstream: with neutral distributed
Dual Utility/Mains System
72 990–5233E–001
Install Isolation Transformer (Option) 20 - 120 kVA 400 V
Single Utility/Mains System
For Transformers Connected to Output and/or One or Two Sources
Upstream: TT, TN or IT system
Downstream: with neutral distributed
Dual Utility/Mains System
Single Utility/Mains System
Dual Utility/Mains System
990–5233E–001 73
20 - 120 kVA 400 V Install Isolation Transformer (Option)
Transformer Configuration Options in Parallel UPS System
WARNING
RISK OF EQUIPMENT DAMAGE
Before turning on the UPS system, make sure that N on the UPSs are parallel
connected and that the output of the UPSs are parallel connected as shown in
the diagram below. This requires extra cables which are not provided by
Schneider Electric.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
A maximum of four UPSs plus transformers can be connected in parallel.
Transformers must be earthed correctly.
• Use power cables of equal resistance, equal length and equal size for the
same function.
• To choose the correct upstream circuit breaker, see the table in Install
Isolation Transformer (Option), page 71.
Failure to follow these instructions will result in death or serious injury.
Two UPSs in Parallel
74 990–5233E–001
Install Isolation Transformer (Option) 20 - 120 kVA 400 V
Four UPSs in Parallel
Install Input Isolation Transformer
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Connect PE cables to the transformer first.
Failure to follow these instructions will result in death or serious injury.
990–5233E–001 75
20 - 120 kVA 400 V Install Isolation Transformer (Option)
1. Connect a cable from the transformer input terminals (L1, L2, L3) to the utility/
mains supply.
Input Terminals on the Transformer
2. On the input transformer terminals, do the following interconnections
depending on your available voltage from the utility/mains supply at input side
to transformer:
a. Utility/mains supply 380 V: Interconnect the terminals as shown.
Transformer Input Cable Interconnection— Utility/Mains Supply 380
V
76 990–5233E–001
Install Isolation Transformer (Option) 20 - 120 kVA 400 V
b. Utility/mains supply 400 V: Interconnect the terminals as shown.
Transformer Input Cable Interconnection— Utility/Mains Supply 400
V
c. Utility/mains supply 420 V: Interconnect the terminals as shown.
Transformer Input Cable Interconnection— Utility/Mains Supply 420
V
990–5233E–001 77
20 - 120 kVA 400 V Install Isolation Transformer (Option)
3. Connect the following cables as per your system:
a. An AC Input transformer for single utility/mains systems: Connect
L1, L2, L3 from the input terminals to the bypass terminals on the UPS.
Connect a cable from the transformer output terminals (L1, L2, L3) to the
UPS bypass terminals (L1, L2, L3) and to PE.
b. An AC Bypass transformer for dual utility/mains systems: Connect a
cable from the transformer output terminals (L1, L2, L3, N) to the UPS
bypass terminals (L1, L2, L3, N) and to PE.
c. An AC Input transformer for dual utility/mains systems: Connect a
cable from the transformer output terminals (L1, L2, L3) to the UPS input
terminals (L1, L2, L3) and to PE.
78 990–5233E–001
Install Isolation Transformer (Option) 20 - 120 kVA 400 V
Output Terminals on the Transformer
NOTE: The neutral cable is not supplied.
Install Output Isolation Transformer
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Connect PE cables to the transformer first.
Failure to follow these instructions will result in death or serious injury.
990–5233E–001 79
Install Isolation Transformer (Option) 20 - 120 kVA 400 V
2. On the input transformer terminals, do the following interconnections
depending on your available voltage from the utility/mains supply at input side
to transformer:
a. Utility/mains supply 380 V: Interconnect the terminals as shown.
Transformer Input Cable Interconnection— Utility/Mains Supply 380
V
b. Utility/mains supply 400 V: Interconnect the terminals as shown.
Transformer Input Cable Interconnection— Utility/Mains Supply 400
V
c. Utility/mains supply 420 V: Interconnect the terminals as shown.
Transformer Input Cable Interconnection— Utility/Mains Supply 420
V
990–5233E–001 81
20 - 120 kVA 400 V Install Isolation Transformer (Option)
3. Connect a cable from the transformer output terminals (L1, L2, L3, N) to the
load.
Output Terminals on the Transformer
4. For output transformers in parallel systems: parallel connect N between the
output terminals on the UPSs and parallel connect the output of the UPSs.
See Transformer Configuration Options in Parallel UPS System, page 74 for
details. This requires extra cables which are not provided by Schneider
Electric.
82 990–5233E–001
Schneider Electric
35 rue Joseph Monier
92500 Rueil Malmason
France
+ 33 (0) 1 41 29 70 00
www.schneider-electric.com
As standards, specifications, and design change from time to time,
please ask for confirmation of the information given in this publication.
© 2013 – 2018 . All rights reserved.
990–5233E–001