Illuminator™ System Series CIII
Contents
1. Battery Battery Unitand 47 30 22 21 8 11 P 11 43 8 3 9 1870 197 2 Battery 119 38 76 20 63 50 54 61 20 32 28 58 17 78 29 21 11 12 8 26 23 50 47 94 4953 5 08 Cabinets cm cm cm cm cm cm cm cm cm cm Table 3 1 Dimensions Unit L M N P R S 0 Unit 3 1 2 11 1 4 15 1 2 6 2 1 4 5 17 1 4 6 Only 8 89cm 08 58 39 37cm 15 24 572 12 70cm 43 82cm 15 24 Table 3 2 Required Clearances Table 3 3 Conduit Knockouts Sides Top Front Larger Smaller 0 12 39 134 2 7 8 1 1 8 0 0 30 5 cm 99 1 cm 4 45 cm 5 08 cm 1 59 cm 2 86 cm 5 114200D System Installation Manual Location Guidelines Keep the following guidelines in mind when choosing the location for your system and batteries e Verify that the environment meets the requirements in Storage and Operating Environment on page 7 The environment can affect the reliability and performance of both the unit and the batteries e Install any separate battery cabinets as close as possible to the unit to reduce the cost of DC wiring and to improve battery performance We recommend no clearance between the unit and the battery cabinet in other words the battery cabinet should be next to against the right side of the unit when you face the front of the unit If you must place th2. See User Manual for further specific functions of Keys Meter Functions Meter functions are available by pressing the METER keypad to get to the Meter Menu and then pressing the desired function keypad See figure 7 3 Table 7 2 Meter Functions Function Description Keypad Text Voltage Input Measures the AC Input Voltage to the Inverter VIN Voltage Output Measures the AC Output Voltage from the Inverter V OUT Current Output Measures the AC Output Current from the Inverter If I OUT optional Normally Off loads are connected it will read the sum of Normally On and Normally Off outputs Battery Voltage Measures Battery Voltage V Battery Current Measures the Battery Current When in charge mode the current will be positive When Inverter mode the current will be negative VA Output Multiplication of the output voltage and output current VA OUT Inverter Watts Multiplication of the battery voltage and the battery current INV WATTS Inverter Minutes Total minutes the system has run on inverter INV MIN Temperature Measures the ambient temperature of the electronics TEMP enclosure System Days Total days the system has been in service SYS DAYS 114200D Svstem Installation Manual Program Functions All program functions are password protected The password for user level is 1234 When the PROGRAM Keypad is pressed the display will prompt the user for the password
3. THIS APPLIES TO ANY UNIT THAT HAS A DIFFERENCE BETWEEN THE INPUT AND THE OUTPUT VOLTAGES Write down the circuit breaker value that applies to your system from Table 5 1 Now look at Table 5 2 below and use the notes below to find the proper gauge wire or the recommended circuit breaker recorded in step 5 Table 5 2 Recommended Minimum Wire Sizes Read These Important Notes This table lists the AWG and mm2 wire size for each circuit breaker size The minimum recommended circuit breaker sizes for each model and voltage application are listed in Table 5 1 The temperature rating of conductor must not be less than 90 C wire Based on the ampacities given in Tables 310 16 of the National Electrical Code ANSI NFPA 70 1993 Table 2 of the CEC and NEC article 220 CEC Section 4 Circuit conductors must be the same size ampacity wires and equipment grounding conductors must meet Table 250 95 of the National Electrical Code Code may require a larger wire size than shown in this table because of temperature number of conductors in the conduit or long service runs Follow local code requirements For this Input Use this Size 90 C Circuit Breaker Copper Wire Size AWG 0 10 15 20 12 3 31 25 30 10 5 26 35 40 45 8 8 36 50 60 6 13 30 70 80 4 21 15 90 100 2 33 62 110 1 42 11 125 1 0 53 49 150 175 3 0 67 43 225 4 0 74 40 1142000 Svstem Installation Manual 7 T
4. and 16 7 kW systems 8 kW 10 kW and 12 5 kW for 120 Minute systems 114200D Svstem Installation Manual Fuse systems come with a fuse for each battery cabinet to protect the system The battery wiring diagram shows the fuse location a label inside the battery cabinet shows the fuse size The system itself has a DC fuse At each battery cabinet find the cable that is connected to the other end of the fuse block Insert the cable Tighten the connection as shown on the battery wiring diagram Repeat this step for each cabinet Verify that the battery fuse in the electronics cabinet is removed and the fuse s in the battery cabinet s are removed before connecting the batteries Arranging the Batteries NOTE As you arrange the batteries you must be wearing the required safety equipment Arrange the batteries in the cabinet or the system only as shown in the battery wiring diagram This arrangement is designed to maximize airflow around the batteries The cabinets are designed so that battery cases should never touch Air should be free to circulate Clean the entire surface of all battery terminals with the wire brush before you install the batteries to create good contact points Load the batteries into the system or battery cabinet s Starting with the bottom shelf load one shelf at a time CAUTION Never install the batteries in an airtight enclosure Connecting the Cables Between Batteries When you make bat
5. 25 The Length of the Automatic Tests Parameters Monthly Test and Yearly Test determine how long the battery test is Table 7 6 shows the purpose of each parameter Table 7 6 Factories Setting for Automatic Test Parameters Parameter Purpose Factory Default for 90 minute systems Monthly Test Monthly battery test 5 Minutes Yearly Test Yearly battery test 90 Minutes The factory can only reprogram these parameters If you would like to change the setting of any of the above parameters see table 7 3 follow these steps i e setting the Time See Figure 7 3 for Keypad location 1 Press the PROGRAM keypad enter the user password 1234 press the ENTER keypad 2 Press the gt arrow keypad or gt keypads are used for scrolling through the menu to the Time parameter to set the time NOTE Factory default is Eastern Standard Time and with 24 hour formats i e 1 00 PM 1300 hours 3 Enter correct time for your time zone using the NUMBER keypads and then press the PROGRAM keypad to exit AC SYSTEM BATTERY BATTERY FAULT PRESENT READY CHARGING POWER VIN V OUT TOUT 1 z METER V VA OUT 5 CONTROL TEST LOG EVENT Loc INV WATTS INV MIN TEMP 7 Q Q PROGRAM em VS DAVS gt CLEAR ENTER TEST ALARM BUZZER Figure 7 3 Front Panel Display 114200D System Installation Manual 26 Completing th
6. After the password is entered 1234 ENTER key the user can change the Date Time Month Test Date Month Test Time Yearly Test Date and Yearly Test Time Load Reduction Fault Low VAC Alarm High VAC Alarm Ambient Temp Alarm and Near Low Battery settings Time is always in the 24 hour standard Example 4 00 PM is 16 00 Table 7 3 Program Functions Parameter Format Factory Default Date MM DD YY Month Date Year Current Date Time HH MM Hours Minutes Eastern Stand Time Monthly Test Date DD Date 15 of the Month Monthly Test Time HH MM Hours Minutes 5 00 Yearly Test Date Month 01 Yearly Test Time Hours Minutes 8 00 Load Reduction AAAA AMPS 0 0A Low VAC Alarm VVVV Volts 1 0V High VAC Alarm VVVV Volts 999 9V Ambient Temp DDD Degrees Centigrade 70 C Alarm Near Low Battery VVVV Volts See Table 7 4 Table 7 4 Near Low Battery Fault Chart DC Voltage Near Low Battery 144VDC 130VDC 180VDC 162VDC 240VDC 216VDC The Day of the Automatic Tests Table 7 5 shows the purpose of each parameter and its factory setting Table 7 5 Factories Setting for Automatic Test Parameter Parameter Determines Factory Default Monthly Test The time and the day of the month for the monthly tests 157 5 00 AM Yearly Test The time and the date for the yearly test January 1 8 00 AM 24 114200D System Installation Manual
7. hydrogen during float charging The amount of current that the charger supplies to the batteries not the battery ampere hour determines how much hydrogen is produced High Altitude Operation The maximum operating ambient temperature drops 1 C per 300m 2 F per 1000 ft above sea level Maximum elevation is 3000m 10 000 ft 7 1142000 Svstem Installation Manual CHAPTER 4 INSTALLATION OVERVIEW Figure 4 0 shows typical installations of system Figure 4 0 Typical Hardwired Installation CHAPTERS AC INPUT amp AC OUTPUT INSTALLATION WARNING Only qualified service personnel such as a licensed electrician should perform the AC installation Risk of electrical shock exists Read the following cautions before you continue CAUTION e Unit contains hazardous AC and DC voltages Because of these voltages a qualified electrician must install the system AC line service and batteries The electrician must install the AC line s
8. or into the cabinet Install the batteries as shown on the battery wiring diagram provided with the system When connecting cables never allow a cable to short across a battery s terminals the string of batteries or to the cabinet Align the cables on the battery terminals so that the cable lug does not contact any part of the cabinet even if the battery is moved Keep the cable away from any sharp metal edges CAUTION Install the battery cables so the battery cabinet or the system doors cannot pinch them External battery cabinet chassis ground or earth must be connected to the system s chassis ground or earth The ground conductor must be insulated If you use conduit this ground conductor must be routed in the same conduit as the battery conductors Where conductors may be exposed to physical damage protect conductors in accordance with the National Electrical Code NEC or Canadian Electrical Code CEC If you are replacing batteries or repairing battery connections follow the procedure in the system user s Guide to shut down your system and remove both AC and DC input power 114200D Svstem Installation Manual Before Installing the Batteries Tools CAUTION Always use insulated tools when you work with batteries Always torque connections to the manufacturer s recommendations When you work with system batteries you need the following tools The tools must be insulated so they do not short ba
9. Batteries 96 96 10 9 9 211 96 106 191 191 211 Receiving and Moving the Unit and the Batteries Systems weigh several hundred pounds separate battery cabinets are also heavy see Table 3 4 ask your sales representative for additional information Make sure you are prepared for these weights before you unload or move the unit or the batteries Do not install any batteries until you have permanently installed the unit and any battery cabinets and connected all conduit and wiring 6 114200D System Installation Manual Storage and Operating Environment Make sure you store and install the system in a clean cool dry place with normal ventilation for human habitation and level floors Storage Temperature Store the batteries in the system or battery cabinet at 18 to 40 C 0 to 104 F Batteries have a longer shelf life if they are stored below 25 C 77 F Keep stored batteries fully charged Recharge the batteries every 90 120 days The system or battery cabinet without batteries may be stored at 20 to 70 C 4 to 158 F Ventilation The air around the unit must be clean dust free and free of corrosive chemicals or other contaminants Do not place the system or batteries in a sealed room or container Operating Temperature System can operate from 20 to 30 C 68 to 86 F and up to 95 relative humidity The batteries service life is longer if the operating temperatur
10. CONNECTIONS te dok bd LL SIM a 5 H B ro 0UTPU TERMINAL MAINTENANCE BYPASS SWITCH INPUT TERMINAL q GROUND 1 Figure 5 0 AC Input and Output Locations 114200D Svstem Installation Manual CHAPTER 6 INSTALLING BATTERIES AND DC WIRING Only qualified service personnel such as a licensed electrician should perform the battery and DC wiring installation Risk of electrical shock exists This section explains how to install system batteries fuses and cables An electrician who is familiar with battery installations and applicable building and electrical codes should install the batteries The batteries that will need to be installed in this system could cause you harm or severely damage the electronics if proper precautions are not followed Batteries connected in series parallel configuration could produce lethal voltages with unlimited current All batteries should be inspected for damage prior to installation Never install a battery that is leaking electrolyte Battery terminals should be cleaned with a wire brush to remove any oxidation All tools should be insulated Rubber gloves and safety glasses are recommended IN THIS SYSTEM BATTERY NEGATIVE IS TIED TO GR
11. IONS The installation and use of this product must comply with all national federal state municipal or local codes that apply If you need help please call Service 1 1142000 Svstem Installation Manual CAUTION READ ENTIRE MANUAL AND REVIEW ALL DOCUMENTATION BEFORE ATTEMPTING SYSTEM INSTALLATION FOR SERVICE OR INSTALLATION INFORMATION TELEPHONE 610 868 5400 24 HR HOTLINE FAX 610 954 8227 FOR YOUR PROTECTION PLEASE COMPLETE AND RETURN WARRANTY REGISTRATION CARD IMMEDIATELY 2 1142000 Svstem Installation Manual 1 SAFETY WARNINGS Read the following precautions before you install the UPS IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions that you should follow during installation and maintenance of the system and batteries Please read all instructions before operating the equipment and save this manual for future reference This system contains LETHAL VOLTAGES AUTHORIZED SERVICE PERSONNEL should perform all repairs and service ONLY There is NO USER SERVICEABLE PARTS inside the UPS Do not install the system outdoors Do not install near gas or electric heaters or in other high temperature locations Use caution when servicing batteries Battery acid can cause burns to skin and eyes If acid is spilled on skin or in the eyes flush with fresh water and contact a physician immediately Equipment should be mounted in locations w
12. MYERS v Power Products Illuminator System Series 4 8 kW 16 7 kW Installation Guide 44 South Commerce Way Bethlehem PA 18017 1 800 526 5088 e 610 868 3500 Fax 610 868 8686 Service 610 868 5400 www myerspowerproducts com 114200D System Installation Manual This unit contains LETHAL VOLTAGES All repairs and service should be performed by AUTHORIZED SERVICE PERSONNEL ONLY There is NO USER SERVICEABLE PARTS inside this unit IMPORTANT SAFEGUARDS When using electrical equipment you should always follow basic safety precautions including the following 1 READ AND FOLLOW ALL SAFETY INSTRUCTIONS 2 Do not install the system outdoors 3 Do not install near gas or electric heaters or in other high temperature locations 4 Use caution when servicing batteries Depending on battery type batteries contain either acid or alkali and can cause burns to skin and eyes If battery fluid is spilled on skin or in the eyes flush with fresh water and contact a physician immediately 5 Equipment should be mounted in locations where unauthorized personnel will not readily subject it to tampering 6 The use of accessory equipment not recommended by Manufacturer may cause an unsafe condition and void the warranty 7 Do not use this equipment for other than its intended use 8 Qualified service personnel must perform all servicing of this equipment SAVE THESE INSTRUCT
13. OUND INSIDE THE INVERTER This means that the battery cabinet and shelves are at ground potential as soon as negative connections are made to the batteries It is strongly recommended to make all negative connections to the batteries the last step to prevent any chance of shorting battery positive to ground With the DC fuse removed make connections to battery positive first working your way towards battery negative Leave individual strings of batteries open at the last battery negative until all batteries are installed Then connect each string s negative Safety Instructions IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This section contains important instructions that a qualified service person should follow during installation and maintenance of the system and batteries ONLY a qualified service person should work with the batteries CAUTION Full voltage and current are always present at the battery terminals The batteries used in this system can produce dangerous voltages extremely high currents and a risk of electric shock They may cause severe injury if the terminals are shorted together or to ground earth You must be extremely careful to avoid electric shock and burns caused by contacting battery terminals or shorting terminals during battery installation Do not touch uninsulated battery terminals 114200D Svstem Installation Manual A qualified electrician familiar with battery systems and required precaut
14. cable or tool when you disconnect the batteries Batteries contain lead Please dispose of old batteries properly CAUTION Do not dispose of batteries in a fire because the batteries could explode Do not open or mutilate batteries Released electrolyte is harmful to the skin and eyes It may be toxic Dispose of Batteries Properly CAUTION Batteries contain lead Many state and local governments have regulations about used battery disposal Please dispose of the batteries properly 114200D Svstem Installation Manual CHAPTER 7 SETTING THE AUTOMATIC SYSTEM TEST PARAMETERS Several parameters in the system software determine when and how your system conducts the automatic monthly and annual tests Refer to Program Functions in the Front Panel Display chapter of the system user s Guide for a description of each test Starting the Unit Before you can set the parameters you must start the system Verify that the system AC Input Circuit Breaker and Installation Switch are off 1 Turn on the AC input at the building service panel ensure that the systems input breaker 1 is off 2 Locate the DC Pre charge Switch S2 see figure 7 0 press it for five seconds then install the battery fuse 1 inside the electronics cabinet 3 Turn on the System AC input circuit breaker CB1 See figure 5 0 Turn the installation switch to the ON position The Front Panel display should now be illuminated and a sligh
15. ction are correct the equipment may fail Connecting the Negative Battery Cable s to the Battery String s Remove the insulation from the cable that was put on in step 2 of Electronics cabinet battery block connections Connect the cable to the battery negative Repeat this step for systems with 2 strings 114200D Svstem Installation Manual Replacing the Batteries CAUTION A battery can present a risk of electrical shock and high short circuit current A qualified electrician familiar with battery systems should service the batteries Review all the safety instructions at the beginning of this chapter before you replace any batteries Use the Same Quantity and Type of Battery CAUTION You must use the same quantity and type of battery Substituting batteries not supplied by manufacturer voids the UL CUL listing and may cause equipment damage To ensure continued superior performance of your system and to maintain proper charger operation you must replace the batteries in the system or battery cabinets with the same number of batteries These batteries must be the same types as the original batteries The replacement batteries should have the same voltage and ampere hour rating as the original batteries Handle Used Batteries with Care Assume that old batteries are fully charged Use the same precautions you would use when handling a new battery Do not short battery terminals or the battery string with a
16. e Installation Close the doors and lock the cabinet s You have finished installing the system Follow the steps in the Startup and Warranty Validation form to test the installation and startup the system for the first time After you complete this form return it to the manufacturer to validate the warranty Keep the System Installation Guide and the User s Guide the folder attached to the inside of the system door Notes 114200D Svstem Installation Manual 27 114200D Svstem Installation Manual
17. e battery cabinet away from the unit you must supply the proper length gauge and type of battery cables and you must make sure the installation meets the applicable NEC or CEC requirements e Choose a permanent location for the unit and any battery cabinets Attempting to move them after you have installed the batteries can damage the batteries and the cabinet CAUTION Do not move the unit or the battery cabinet after you install the batteries If you do the unit or battery cabinet and batteries may be damaged CEC requires the unit to be located in a service room If the room is equipped with a sprinkler system the unit must be provided with sprinkler proof covers This equipment is heavy Refer to Table 3 4 when you choose a site to make sure that the floor can support the weight of the system the batteries any separate battery cabinets and any other necessary equipment Table 3 4 System Weight in lbs kg 90 Minute System Models 120 Minute System Models 4 8kw 6 0kw 8 0kw 10 0kw 12 5kw 16 7kw 4 8kw 6 0kw 8 0kw 10 0kw 12 5kw Inverter 535 535 535 639 639 639 535 535 639 639 639 243 243 243 290 290 290 243 243 290 29 290 Battery Cabinet s 1098 1320 1712 2196 2640 3424 1320 1712 2196 2640 3424 with Standard SLC 498 599 777 996 1198 1554 599 777 996 1198 1554 Batteries Battery Cabinet s 210 20 232 420 420 464 210 232 420 420 464 without
18. e stays below 25 C 77 F Batteries The temperature should be near 25 C 77 F for optimum battery performance Batteries are less efficient at temperatures below 18 C 65 F and high temperatures reduce battery life Typically at about 35 C 95 F battery life is half of what it would be at a normal temperature of 25 C 77 F At about 45 C 113 F battery life is one fourth of normal Make sure that heaters sunlight air conditioners or outside air vents are not directed toward the batteries These conditions can make the temperature within battery strings vary which can cause differences in the batteries voltages Eventually these conditions affect battery performance If the batteries are not in the system remember that the batteries should be installed as close as possible to the unit to reduce DC wiring costs and improve battery performance Do not allow tobacco smoking sparks or flames in the system location because hydrogen is concentrated under the vent cap of each cell of the battery Hydrogen is highly explosive and it is hard to detect because it is colorless odorless and lighter than air Every type of battery can produce hydrogen gas even sealed maintenance free batteries The gas is vented through the vent caps and into the air mainly when the unit is charging the batteries The batteries produce the most hydrogen when maximum voltage is present in fully charged batteries the batteries do not produce
19. e there is not already a knockout Electronics Cabinet Battery Block Connections Do not connect any battery cables at this time In the following procedure you should only make connections to the electronics cabinet s battery block Use the battery wiring diagram shipped with the battery cables as you follow these steps 1 Find the positive battery cable pulled between the electronics cabinet and the battery cabinet At the ends of the cable strip off 0 5 1 3 cm of insulation Now look at the battery wiring diagram Notice that this cable is connected from the positive position of the battery terminal block inside the electronics cabinet to the outside of the fuse block inside of the battery cabinet Insert the positive cable into fuse block and into the terminal block Tighten the connections as shown on the battery wiring diagram 2 Find the negative battery cable pulled between the electronics cabinet and the battery cabinet At the bare end of the cable strip off 0 5 1 3 cm of insulation Now look at the battery wiring diagram Notice that this is connected from the negative position of the battery terminal block inside the electronics cabinet to a battery inside of the battery cabinet Insert the negative cable into the terminal block and insulate the other end that is in the battery cabinet Tighten the connection as shown on the battery wiring diagram 3 Repeat step 1 and 2 for units with 2 strings 10 kW 12 5 kW
20. ervice according to local and national codes and must be familiar with batteries and battery installation e Before you install maintain or service the unit always remove or shut off all sources of AC and DC power and shut off the system You must disconnect AC line input at the service panel and turn off the Installation Switch S1 the Main AC Input Circuit Breaker CB1 and the Battery Fuse s to make sure the unit does not supply output voltage e Whenever AC and or DC voltage is applied there is AC voltage inside the unit this is because the unit can supply power from AC line or from its batteries To avoid equipment damage or personal injury always assume that there may be voltage inside the unit e Remove rings watches and other jewelry before installing the AC wiring Always wear protective clothing and eye protection and use insulated tools when working near batteries Whenever you are servicing an energized unit with the inside panel open electric shock is possible follow all local safety codes TEST BEFORE TOUCHING e To reduce the risk of fire or electric shock install the unit and its batteries in a temperature and humidity controlled indoor area free of conductive contaminants See page 7 for operating environment specifications 1 Open the unit s doors Make sure the installation switch and the input circuit breaker are off and the battery fuse removed inside the unit 2 Look at the ID label on the inside ri
21. ght door Write down the following information Input Voltage Output Voltage 3 Now make sure the input and output voltages are what you need The Input must be a 4 wire three phases Neutral must be connected Does the input voltage available for the system at the AC service panel match the input voltage shown on the unit s ID label 9 114200D System Installation Manual Service Panel Voltage e Does the output voltage on the ID label match the voltage your loads protected equipment need Input Voltage _ Yes Load Voltage Output Voltage _ Yes _ No Ifyou answered NO to either of the preceding questions call SERVICE 4 Now use the information you wrote down in Step 2 to find the correct circuit breaker for the service panel that is for your system Table 5 1 Recommended Circuit Breaker for Maximum Input Current System Input Voltage Vac Max Current Recommended Circuit Breaker 4 8 KW 120 208 17 20 4 8 KW 277 480 7 15 6 KW 120 208 21 25 6 KW 277 480 9 15 8 KW 120 208 28 35 8 KW 277 480 12 15 10KW i 120 208 35 40 10KW 277 1480 15 20 12 5 KW 120 208 43 50 12 5 KW 277 1480 19 25 16 7 KW 120 208 58 70 16 7 KW 277 480 25 35 WARNING THE EXTERNAL INPUT CIRCUIT BREAKER PROTECTING THE SYSTEM MUST BE A MOTOR START DELAYED TRIP TYPE THIS IS DUE TO MAGNETIC INRUSH CURRENT DRAWN DURING APPLICATION OF AC POWER PLEASE NOTE THAT
22. he input circuit breaker in the input service panel provides the means for disconnecting AC to the unit Only authorized persons shall be able to disconnect AC to the unit see NEC 700 20 and 700 21 CEC Section 46 If you are using the input circuit breaker to disconnect AC you must make sure that only authorized persons have control of the circuit breaker panel to meet the requirements of NEC 700 20 CEC Section 46 8 Read the following caution before removing conduit knockouts CAUTION To prevent electrical shock or damage to your equipment the Installation Switch S1 the Main AC Input Circuit Breaker CB1 and the circuit breaker at the input service panel should all be turned off The Main DC Battery Fuse and the external DC Disconnect Fuse s if you have one should be removed 9 Remove knockouts for AC Input and AC Output in the top or left side of the system AC input conductors and AC output conductors must be installed in separate conduits and emergency and non emergency output circuits must be installed in separate conduits CAUTION Do not drill the cabinet drill filings may damage the unit and keep it from operating If you need larger knockouts use a chassis punch to punch out the appropriate knockout Do not create additional knockouts 10 Install the conduit You must run the AC input service conductors and AC output conductors through separate conduits Emergency output conductors and non emergency output cond
23. here it is not readily subjected to tampering by unauthorized personnel The use of accessory equipment not recommended by the manufacturer may cause an unsafe condition e Do not use this equipment for other than intended use Only qualified service personnel such as a licensed electrician should perform the system and battery installation and initial startup Risk of electrical shock 1142000 System Installation Manual CHAPTER 2 INTRODUCTION Please read this manual thoroughly before operating your safety system Keep this manual and the system User s Guide in the folder mounted inside the unit s door Only qualified service personnel such as a licensed electrician should perform the system and battery installation and initial startup Risk of electrical shock exists Please record your unit s part number serial number and model number below You can find these numbers on the labels on the inside of the system s right door Part Number Serial Number Model Number 4 1142000 Svstem Installation Manual CHAPTER 3 BEFORE INSTALLING THE UNIT Installation Dimensions and Clearances i x DR i u mi MEI I l IL Figure 3 0 Svstem Dimensions Table 3 1 Dimensions Unit Height Width Depth D E E G H 7 K L W Y A B
24. ions must install and service the batteries Any battery used with this unit shall comply with the applicable requirements for batteries in the standard for emergency lighting and power equipment UL 924 Canada s National Building Code Cabinets are design to be used with and batteries must be replaced with manufacturer battery number BAT CG12105 or a manufacturer approved equivalent see the battery wiring diagram that came with the battery cables If you substitute batteries not supplied by manufacturer the unit s UL cUL listing is void and the equipment may fail Installation must conform to national and local codes as well Keep unauthorized personnel away from batteries The electrician must take these precautions Wear protective clothing and eyewear For battery systems gt 48vdc wear rubber gloves and boots Batteries contain corrosive acids or caustic alkalis and toxic materials and can rupture or leak if mistreated Remove rings and metal wristwatches or other metal objects and jewelry Don t carry metal objects in your pockets where the objects can fall onto the batteries or into the system or battery cabinet Tools must have insulated handles and must be insulated so that they do not short battery terminals Do not allow a tool to short a battery terminal to another battery terminal or to the cabinet at any time Do not lay tools or metal parts on top of the batteries and do not lay them where they could fall onto the batteries
25. ke the connection first then torque it to the value shown in Table 6 1 After you make the connection apply a coating of the nonconductive grease to the hardware at the battery terminals 3 In each battery string connect the battery cables between the batteries as shown in the battery wiring diagram positive terminal to negative terminal Torque the connections to the value shown for your battery in Table 6 1 4 Connect the battery cables from one shelf to the next as shown on the battery wiring diagram 5 fuse block to the positive of the battery as shown on the battery wiring diagram CAUTION Hazardous voltage is present System batteries are high current sources These batteries can produce dangerous voltages extremely high currents and a risk of electric shock 6 Install only the battery cabinet s fuse s Next use the voltmeter to check the DC voltage between the positive position on the battery block inside the electronics cabinet and the unconnected battery negative terminal This voltage should be approximately the battery voltage record on the unit ID label If it is greater than or 5 review the battery wiring diagram Correct any wiring errors and recheck the DC voltage do not go on until your measurement is within or 5 If the measurement is too high and you cannot find the cause of the problem call SERVICE CAUTION If you do not verify that voltage and current dire
26. must be connected to the system s chassis ground You can make this connection at the ground terminals inside the system and the battery cabinet as follows CAUTION All grounding conductors should be insulated If you are using non insulated grounding conductors take special care to make sure that the grounding conductors cannot accidentally contact live wires or the batteries In the system find the ground compression lug labeled GROUND This terminal is next to the AC terminal blocks 1 You must supply the equipment grounding conductor that connects the system to the nearest or only battery cabinet Strip 0 5 1 3 cm of insulation from each end of the equipment grounding conductor Then connect one end of the conductor to the ground lug in the system 2 Atthe battery cabinet s ground lug Connect the end of the grounding conductor to this lug 3 If the unit has two battery cabinets you must supply the grounding conductor that connects the cabinets Strip 0 5 1 3 cm of insulation from each end of this grounding conductor Connect one end to the ground lug in the first battery cabinet and connect the other end to the matching ground lug in the next battery cabinet Repeat this step if you have more than two battery cabinets NOTE When you connect a separate equipment grounding conductor directly to building steel use the knockouts that are already on the unit Do not make a knockout anywhere on the cabinet wher
27. ocated in the battery cabinets 15 114200D System Installation Manual Installing and Connecting the Batteries Battery Wiring Diagram You should have received a battery wiring diagram with your system This battery wiring diagram shows how you should install the batteries make terminal and fuse connections Use the diagram as you follow the steps below Location Before you start installing the batteries you must install the system and any battery cabinets in their permanent location If you have not already done this see Location Guidelines on page 6 to choose a location CAUTION To prevent damage to your equipment do not move the system or separate battery cabinets after the batteries are installed To make sure a location is acceptable for the system review the requirements in Chapter 3 Connecting the Cabinets Wherever conductors may be exposed to physical damage you must protect the conductors in accordance with the NEC or CEC This includes battery cables between the system and a separate battery cabinet and cables between battery cabinets if you have more than one We recommend routing the battery cable through the chase nipples The battery cables shipped with the unit are designed for an installation with the battery cabinet immediately to the right of touching the system If the cabinets must be farther apart we recommend that you use conduit cables not included Install the conduit for the ba
28. t hum should be heard from the inverter transformer The unit is now charging and the output should be energized 21 1142000 Svstem Installation Manual 22 INSTALLATION BATTERY TERMINAL BATTERY FUSE Figure 7 0 Battery Fuse DC Pre charge Switch amp Installation Switch 114200D Svstem Installation Manual FRONT PANEL DISPLAY The Front Panel Display consists of a 2 x 20 alpha numeric LCD display with LED back lighting 5 status LED indicators and a 4 x 4 keypad for user interface Control Panel Keypads Table 7 1 Keypad Functions Key Name Description Meter Blue Pressing this key will activate Meter Functions Control Red Pressing this key will activate Control Functions Program Black Using this key you can enter passwords or change parameter values To enter passwords press PROGRAM enter the password and press ENTER NOTE A password must be entered to change parameters Enter Grey This key records or enters a task you perform using the control panel keys lt This key functions as Left scroll key P gt This key functions as Right scroll key 0 This key works as a number key it is also used to display active alarms when in CONTROL Mode 1 through 9 These keys work as number keys
29. tery terminal connections use the torque wrench to tighten the battery terminal connections securely For most batteries you can find out what torque value to use by finding the battery number on the top of the battery Then use Table 6 1 to find the torque value for that battery Table 6 1 Battery Torque Battery Type Torque BAT CG12105 or SL 12105 Torque to 120 in Ibs 13 6 Nm BAT CG12105A or SL 12105M Torque to 120 in Ibs 13 6 Nm BAT CG12105B Torque to 55 in Ibs 6 5 Nm BAT CG12105E or 12AVR100 3ET Torque to 60 in Ibs 6 8 Nm BAT CG12105G Torque to 60 in Ibs 6 8 Nm Now follow these steps to connect the cables 1 Using the battery wiring diagram determine which batteries belong to each battery string 114200D System Installation Manual NOTE For standard 90 minute runtimes 4 8 kW 6 0 kW and 8 0 kW models have only one battery string 10 0 kW 12 5 kW and 16 7 kW models have two battery strings 2 Clean the cable connectors with the wire brush before you make the battery connections NOTE As you carry out the following step use these guidelines If you are using conductive grease apply a thin coating of high temperature conductive grease on each post and every cable connector before you assemble and torque the connection to slow corrosion If you use nonconductive grease like petroleum jelly do not apply any grease before you make the connections and torque them Instead ma
30. ttery cables according to local or national codes If you are using conduit you must substitute your own cables for the cables shipped with the unit as you follow the battery installation instructions Remember that the terminal blocks supplied with the unit and battery cabinets accept up to 4 0 AWG 21 15 mm wire If code requires a larger size cable you must use cable splices Perform the splices when the instructions describe terminations at the terminal blocks Use the correct type length and gauge of cable make sure your installation meets all applicable electrical codes Installing the Battery Cables between Cabinets You must pull the battery cables and the equipment grounding conductor through the connecting nipple or through the conduit between the unit and the battery cabinet s NOTE If you are using conduit you must supply the correct length gauge and type of battery cables Refer to the battery wiring diagram to identify the battery cables you use to connect the unit to the battery cabinet s Pull the cables through the nipple or conduit Do not connect any cables at this time If your unit has more than one battery cabinet use the battery wiring diagram to identify the cables you use to connect the battery cabinets Pull these cables through the connecting nipple or conduit Do not connect the cables 114200D Svstem Installation Manual Making the Equipment Ground Connection Each battery cabinet ground or earth
31. ttery terminals to the cabinet Wear the safety equipment required by local code whenever the doors are open and whenever you are working on batteries Other tools may be necessary for optional batteries Digital volt ohm meter Conductive grease or petroleum jelly 7 16 open end wrench Brush to apply grease or petroleum jelly to terminals 3 extension socket e Safety equipment required by local codes e Ratchet Torque wrench calibrated in inch pounds or Newton meters e Wire brush e 7 16 socket wrench Electrical tape Safety glasses with side shields Battery Voltage vdc 90 Minute System Models 120 Minute System Models Models 4 8K 6 0K 8 0K 10 0K 12 5K 16 7K 4 8K 6 0K 8 0K 10 0 12 5 233 144v 180v 240v 144 180v 240v 180v 240v 144v 180v 240v Battery Cable Sizing The battery cable or wire used is No 6 AWG 13 30 mm for all applications If the batteries must be more than two feet 0 6 meters from the system you may need to install larger battery cables between the battery cabinets and the system Using long cable runs and larger diameter cables require a modified installation of the system call SERVICE if you did not order the longer larger diameter cable with the system DC Disconnect Systems have a Main Battery Fuse F1 inside the electronics cabinet this fuse lets you remove DC power from the batteries Systems also have a fuse on each battery string l
32. uctors must also be run through separate conduits Emergency output circuits shall be installed in dedicated conduit systems and not shared with other electrical circuits as described in NEC 700 9 b CEC Section 47 108 The next step explains where to make the AC connections to the system INSTALLING AC INPUT WIRES 11 Connect AC utility from the service panel to the system s terminal block labeled INPUT Phasing must be clockwise Rotation i e Phase B lags Phase Connect each Line hot wire to each of the input block positions marked Line connect the Neutral common wire to the input block marked Neutral and the ground wire to the compression lug next to the input terminal block INSTALLING AC OUTPUT WIRES 12 Connecting load wires without system distribution circuit breakers connect load wires to the system s terminal block labeled OUTPUT Repeat as in step 11 13 Connecting load wires with distribution circuit breakers connect load wires directly to the circuit breakers and the neutral wires to the neutral bar 114200D Svstem Installation Manual 12 DISTRIBUTION BREAKERS DD onl lt L INPUT BREAKER i 4 D Fik NEUTRAL of oe
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