Table of Contents
- Important Safety Instructions — SAVE THESE INSTRUCTIONS
- Specifications
- Installation Procedure for System with PDU with Modular Batteries
- Installation Procedure for Systems with UPS and Modular or Classic Batteries
- Mechanical Assembly
- Rearrange the Side Panels
- Prepare the UPS for Cables
- Prepare the UPS for Cables in Top Cable Entry Systems with Conduits
- Prepare the UPS for Cables in Top Cable Entry Systems without Conduits
- Prepare the UPS for Cables in Bottom Cable Entry Systems without Conduits
- Prepare the UPS for Cables in Bottom Cable Entry Systems with Conduits
- Access the Cable Connection Area in the UPS
- Prepare the PDU with Modular Batteries for Cables
- Access the Cable Connection Area of the PDU with Modular Batteries
- Prepare the PDU with Modular Batteries for Cables in Top Cable Entry Systems
- Prepare the PDU with Modular Batteries for Cables in Bottom Cable Entry Systems with Front Cable Entry without Conduits
- Prepare the PDU with Modular Batteries for Cables in Bottom Cable Entry Systems with Front Cable Entry with Conduits
- Connect the Communication Cables
- Connect the Battery Breaker Trip Cables and Communication Cables in Installations with UPS and PDU with Modular Batteries
- Connect the Battery Breaker Trip Cables and the Communication Cables in Installations With UPS and Modular Battery Cabinets
- Connect the Network Communication Cable
- Connect the Emergency Power Off (EPO) Switch
- Perform Equipotential Bonding
- Connect Power Cables Between the UPS and the PDU with Modular Batteries
- Interconnect the Cabinets
- Level the Cabinets
- Connect Power Cables
- Install the Maintenance Bypass Cabinet (Option)
- Remove the Breaker Cover Panel from the Maintenance Bypass Cabinet
- Prepare the Maintenance Bypass Cabinet for Cables in Bottom Cable Entry Systems
- Prepare the Maintenance Bypass Cabinet for Cables in Top Cable Entry Systems
- Connect Power Cables between the UPS and the Maintenance Bypass Cabinet
- Connect Input and Output Power Cables to the Maintenance Bypass Cabinet
- Install the Battery Solution
- Post-Installation Checklist
APC SY128K160H-NB User Manual
Displayed below is the user manual for SY128K160H-NB by APC which is a product in the Uninterruptible Power Supplies (UPSs) category. This manual has pages.
Related Manuals
Symmetra™ PX
96 and 160 kW 400 V
Installation
3/2019
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
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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
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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.
96 and 160 kW 400 V
Table of Contents
Important Safety Instructions — SAVE THESE
INSTRUCTIONS.........................................................................................5
Electromagnetic Compatibility .....................................................................6
Safety Precautions .....................................................................................6
Electrical Safety....................................................................................8
Battery Safety.......................................................................................9
Specifications ............................................................................................ 11
Input Specifications .................................................................................. 11
Bypass Specifications ............................................................................... 11
Output Specifications................................................................................12
Required Upstream and Downstream Protection.........................................12
Single and Dual Mains Systems ........................................................... 12
Modular Battery Specifications ..................................................................13
Classic Battery Specifications....................................................................13
Heat Dissipation .......................................................................................14
Installation Procedure for System with PDU with Modular
Batteries .....................................................................................................15
Installation Procedure for Systems with UPS and Modular or
Classic Batteries .......................................................................................16
Mechanical Assembly ..............................................................................17
Rearrange the Side Panels........................................................................17
Prepare the UPS for Cables ......................................................................18
Prepare the UPS for Cables in Top Cable Entry Systems with
Conduits ............................................................................................18
Prepare the UPS for Cables in Top Cable Entry Systems without
Conduits ............................................................................................19
Prepare the UPS for Cables in Bottom Cable Entry Systems without
Conduits ............................................................................................19
Prepare the UPS for Cables in Bottom Cable Entry Systems with
Conduits ............................................................................................20
Access the Cable Connection Area in the UPS......................................22
Prepare the PDU with Modular Batteries for Cables.....................................24
Access the Cable Connection Area of the PDU with Modular
Batteries ............................................................................................24
Prepare the PDU with Modular Batteries for Cables in Top Cable
Entry Systems ....................................................................................25
Prepare the PDU with Modular Batteries for Cables in Bottom Cable
Entry Systems with Front Cable Entry without Conduits .........................26
Prepare the PDU with Modular Batteries for Cables in Bottom Cable
Entry Systems with Front Cable Entry with Conduits ..............................26
Connect the Communication Cables .....................................................27
Connect the Battery Breaker Trip Cables and Communication Cables in
Installations with UPS and PDU with Modular Batteries ...............................27
Connect the Battery Breaker Trip Cables and the Communication Cables
in Installations With UPS and Modular Battery Cabinets ..............................30
Connect the Network Communication Cable...............................................33
990-3017K-001 3
96 and 160 kW 400 V
Connect the Emergency Power Off (EPO) Switch .......................................34
Perform Equipotential Bonding...............................................................36
Connect Power Cables Between the UPS and the PDU with
Modular Batteries......................................................................................37
Interconnect the Cabinets........................................................................40
Level the Cabinets ....................................................................................41
Connect Power Cables ............................................................................42
Connect Power Cables in Installations with UPS and PDU with Modular
Batteries ..................................................................................................42
Connect the Input Cables in the PDU with Modular Batteries ..................42
Connect the PDU Subfeed Breakers ....................................................46
Install Power Distribution Modules in the PDU with Modular
Batteries ............................................................................................48
Connect Power Cables in Systems with UPS and Modular Battery
Cabinets or Classic Battery Cabinets .........................................................53
Connect the Power Cables in the UPS..................................................53
Connect Power Cables in Single Mains Installations ..............................53
Connect Power Cables in Dual Mains Installations ................................54
Connect the Battery Cables in the UPS ......................................................56
Connect Battery Cables to the UPS in Systems with Modular Battery
Solution and Side Cable Entry .............................................................56
Connect Battery Cables to the UPS – Top and Bottom Cable
Entry..................................................................................................57
Install the Maintenance Bypass Cabinet (Option)................................59
Remove the Breaker Cover Panel from the Maintenance Bypass
Cabinet....................................................................................................59
Prepare the Maintenance Bypass Cabinet for Cables in Bottom Cable
Entry Systems..........................................................................................60
Prepare the Maintenance Bypass Cabinet for Cables in Top Cable Entry
Systems ..................................................................................................61
Connect Power Cables between the UPS and the Maintenance Bypass
Cabinet....................................................................................................62
Connect Input and Output Power Cables to the Maintenance Bypass
Cabinet....................................................................................................64
Install the Battery Solution.......................................................................66
Install the Modular Battery Solution ............................................................66
Connect the Battery Cables between the Modular Battery
Cabinets ............................................................................................66
Install the Classic Battery Solution .............................................................70
Prepare the Classic Battery Cabinet for Installation ...............................70
Install Classic Battery Cabinet..............................................................70
Post-Installation Checklist .......................................................................82
4 990-3017K-001
Important Safety Instructions — SAVE THESE
INSTRUCTIONS 96 and 160 kW 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.
990-3017K-001 5
96 and 160 kW 400 V
Important Safety Instructions — SAVE THESE
INSTRUCTIONS
Electromagnetic Compatibility
NOTICE
RISK OF ELECTROMAGNETIC DISTURBANCE
This is a product category C2 UPS product. In a residential environment, this
product may cause radio inference, in which case the user may be required to
take additional measures.
Failure to follow these instructions can result in equipment damage.
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.
6 990-3017K-001
Important Safety Instructions — SAVE THESE
INSTRUCTIONS 96 and 160 kW 400 V
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.
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.
990-3017K-001 7
96 and 160 kW 400 V
Important Safety Instructions — SAVE THESE
INSTRUCTIONS
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.
Electrical Safety
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Electrical equipment must be installed, operated, serviced, and maintained
only by qualified personnel.
• 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 mains supply. Before installing or
servicing the UPS system, ensure that the units are OFF and that mains and
batteries are disconnected. Wait five minutes before opening the UPS to
allow the capacitors to discharge.
• 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):
8 990-3017K-001
Important Safety Instructions — SAVE THESE
INSTRUCTIONS 96 and 160 kW 400 V
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.
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.
990-3017K-001 9
96 and 160 kW 400 V
Important Safety Instructions — SAVE THESE
INSTRUCTIONS
NOTICE
RISK OF EQUIPMENT DAMAGE
• Wait until the system is ready to be powered up before installing batteries in
the system. The time duration from battery installation until the UPS system
is powered up must not exceed 72 hours or 3 days.
• 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,
Schneider Electric recommends 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 equipment damage.
10 990-3017K-001
Specifications 96 and 160 kW 400 V
Specifications
All below values are based on 96 kW and 160 kW maximum configurations. If the
cables and current protection are configured for a 96 kW system, only six power
modules must be installed in the system. To upgrade to a 160 kW system, a
redimensioning of cables and current protections is required.
NOTE: All electrical power and power control wiring must be installed by a
qualified electrician, and must comply with local and national regulations for
maximum power rating.
Input Specifications
96 kW 160 kW
380 V 400 V 415 V 380 V 400 V 415 V
Connection type 3PH + N + PE1
Input frequency
(Hz)
40–70
Total harmonic
distortion (THDI)
< 5% at full load
Nominal input
current (A)2
154 146 141 256 243 234
Maximum input
current (A)3
169 160 155 281 267 258
Input current
limitation (A)4
197 197 197 295 295 295
Input power
factor correction
> 0.98 at load > 50%
Maximum short
circuit level Icc
(kA)
Rated conditional short–circuit current Icc: 30 kA.
Rated peak withstand current Ipk: Icc x 1.7.
Device: Refer to Required Upstream and Downstream Protection, page 12.
Bypass Specifications
96 kW 160 kW
380 V 400 V 415 V 380 V 400 V 415 V
Connection type 3PH + N + PE1
Input frequency
(Hz)
40–70
Nominal input
current (A)
147 139 134 243 231 223
Maximum short
circuit level Icc
(kA)
Rated conditional short–circuit current Icc: 30 kA.
Rated peak withstand current Ipk: Icc x 1.7.
Device: Refer to Required Upstream and Downstream Protection, page 12.
990-3017K-001 11
1. TN, TT, and IT power distribution systems with no earthed line conductors are supported.
2. Input current is based on nominal voltage and rated load, batteries fully charged
3. Input current is based on nominal voltage, rated load and full battery charge current.
4. Integrated electronic current limitation functionality.
96 and 160 kW 400 V Specifications
Output Specifications
96 kW 160 kW
380 V 400 V 415 V 380 V 400 V 415 V
Connection type 3PH + N + PE
Output capacity 150% for 60 seconds (normal operation)
125% for 10 minutes (normal operation)
150% for 60 seconds (battery operation)
125% for 10 minutes (battery operation)
100% load (bypass operation)
1000% for 100 ms (bypass operation)
Nom output
current (A)
147 139 134 243 231 223
Output
frequency (sync
to bypass)
47–53 Hz for 50 Hz nominal5
Slew rate (Hz/
sec)
Programmable to 0.25, 0.5, 1, 2, 4, and 6
Total harmonic
distortion
(THDU)
< 2% linear
< 5% non-linear
Output power
factor
0.5 leading to 0.5 lagging without derating
Dynamic load
response
+/- 5%
Output voltage
regulation
+/- 1%
Crest factor 2.7
Required Upstream and Downstream Protection
The specified upstream breakers below are required to obtain the conditional
short-circuit current rating, Icc at 30 kA symmetrical rms.
Single and Dual Mains Systems
Input and Bypass
With Breaker PowerPact NLGF36400U3XTW
96 kW 160 kW
Input Bypass Input Bypass
Trip setting 96 kW 96 kW 160 kW 160 kW
Ir (A) 225 160 400 250
Ir (@ 6 Ir)60.5–16 0.5–16 0.5–16 0.5–16
li (x In) 1.5–12 1.5–12 1.5–12 1.5–12
12 990-3017K-001
5. The following options can be selected: 40–60 Hz, 47–53 Hz, 49.9–50.1 Hz.
6. Ir and Isd must be set by the installer based on the installation coordination
Specifications 96 and 160 kW 400 V
Output
96 kW 400 V 160 kW 400 V
Fuse Breaker (A) Fuse Breaker (A)
Battery breaker (max
value)7
—550 —550
UPS output Q2 160 A gL type fuse 160 250 A gL type fuse 250
Modular Battery Specifications
NOTE: The batteries must be connected to a DC rated circuit breaker.
Battery Type Sealed lead–acid
Nominal voltage (VDC) +/- 192 (96 cells at 2 V)
Float voltage (VDC) +/- 218 (96 cells at 2.27 V)
End of discharge voltage at full load (VDC) +/- 154 (96 cells at 1.6 V)
End of discharge maximum battery current (A) 96 kW: 332
160 kW: 550
Maximum charging power896 kW: 9.6/19.2 kW (selected via the display)
160 kW: 16/32 kW (selected via the display)
Classic Battery Specifications
NOTICE
HAZARD OF EQUIPMENT DAMAGE
Do not mix battery types in the same installation.
Failure to follow these instructions can result in equipment damage.
Pre-installed batteries XP12V1800 XP12V2500
Battery Type Sealed lead-acid
Nominal voltage (V) 12 12
Power91370 1870
Nominal capacity10 56.4 69.5
Internal resistance (mOhm) 8.6 6.2
Short circuit current (A) 1521 2030
DC Power Levels for Battery Sizing with Output Power Factor = 1
DC power in kW
Load 25% 50% 75% 100%
32 kVA 8.5 16.9 25.4 33.9
64 kVA 16.9 33.9 50.8 67.7
96 kVA 25.4 50.8 76.2 101.6
990-3017K-001 13
7. For more information see Install the Classic Battery Solution, page 70.
8. Input current limit may lower charging capability in some line and load conditions.
9. 15 min 1.60 VDC 25 °C W/block
10. C10 1.80 VDC 25 °C Ah
96 and 160 kW 400 V Specifications
DC power in kW
Load 25% 50% 75% 100%
128 kVA 33.9 67.7 101.6 135.4
160 kVA 42.3 84.7 127.0 169.3
DC Power Levels for Battery Sizing with Output Power Factor = 0.8
DC power in kVA
Load 25% 50% 75% 100%
32 kVA 6.8 13.5 20.3 27.1
64 kVA 13.5 27.1 40.6 54.2
96 kVA 20.3 40.6 61.0 81.3
128 kVA 27.1 54.2 81.3 108.4
160 kVA 33.9 67.7 101.6 135.4
Maximum Current with Battery at End of Discharge (A)
Load 25% 50% 75% 100%
32 kW 27.6 55.1 82.7 110.2
64 kW 55.1 110.2 165.3 220.5
96 kW 82.7 165.3 248.0 330.7
128 kW 110.2 220.5 330.7 440.9
160 kW 137.8 275.6 413.4 551.1
Heat Dissipation
NOTE: Full load heat loss at nominal mains and fully charged batteries.
UPS rating 32 kW 64 kW 96 kW 128 kW 160 kW
Heat dissipation
kWh (BTU/hr)
1.68 (5748) 3.37 (11496) 5.05 (17244) 6.73 (22992) 8.42 (28741)
14 990-3017K-001
Installation Procedure for System with PDU with Modular
Batteries 96 and 160 kW 400 V
Installation Procedure for System with PDU with
Modular Batteries
1. Mechanical Assembly, page 17 (not shown on the drawing).
a. Rearrange the Side Panels, page 17.
b. Prepare the PDU with Modular Batteries for Cables, page 24.
2. Connect the Battery Breaker Trip Cables and Communication Cables in
Installations with UPS and PDU with Modular Batteries, page 27.
3. Connect the Network Communication Cable, page 33.
4. Connect the Emergency Power Off (EPO) Switch, page 34.
5. Install the Modular Battery Solution, page 66.
6. Connect Power Cables Between the UPS and the PDU with Modular
Batteries, page 37.
7. Interconnect the Cabinets, page 40 and Level the Cabinets, page 41.
8. Connect Power Cables in Installations with UPS and PDU with Modular
Batteries, page 42.
NOTE: Input neutral is always ON. Input neutral is never switched OFF
when Q1 circuit breaker is switched ON or OFF. A continuous grounded
neutral must be connected to the input of the UPS. This connection
ensures that the UPS neutral remains grounded while in battery operation
mode. Operation of the UPS in battery mode without the continuously
grounded neutral can result in excessive voltage potentials between
ground and line voltage. This excessive voltage potential could lead to
damage to externally connected equipment. The neutral connection to the
load is switched when operating Q2 and Q3.
990-3017K-001 15
96 and 160 kW 400 V
Installation Procedure for Systems with UPS and Modular or
Classic Batteries
Installation Procedure for Systems with UPS and
Modular or Classic Batteries
1. Mechanical Assembly, page 1711 (not shown on the drawing)
a. Rearrange the Side Panels, page 17.
b. Prepare the UPS for Cables, page 18.
2. Connect the Battery Breaker Trip Cables and the Communication Cables in
Installations With UPS and Modular Battery Cabinets, page 3012
3. Connect the Network Communication Cable, page 33.
4. Connect the Emergency Power Off (EPO) Switch, page 34.
5. Install your battery solution:
–Install the Modular Battery Solution, page 66
–Install the Classic Battery Solution, page 70
6. Interconnect the Cabinets, page 40 and Level the Cabinets, page 4113
7. Connect Power Cables in Systems with UPS and Modular Battery Cabinets
or Classic Battery Cabinets, page 53.
16 990-3017K-001
11. Note that for classic battery cabinets, rearranging of side panels is not necessary
12. Note that for classic battery cabinet, battery signal cables are connected at a later time
13. Only modular battery cabinets must be interconnected with the other cabinets. Classic battery cabinets only need to be levelled
Mechanical Assembly 96 and 160 kW 400 V
Mechanical Assembly
Rearrange the Side Panels
NOTE: Only systems installed on a raised floor can use bottom cable entry.
NOTE: For systems with classic battery cabinets, rearranging the side panels
is not necessary.
1. Rearrange the side panels depending on your configuration:
–System with UPS and PDU with modular batteries: Remove the side
panels on both sides of the UPS and install one of the side panels on the
last modular battery cabinet in the row, and the other side panel on the
open side of the PDU with modular batteries.
–System with UPS and line-up modular battery cabinets: Remove the
side panel from the UPS from the side placed up against the modular
battery cabinet and install it on the last modular battery cabinet in the row.
–System with UPS and remote modular battery cabinets: Leave the
side panels on the UPS. The extra side panels are needed for the open
side of the modular battery cabinets.
2. To remove the side panels, unlock the side panels with the key (provided).
Press down on the lock and then pull out and up.
3. To install the side panels, set the base of the panel at an angle and push the
panel in. Lock the side panels with the key
990-3017K-001 17
96 and 160 kW 400 V Mechanical Assembly
Prepare the UPS for Cables
There are four ways of routing the cables. Follow the procedure applicable to your
installation:
•Prepare the UPS for Cables in Top Cable Entry Systems without Conduits,
page 19.
•Prepare the UPS for Cables in Top Cable Entry Systems with Conduits, page
18.
•Prepare the UPS for Cables in Bottom Cable Entry Systems without
Conduits, page 19.
•Prepare the UPS for Cables in Bottom Cable Entry Systems with Conduits,
page 20.
Prepare the UPS for Cables in Top Cable Entry Systems with Conduits
1. Remove the brush slot plate and the gland plate.
Rear View of the UPS
2. Drill as many holes as needed in the gland plate and install the conduits.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Do not drill or cut holes for cables or conduits with the gland plate 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.
3. Reinstall the gland plate.
Rear View of the UPS
18 990-3017K-001
Mechanical Assembly 96 and 160 kW 400 V
Prepare the UPS for Cables in Top Cable Entry Systems without Conduits
1. Remove the brush slot plate and the gland plate.
Rear View of the UPS
2. Reinstall the brush slot plate.
Rear View of the UPS
Prepare the UPS for Cables in Bottom Cable Entry Systems without Conduits
CAUTION
HAZARD OF RODENT DAMAGING EQUIPMENT
In areas with risk of rodent infestation, make holes in the bottom plate, reinstall
the bottom plate, and route cables through the plate. Ensure that there are no
sharp edges that can damage the cables.
Failure to follow these instructions can result in injury or equipment
damage.
1. Remove the grounding cable.
2. Remove the screws in front of the bottom plate.
990-3017K-001 19
96 and 160 kW 400 V Mechanical Assembly
3. Lift the bottom plate to remove it.
Rear View of the UPS
Prepare the UPS for Cables in Bottom Cable Entry Systems with Conduits
1. Remove the grounding cable.
2. Remove the screws in front of the bottom plate.
3. Lift the bottom plate to remove it.
4. Drill holes in the bottom plate and install the conduits.
Rear View of the UPS
5. Reinstall the bottom plate with the conduits installed.
6. Reinstall the screws in front of the bottom plate
20 990-3017K-001
96 and 160 kW 400 V Mechanical Assembly
Access the Cable Connection Area in the UPS
1. Open the rear door of the UPS.
2. Remove all four covers, starting from the top, by loosening the two screws in
each cover.
3. Lift the cover up and out.
Rear View of the UPS
3
22
3
22
3
22
3
22
NOTE: The following steps are only applicable to systems with the PDU
with modular batteries placed to the left of the UPS.
4. Remove the three cable reliefs from the left side and save for later.
5. Remove the neutral busbar from the right side of the UPS by loosening the
four bolts and mount the busbar on the left side of the UPS.
22 990-3017K-001
96 and 160 kW 400 V Mechanical Assembly
Prepare the PDU with Modular Batteries for Cables
•Prepare the PDU with Modular Batteries for Cables in Top Cable Entry
Systems, page 25.
•Prepare the PDU with Modular Batteries for Cables in Bottom Cable Entry
Systems with Front Cable Entry without Conduits, page 26.
•Prepare the PDU with Modular Batteries for Cables in Bottom Cable Entry
Systems with Front Cable Entry with Conduits, page 26.
Access the Cable Connection Area of the PDU with Modular Batteries
1. Open the dead front in the PDU with modular batteries.
Front View of the PDU with Modular Batteries
2. Remove the three blanking panels.
24 990-3017K-001
Mechanical Assembly 96 and 160 kW 400 V
3. Remove the two bolts at the bottom of the cable channel and remove the
cable channel.
Front View of the PDU with Modular Batteries
Prepare the PDU with Modular Batteries for Cables in Top Cable Entry Systems
1. Remove the dedicated cover plate. Continue with step 2 if you are using
conduits.
Front View of the PDU with Modular Batteries
990-3017K-001 25
96 and 160 kW 400 V Mechanical Assembly
2. Drill holes in the top plate and install the conduits.
Front View of the PDU with Modular Batteries
3. Reinstall the top plate with the conduits installed.
Prepare the PDU with Modular Batteries for Cables in Bottom Cable Entry Systems with
Front Cable Entry without Conduits
1. Loosen the bolts and remove the plate by lifting it up and to the right.
Front View of the PDU with Modular Batteries
Prepare the PDU with Modular Batteries for Cables in Bottom Cable Entry Systems with
Front Cable Entry with Conduits
1. Remove the bolts. Remove the plate by lifting it up and to the right.
2. Drill holes in the bottom plate for conduits.
3. Reinstall the bottom plate with the conduits installed.
Front View of the PDU with Modular Batteries
26 990-3017K-001
Connect the Communication Cables 96 and 160 kW 400 V
Connect the Communication Cables
Follow one of the below procedures:
•Connect the Battery Breaker Trip Cables and Communication Cables in
Installations with UPS and PDU with Modular Batteries, page 27.
•Connect the Battery Breaker Trip Cables and the Communication Cables in
Installations With UPS and Modular Battery Cabinets, page 30
Connect the Battery Breaker Trip Cables and Communication
Cables in Installations with UPS and PDU with Modular Batteries
Move the cabinets just close enough so that the communication cables can reach
between them. The cabinets should not be positioned too close to one another.
The extra space is needed to complete the wiring.
Overview of the Communication Cables
1. Route the battery breaker trip cable from J1 in the first modular battery
cabinet to the J3 port in the next modular battery cabinet. Repeat the
procedure for all modular battery cabinets.
2. Route the battery breaker trip cable from the PDU with modular batteries to
J28 on the EPO/ancillary interface board (0P4123) in the UPS.
NOTE: When the UPS is installed in environments sensitive to
interference, the EMC kit with three ferrite cores must be installed with
three loops. Add a clip on ferrite for high frequency noises. Use kit 0J-
9147.
990-3017K-001 27
96 and 160 kW 400 V Connect the Communication Cables
3. Route the battery breaker trip cable from J1 in the last modular battery
cabinet to J27 on the EPO/ancillary interface board (0P4123) in the UPS.
4. Route the communication cable from XR Communications port 1 in each
modular battery cabinet to port 2 in the next modular battery cabinet. Remove
the terminator when necessary.
5. Route the communication cable from XR Communications port 1 on the last
modular battery cabinet in the row to XR Communications port 2 on the UPS.
28 990-3017K-001
Connect the Communication Cables 96 and 160 kW 400 V
6. Route the communication cable from XR Communications port 2 on the PDU
with modular batteries to XR Communications port 1 on the UPS.
7. Route the three PDU communication cables from the PDU with modular
batteries to J7, J8, and J1 on the maintenance bypass interface board
(0P3199) in the UPS.
990-3017K-001 29
96 and 160 kW 400 V Connect the Communication Cables
Connect the Battery Breaker Trip Cables and the Communication
Cables in Installations With UPS and Modular Battery Cabinets
NOTE: Communication cables for classic battery cabinets are connected later
in Connect the Signal Cables with Only One Classic Battery Cabinet Installed,
page 76 and Connect the Signal Cables with Multiple Classic Battery Cabinets
Installed, page 79.
Move the cabinets just close enough so that the communication cables can reach
between them. The cabinets should not be positioned too close to one another.
The extra space is needed to complete the wiring.
Overview of the Communication Cables
1. Route the battery breaker trip cable from J1 in the first modular battery
cabinet to J3 in the next modular battery cabinet. Repeat the procedure for all
modular battery cabinets.
Rear View of the Modular Battery Cabinets
2. Route the battery breaker trip cable from J1 in the last modular battery
cabinet to J27 on the EPO/ancillary interface board (0P4123) in the UPS.
NOTE: When the UPS is installed in environments sensitive to
interference, the EMC kit with three ferrite cores must be installed with
three loops. Add a clip on ferrite for high frequency noises. Use kit 0J-
9147.
30 990-3017K-001
Connect the Communication Cables 96 and 160 kW 400 V
3. Route the communication cable from XR Communications port 1 in each
modular battery cabinet to port 2 in the next modular battery cabinet. Remove
the terminator when necessary.
4. Route the communication cable from XR Communications port 1 in the last
modular battery cabinet to the UPS XR Communications port 2.
990-3017K-001 31
96 and 160 kW 400 V Connect the Communication Cables
5. Route the communication cables from the maintenance bypass panel to the
maintenance bypass interface board (0P3199) in the UPS.
NOTE: When the UPS is installed in environments sensitive to
interference, the EMC kit with three ferrite cores must be installed with
three loops. Add a clip on ferrite for high frequency noises. Use kit 0J-
9147.
6. For third party switchgear without surveillance, remove the jumper between
pins 13 and 14 of J2. For switchgear with surveillance connected to the
maintenance bypass interface board, leave the jumper installed.
32 990-3017K-001
Connect the Communication Cables 96 and 160 kW 400 V
Connect the Network Communication Cable
1. The network communication cable (supplied) has been preconnected to the
UPS and is located on the top of the UPS cabinet. Connect the network
communication cable to your local area network.
Top View of the UPS
990-3017K-001 33
96 and 160 kW 400 V Connect the Communication Cables
Connect the Emergency Power Off (EPO) Switch
Rear View of the UPS
The UPS must be connected to either a dry contact or an external 24 VDC source.
EPO can be achieved with either a contact closure or application of an external 24
VDC from a SELV (Safety Extra Low Voltage) source. It is important to note that
hazardous voltage from the mains must be isolated from the contact closure or 24
VDC. The EPO circuit contact closure or 24 VDC is considered a SELV circuit as
defined in EN60950-1 “Safety of Information Technology Equipment”. SELV
circuits are isolated from the mains through a safety isolating transformer, and
designed so that, under normal conditions, the voltage is limited to 42.4 V peak or
60 VDC.
NOTE: EPO switch wiring must comply with local and national electrical wiring
rules.
NOTE: When the UPS is installed in environments sensitive to interference,
the EMC kit with three ferrite cores must be installed with three loops. Add a
clip on ferrite for high frequency noises. Use kit 0J-9147.
34 990-3017K-001
96 and 160 kW 400 V Perform Equipotential Bonding
Perform Equipotential Bonding
NOTE: It might be necessary to move some of the equipotential bonding wires
to fit your system configuration.
1. Connect the two equipotential bonding conductors between all cabinets in the
system. The bonding conductors are preconnected to the PDU with modular
batteries, the UPS, and all the modular battery cabinets. Add the bonding
conductor (B) and the star washer on to the PEM stud (A) in the neighboring
cabinet, then fasten the M8 nut (C) to the PEM stud (A) to complete the
bonding. (Note: Star washer may be captive on the nut.)
36 990-3017K-001
Connect Power Cables Between the UPS and the PDU with
Modular Batteries 96 and 160 kW 400 V
Connect Power Cables Between the UPS and the
PDU with Modular Batteries
NOTE: This procedure is only applicable to systems with UPS and PDU with
modular battery cabinets.
Schneider Electric recommends using a 45º cable lug.
Schneider Electric recommends using multiflexible copper cables to route the
cables as shown.
NOTE: Ensure clockwise phase rotation and neutral location. The power
terminal bolt diameter is 10 mm and the required torque value is 26 Nm.
NOTE: Do not remove the 12 pcs M10 nylon hex bolts from the busbars.
Mount the cables in the open holes.
NOTE: In the UPS, route the cables on the outside of the guide rails when
possible (see illustration).
NOTE: The M10 bolts, washers and cable ties are supplied in the UPS
accessory kit.
990-3017K-001 37
96 and 160 kW 400 V
Connect Power Cables Between the UPS and the PDU with
Modular Batteries
Rear View of the UPS
1. Before running the cables, loosen the three bolts on each cable relief next to
the PDU.
2. Route the cables to the UPS through the holes in the cable relief on the side
of the cabinet starting from the bottom with the bypass L3 and then working
your way upwards. Deposit the cables neatly to minimize cable build-up. Do
not fasten the cables.
3. Mount the cables to the busbars according to the labels.
38 990-3017K-001
96 and 160 kW 400 V Interconnect the Cabinets
Interconnect the Cabinets
NOTE: The communication and power cables must be connected between the
cabinets before the cabinets are interconnected. Follow the described
installation procedure.
1. Align the cabinets.
2. Connect the exterior joining brackets (provided) to secure and bond the
cabinets.
40 990-3017K-001
Level the Cabinets 96 and 160 kW 400 V
Level the Cabinets
WARNING
TIP HAZARD
The system must be installed on a level floor. The leveling feet will stabilize the
cabinet, but will not compensate for a badly sloped floor.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
1. Use a screwdriver to lower the four leveling feet
2. Use a wrench to adjust the four leveling feet and ensure that the cabinet is
level.
WARNING
TIP HAZARD
Do not move the cabinet after the leveling feet have been lowered.
Failure to follow these instructions can result in death, serious injury,
or equipment damage.
990-3017K-001 41
96 and 160 kW 400 V Connect Power Cables
Connect Power Cables
Connect Power Cables in Installations with UPS and PDU with
Modular Batteries
1. Connect the Input Cables in the PDU with Modular Batteries, page 42. Follow
one of the procdures:
–Connect Power Cables in Single Mains Installations, page 43.
–Connect Power Cables in Dual Mains Installations, page 44
2. Connect the PDU Subfeed Breakers, page 46.
3. Install Power Distribution Modules in the PDU with Modular Batteries, page
48.
Connect the Input Cables in the PDU with Modular Batteries
CAUTION
HAZARD OF EQUIPMENT DAMAGE
Ensure clockwise phase rotation and neutral location of the power terminal bolt.
The cable lug accepts up to 300 mm² copper cables (or two 130 mm² copper
cables). In dual mains systems the maximum cables sizes are limited by the
cable channel which accepts up to 120 mm² input and bypass copper cables.
The required torque value is 62 Nm.
Failure to follow these instructions can result in injury or equipment
damage.
NOTE: The neutral wire from the input and bypass is hardwired in the UPS.
Do not install a jumper between the two neutral connections in single mains
installations.
42 990-3017K-001
Connect Power Cables 96 and 160 kW 400 V
Connect Power Cables in Single Mains Installations
Front View of the PDU with Modular Batteries
NOTE: Run the input cables as far to the right as possible to make room for
the power distribution module cables, that will be connected later.
1. Route the cables from the top or bottom and connect as follows:
– In systems with top cable entry, connect the input cables to the input
terminals.
– In systems with bottom cable entry, connect the input cables to the bypass
terminals.
2. In top entry systems, fasten the cables to the cable tray using cable ties with a
minimum loop tensile of 80 kg (supplied).
990-3017K-001 43
96 and 160 kW 400 V Connect Power Cables
Connect Power Cables in Dual Mains Installations
Front View of the PDU with Modular Batteries
1. Remove the three single mains busbars.
2. Route the cables through the top or bottom and connect the input cables to
the input and the bypass cables to the bypass terminals.
3. In top cable systems, fasten the cables to the cable tray using cable ties with
a minimum loop tensile of 80 kg (supplied).
44 990-3017K-001
96 and 160 kW 400 V Connect Power Cables
Bottom Cable Entry System – Front View of the PDU with Modular Batteries
Connect the PDU Subfeed Breakers
CAUTION
HAZARD OF EQUIPMENT DAMAGE
Ensure clockwise phase rotation and neutral location of the power terminal bolt.
The breaker terminals accept up to 70 mm² cables. The required torque value is
26 Nm.
Failure to follow these instructions can result in injury or equipment
damage.
Each subfeed breaker is rated for a maximum of 160 A.
1. Reinstall the three blanking panels.
46 990-3017K-001
96 and 160 kW 400 V Connect Power Cables
3. Reinstall the cable channel.
Install Power Distribution Modules in the PDU with Modular Batteries
DANGER
HAZARD OF ELECTRIC SHOCK
To install a power distribution module:
• Turn off all power supplying the equipment and perform appropriate lockout/
tagout procedures.
OR
• Place the UPS in battery operation.
See the operation manual for information on how to install the power distribution
modules in battery operation.
Failure to follow these instructions will result in death or serious injury.
48 990-3017K-001
Connect Power Cables 96 and 160 kW 400 V
CAUTION
RISK OF INJURY OR EQUIPMENT DAMAGE
• Install only Schneider Electric power distribution modules with matching
output voltage.
• Install power distribution modules starting from the bottom of the panel to
avoid cable congestion.
• Save filler plates for future reuse. If a module is removed, a filler plate must
be installed to cover the open busbar.
• Slot locks (attached together in pairs) must always be installed on all power
distribution module positions in the panel whether filled by a power
distribution module or a filler plate.
• Make sure all breakers on the power distribution modules being installed are
in the OFF (open) position.
Failure to follow these instructions can result in injury or equipment
damage.
1. Remove the left top plate of the PDU with the modular batteries.
Front View of the PDU with Modular Batteries
2. Insert the slot key in the slot lock.
OFF OFF OFF
OFF OFF OFF
3. Squeeze the sides of the key inwards to grasp the slot lock firmly.
990-3017K-001 49
96 and 160 kW 400 V Connect Power Cables
4. Pull the slot key out while squeezing to extract the slot lock from the slot.
5. To remove a filler plate: Press down on the filler plate clip to release the
locking mechanism and pull the filler plate directly towards you.
OFF OFF OFF
OFF OFF OFF
6. Press down on the red button to open the latch on the front of the power
distribution module.
7. Route the cable on the power distribution module through the top of the
cabinet.
NOTE: Leave a minimum of 178 mm of slack in the cable behind the
module. The slack is useful in case the module is ever removed or
replaced. (254 to 508 mm (10 to 20 in) is recommended, but space
restrictions in the PDU and cable diameter size will cause the amount of
slack to necessarily vary.)
NOTE: When installing power distribution modules near the top of the
panel, feed the cable first, pull up the slack, and then fasten the module to
the busbar to avoid cable congestion between the panel and the slot.
8. Slide the power distribution module into the panel via the slots. Make sure
that you slide it all the way in, so it connects with the busbar.
50 990-3017K-001
96 and 160 kW 400 V Connect Power Cables
11. Only for power distribution positions that are empty:
a. Insert the bottom tab of the filler plate into the slot and slide the filler plate
towards the busbar.
b. Snap the filler plate into position and check that the latch is secure.
OFF OFF OFF
OFF OFF OFF
12. Install the slot lock by pressing it into the slots.
OFF OFF OFF
OFF OFF
OFF
13. Connect the power distribution module cable to the appropriate equipment.
52 990-3017K-001
Connect Power Cables 96 and 160 kW 400 V
Connect Power Cables in Systems with UPS and Modular Battery
Cabinets or Classic Battery Cabinets
1. Connect the Power Cables in the UPS, page 53. Follow one of the
procedures:
–Connect Power Cables in Single Mains Installations, page 53.
–Connect Power Cables in Dual Mains Installations, page 54.
Connect the Power Cables in the UPS
Schneider Electric recommends using a 45º cable lug.
NOTE: Do not remove the 12 pcs M10 nylon hex bolts from the busbars.
Mount the cables in the open holes.
NOTE: The M10 bolts, washers, and cable ties are supplied in the UPS
accessory kit.
Connect Power Cables in Single Mains Installations
CAUTION
HAZARD OF EQUIPMENT DAMAGE
Ensure clockwise phase rotation and neutral location. The power terminal bolt
diameter is 10 mm. The required torque value is 26 Nm.
Failure to follow these instructions can result in injury or equipment
damage.
NOTE: The neutral wire from the input and bypass is hardwired in the UPS.
Do not install a jumper between the two neutral connections in single mains
installations.
1. Run the cables through top or bottom of the UPS cabinet and mount the
cables to the busbars according to the labels.
2. Connect the PE cable in the UPS cabinet according to the symbol on the
grounding rail.
990-3017K-001 53
96 and 160 kW 400 V Connect Power Cables
3. Install the three cables (0W3617) included with the unit.
Rear view of the UPS
Connect Power Cables in Dual Mains Installations
NOTE: Ensure clockwise phase rotation and neutral location. The power
terminal bolt diameter is 10 mm. The required torque value is 26 Nm.
1. Route the cables through top or bottom of the UPS cabinet and mount the
cables to the busbars according to the labels.
54 990-3017K-001
96 and 160 kW 400 V Connect Power Cables
Connect the Battery Cables in the UPS
NOTE: Battery cables from modular battery cabinets can be routed through
the side, top, or bottom of the UPS. Battery cables from classic battery
cabinets can only be routed through the bottom of the UPS. Battery cables
from third party battery cabinets can only be routed through the top or bottom
of the UPS.
NOTE: When possible, route the battery cables on the outside of the guide
rails in the UPS.
NOTE: Do not remove the 12 pcs M10 nylon hex bolts from the busbars.
Mount the cables in the open holes.
NOTE: The M10 bolts, washers, and cable ties are supplied in the UPS
accessory kit.
Schneider Electric recommends using a 45º cable lug.
Connect Battery Cables to the UPS in Systems with Modular Battery Solution and Side
Cable Entry
1. Before running the cables through the side, loosen the three bolts on the
cable relief in the UPS next to the battery cabinet.
2. Route the battery cables to the UPS through the holes in the cable relief.
3. Mount the battery cables BAT-, BAT+, CT (midpoint) to the busbars according
to the labels. Secure the cables with cable ties.
56 990-3017K-001
Connect Power Cables 96 and 160 kW 400 V
4. Tighten the three bolts on the cable relief.
Rear View of the UPS
Connect Battery Cables to the UPS – Top and Bottom Cable Entry
DANGER
HAZARD OF FIRE OR ARC FLASH
It is mandatory to protect the battery circuit with a Schneider Electric circuit
breaker equipped with an power on trip coil (MX 230 VAC).
Failure to follow these instructions will result in death or serious injury.
1. Route the battery cables through either the top or the bottom of the UPS.
990-3017K-001 57
Install the Maintenance Bypass Cabinet (Option) 96 and 160 kW 400 V
Install the Maintenance Bypass Cabinet (Option)
NOTE: These instructions are valid for the floor-mount half-rack (300 mm
wide) maintenance bypass cabinet. For other types of maintenance bypasses,
please refer to the instructions provided with the maintenance bypass.
Remove the Breaker Cover Panel from the Maintenance Bypass
Cabinet
1. Remove the front panel by pushing the two latches in the top of the panel.
2. Remove the breaker cover panel by removing the four mounting screws.
Front View of the Maintenance Bypass Cabinet
3. Perform equipotential bonding and interconnect and level the maintenance
bypass cabinet with the other cabinets – see Perform Equipotential Bonding,
page 36 and Interconnect the Cabinets, page 40 on how to do this.
Maintenance Bypass Field Wiring Specification
Input wiring
Ambient temperature Max input current Wire size
30 ºC 332 A 2 x 120 mm2(AWG 4/0)
Output wiring
Ambient temperature Max input current Wire size
30 ºC 278 A 2 x 120 mm2(AWG 4/0)
NOTE: If the ambient room temperature is higher than 30 ºC, larger wires
are to be selected in accordance with the national wiring requirements.
990-3017K-001 59
96 and 160 kW 400 V Install the Maintenance Bypass Cabinet (Option)
Prepare the Maintenance Bypass Cabinet for Cables in Bottom
Cable Entry Systems
CAUTION
HAZARD OF EQUIPMENT DAMAGE
Ensure sharp edges from drilling are properly covered to prevent damaging
cable insulation.
Failure to follow these instructions can result in injury or equipment
damage.
CAUTION
HAZARD OF EQUIPMENT DAMAGE
Remove the cover plates from the cabinet. Drilling or cutting of plates must not
take place over the top or inside the cabinet or while plates are installed in the
cabinet.
Failure to follow these instructions can result in injury or equipment
damage.
1. Remove the dedicated bottom cover plate for power cables.
Front View of the Maintenance Bypass Cabinet
60 990-3017K-001
Install the Maintenance Bypass Cabinet (Option) 96 and 160 kW 400 V
2. Drill holes as needed in the bottom plate for conduits and reinstall the bottom
plate with the conduits installed.
Front View of the Maintenance Bypass Cabinet
Prepare the Maintenance Bypass Cabinet for Cables in Top Cable
Entry Systems
CAUTION
HAZARD OF EQUIPMENT DAMAGE
Ensure sharp edges from drilling are properly covered to prevent damaging
cable insulation.
Failure to follow these instructions can result in injury or equipment
damage.
CAUTION
HAZARD OF EQUIPMENT DAMAGE
Remove the cover plates from the cabinet. Drilling or cutting of plates must not
take place over the top or inside the cabinet or while plates are installed in the
cabinet.
Failure to follow these instructions can result in injury or equipment
damage.
990-3017K-001 61
96 and 160 kW 400 V Install the Maintenance Bypass Cabinet (Option)
1. Remove the dedicated top cover plate for power cables.
Front View of the Maintenance Bypass Cabinet
2. Drill holes as needed in the top plate for conduits and reinstall the top plate
with the conduits installed.
Front View of the Maintenance Bypass Cabinet
Connect Power Cables between the UPS and the Maintenance
Bypass Cabinet
CAUTION
HAZARD OF EQUIPMENT DAMAGE
Ensure sharp edges from drilling are properly covered to prevent damaging
cable insulation.
Failure to follow these instructions can result in injury or equipment
damage.
The connection can be done from the left or right side of the maintenance bypass
cabinet.
62 990-3017K-001
Install the Maintenance Bypass Cabinet (Option) 96 and 160 kW 400 V
Right Side View of the Maintenance Bypass Cabinet
1. Untie/cut the zip ties to uncoil the cables.
2. Route the output and bypass/input cables through the side of the
maintenance bypass cabinet and through the cable relief in the UPS.
3. Connect L1, L2, and L3 from maintenance bypass cabinet Q1 bottom and N
from maintenance bypass cabinet Q3 top to the UPS bypass.
4. Connect L1, L2, L3 and N from maintenance bypass cabinet Q2 top to the
UPS output.
5. Route the signal cable through the side of the maintenance bypass cabinet
and into the UPS.
NOTE: When the UPS is installed in environments sensitive to
interference, the EMC kit with three ferrite cores must be installed with
three loops. Add a clip on ferrite for high frequency noises. Use kit 0J-
9147.
990-3017K-001 63
96 and 160 kW 400 V Install the Maintenance Bypass Cabinet (Option)
6. Remove the jumper wire harness between J1 and J2 on the maintenance
bypass interface board (0P3199) in the UPS.
7. Connect the signal cable to J1 and J8 on the maintenance interface board
(0P3199) in the UPS.
NOTE: For third party switchgear without surveillance, remove the jumper
pin between J2 pins 13 and 14. For wallmounted switchgear with
surveillance interconnected to the maintenance bypass interface board,
leave the jumper pin installed between J2 pins 13 and 14.
Connect Input and Output Power Cables to the Maintenance
Bypass Cabinet
CAUTION
HAZARD OF EQUIPMENT DAMAGE
Ensure clockwise phase rotation. The required torque value for the dual-lug
breaker input connector is 31 Nm. Use the long set screws for the input cable
range of 70 mm2minimum to 120 mm2maximum. Use the short set screws,
supplied with maintenance bypass cabinet, for the input cable range of 150 mm2
minimum to 300 mm2maximum. Ensure that the plastic cover is installed over
the breaker terminals.
Failure to follow these instructions can result in injury or equipment
damage.
1. Route the input cables through the top or bottom of the maintenance bypass
cabinet to the Q1 input. Remove the plastic cover from the top breaker
terminals.
2. Connect the input cables to the L1, L2, L3, N terminals.
3. Connect the Protective Earth (PE) cable to the PE terminal. Install the plastic
cover on the top breaker terminals.
4. Route the output cables through the top or bottom of the maintenance bypass
cabinet to the Q2 output. Remove the plastic cover from the bottom breaker
terminals.
5. Connect the output cables to the L1, L2, L3, N terminals.
64 990-3017K-001
96 and 160 kW 400 V Install the Battery Solution
Install the Battery Solution
Install the Modular Battery Solution
The Symmetra PX 160 kW UPS can monitor up to three modular battery cabinets
in systems with the PDU with modular batteries and up to four modular battery
cabinets in systems without the PDU with modular batteries.
CAUTION
HAZARD OF EQUIPMENT DAMAGE
The system accepts up to 150 mm² cables. The power terminal bolt diameter is
10 mm and the required torque value is 26 Nm.
Failure to follow these instructions can result in injury or equipment
damage.
NOTE: In installations with third party batteries, follow the documentation
provided with the batteries.
Connect the Battery Cables between the Modular Battery Cabinets
NOTE: For remote modular battery cabinets, the length of the signal cables
must not exceed 50 m for the cable that connects the modular battery cabinet
to the UPS. The length of the power cables must not exceed 200 m for the
cable that connects the modular battery cabinet to the UPS. For power cables
between 50 and 200 m, the voltage drop must be taken into account when the
cable size is chosen. If the cables exceed the length limit this will result in
erratic operation and reduced runtime.
1. In top entry systems, loosen the two top bolts and remove the eight lower
bolts from the upper cover plate on the modular battery cabinet. Lift the plate
to remove it.
2. Loosen the two top bolts and remove the eight lower bolts from the lower
cover plate. Lift the plate to remove it.
Rear View of the Modular Battery Cabinet
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Install the Battery Solution 96 and 160 kW 400 V
3. Unwind the cables included in each modular battery cabinet. Remove the
cable lugs from the cables that will connect to other modular battery cabinets.
For the cables that will connect to the UPS, cut off the cable lug on the end
that will be mounted in the modular battery cabinet.
Rear View of the Modular Battery Cabinet
4. Connect the ground cable first, and then connect BAT+, BAT-, and CT
(midpoint) cables between the modular battery cabinets. Up to three modular
battery cabinets can be connected in a daisy chain.
NOTICE
RISK OF LOAD DROP
If a fourth modular battery cabinet is present, it must be connected
separately to the UPS. Four modular battery cabinets connected in a daisy
chain at 100% load creates risk of load drop.
Failure to follow these instructions can result in equipment damage.
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Install the Battery Solution 96 and 160 kW 400 V
6. Connect the equipment grounding cable in the modular battery cabinet that is
farthest from the UPS. Route it through the other modular battery cabinets by
connecting it from modular battery cabinet to modular battery cabinet to the
UPS through the side, top, or bottom of the modular battery cabinet.
Fuse rating 300 A Class J
Breaker rating 320 A with thermal and magnetic trip-unit
7. Place the cabinet address on the front of each modular battery cabinet and
PDU with modular batteries (if present).
Cabinet address UPS containing modular
batteries14
UPS not containing
modular batteries
1Modular battery cabinet 1 PDU with modular batteries/
Modular battery cabinet 1
2Modular battery cabinet 2 Modular battery cabinet 2
3Modular battery cabinet 3 Modular battery cabinet 3
4Modular battery cabinet 4 Modular battery cabinet 4
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14. Modular batteries inside a UPS are called mainframe batteries in the display, so a UPS with modular batteries does not have a separate
cabinet address.
96 and 160 kW 400 V Install the Battery Solution
Install the Classic Battery Solution
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
In an installation with third party batteries in the classic battery cabinet:
• Minimum short-circuit current of the batteries must be 1500 A.
• Circuit breaker NSX630S DC MP1 must be installed.
• The documentation from the third party battery vendor must be followed.
Failure to follow these instructions will result in death or serious injury.
NOTE: Up to four classic battery cabinets can be installed with the Symmetra
PX 160 kW UPS.
Prepare the Classic Battery Cabinet for Installation
Remove Battery Protection on Batteries
WARNING
HAZARD OF ELECTRIC SHOCK
Transportation straps and paperboard must be removed from the battery before
installation.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
1. Remove the cable and copper bar kit from the cabinet and save for battery
installation.
2. Remove the transportation straps and the paperboard from the batteries.
Install Classic Battery Cabinet
NOTE: Cables can only be routed through the bottom of the classic battery
cabinet.
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Connect the Battery Cables in the Classic Battery Cabinet
DANGER
HAZARD OF ELECTRIC SHOCK
The classic battery cabinet and the UPS must be earthed properly.
Failure to follow these instructions will result in death or serious injury.
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.
• Turn the battery circuit breakers OFF before connecting cables to the
terminals.
Failure to follow these instructions will result in death or serious injury.
NOTE: For remote classic battery cabinets, the length of the signal cables
must not exceed 50 m for the cable that connects the classic battery cabinet to
the UPS. The length of the power cables must not exceed 200 m for the cable
that connects the classic battery cabinet to the UPS. For power cables
between 50 and 200 m, the voltage drop must be taken into account when the
cable size is chosen. If the cables exceed the length limit this will result in
erratic operation and reduced runtime.
Power cable size UPS-to-classic battery
cabinet15
150 mm2
Power cable size classic battery cabinet-to-
classic battery cabinet15
95 mm2
Power terminal bolt 10 mm (required tightening torque: 26 Nm)
1. Connect the Protective Earth (PE) cable between the classic battery cabinet
(s) and the UPS.
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15. Note that these cables are not supplied
96 and 160 kW 400 V Install the Battery Solution
2. Remove the two protection covers on the battery circuit breaker in the classic
battery cabinet(s).
3. Remove the screws securing the sheet metal plate and the terminal block in
the right side of the battery cabinet(s) and remove them.
NOTE: Taking the sheet metal plate and the terminal block out of the
cabinet for cable installation is not mandatory, but makes the cable
installation easier due to limited space inside the cabinet.
4. Connect the copper busbar (supplied) between the batteries on the shelves
as shown in the illustration (20 busbars for XP12V1800 batteries and 16
busbars for XP12V2500 batteries).
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96 and 160 kW 400 V Install the Battery Solution
6. If more than one classic battery cabinet is installed: Connect the BAT+,
BAT-, and CT (midpoint) cables between the classic battery cabinets in a
parallel connection (output to output) in groups of two or three. Up to four
classic battery cabinets in total can be connected to the UPS.
Installation with three classic battery cabinets
Installation with two or four classic battery cabinets
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96 and 160 kW 400 V Install the Battery Solution
7. Connect the BAT+, BAT-, and CT battery cables to the OUTPUT of the battery
circuit breaker in the classic battery cabinet that will be connected to the UPS
and route these cables through the bottom of the classic battery cabinet.
Fasten the cables to the bottom sheet metal of the cabinet with cable ties.
Connection of power cables between UPS and classic battery cabinets
NOTE: In installations with four battery cabinets, there will be two battery
cable sets (one from each classic battery cabinet group) to connect to the
UPS.
8. Reinstall the sheet metal plate and the terminal block in the right side of the
battery cabinet(s) with the screws, if removed earlier.
Connect the Signal Cables with Only One Classic Battery Cabinet Installed
NOTE: A 5 meter signal cable is supplied. If a longer signal cable is needed,
use the supplied signal cable as reference for making a new one.
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1. Remove the right bottom protection cover to access the terminal block
located on the right inside the classic battery cabinet.
DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION, OR ARC FLASH
Live busbars are present behind the protection cover.
Failure to follow these instructions will result in death or serious
injury.
Front View of Classic Battery Cabinet
2. Run the signal cable from the classic battery cabinet terminal block (Ter J1) to
the PCBA board (0P4123 J27) in the UPS.
Overview of Terminal Block in Classic Battery Cabinet
3. Run the signal cable from the classic battery cabinet terminal block (TB1,TB2,
TB3,TB4) to the PCBA board terminal ports (J21/7,J21/8,J21/3,J21/6) in the
UPS. Terminal tightening torque is 0.6 Nm.
NOTE: Check that the preinstalled temperature sensor is connected to
TB1 (red cable) and TB2 (black cable).
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96 and 160 kW 400 V Install the Battery Solution
4. Connect the UPS terminal ports J21/1 to J21/2 with a jumper and J21/9 to
J21/10 with a jumper.
5. Fasten the signal cables to the bottom sheet metal in the classic battery
cabinet and to the UPS plate relief with cable ties.
6. Reinstall the right bottom protection cover.
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Connect the Signal Cables with Multiple Classic Battery Cabinets Installed
NOTE: A 5 meter signal cable is supplied. If a longer signal cable is needed,
use the supplied signal cable as reference for making a new one.
1. The terminal block is located on the right inside the classic battery cabinet
behind the right bottom protection cover.
DANGER
HAZARD OF ELECTRICAL SHOCK, EXPLOSION, OR ARC FLASH
Live busbars are present behind the protection cover.
Failure to follow these instructions will result in death or serious
injury.
Front View of Classic Battery Cabinet
2. Remove the jumper (TB5 to TB6) on all the classic battery cabinets except for
the classic battery cabinet located farthest away from the UPS.
Overview of Terminal Block in Classic Battery Cabinet
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96 and 160 kW 400 V Install the Battery Solution
3. Run the signal cable from the terminal block (TB6,TB5) in classic battery
cabinet 1 to the terminal block (TB3,TB4) in classic battery cabinet 2.
a. For more than two classic battery cabinets installed: Run the signal cable
from the terminal block (TB6,TB5) on classic battery cabinet 2 to the
terminal block (TB3,TB4) in classic battery cabinet 3. Continue
connecting the classic battery cabinets this way until all are connected.
4. Run the cable from the terminal block (Ter J2) in classic battery cabinet 1 to
terminal block (Ter J1) in classic battery cabinet 2.
a. For more than two classic battery cabinets installed: Run the signal cable
from the terminal block (Ter J2) in classic battery cabinet 2 to the terminal
block (Ter J1) in classic battery cabinet 3. Continue connecting the
classic battery cabinets this way until all are connected.
5. Run the cable from the terminal block (Ter J1) in classic battery cabinet 1 to
the PCBA board (0P4123 J27) in the UPS.
6. Run the cable from the terminal block (TB1,TB2,TB3,TB4) in classic battery
cabinet 1 to the PCBA board terminal ports (J21/7,J21/8,J21/3,J21/6) in the
UPS .
NOTE: Check that the preinstalled temperature sensor is connected to
TB1 (red cable) and TB2 (black cable).
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Install the Battery Solution 96 and 160 kW 400 V
7. Connect the UPS terminal ports J21/1 to J21/2 with a jumper and J21/9 to
J21/10 with a jumper.
Top View of Cabinets
8. Secure the signal cables to the bottom sheet metal in the classic battery
cabinets and to the UPS plate relief with cable ties.
9. Reinstall the right bottom protection covers.
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96 and 160 kW 400 V Post-Installation Checklist
Post-Installation Checklist
• If modular battery cabinets are installed, make sure that all DC breakers are
in the OFF position.
• If classic battery cabinets are installed, make sure that all DC breakers are in
the OFF position.
• Check that the power wiring is properly torqued: UPS = 230 lbf in/26 Nm,
PDU with modular batteries = 550 lbf in/62 Nm, and modular battery cabinet =
274 lbf in/31 Nm.
• Verify clockwise phase-rotation (L1, L2, L3) and make sure a neutral
connection is present.
• Leave a wiring diagram on site for service personnel.
• Reinstall all wiring access panels on the UPS.
• Reinstall all protections covers on the battery circuit breaker in the classic
battery cabinets.
• Remount the doors on all cabinets and connect the ground cables between
the front doors and the frames.
• For any optional equipment, refer to product-specific manuals.
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Schneider Electric
35 rue Joseph Monier
92500 Rueil Malmason
France
+ 33 (0) 1 41 29 70 00
*990-3017K-001*
As standards, specifications, and design change from time to time,
please ask for confirmation of the information given in this publication.
© 2013 – 2019 Schneider Electric. All rights reserved.
990-3017K-001