9350 Series 685 and 1085 Auxiliary Battery Cabinets Installation Manual 164201408 Rev.
IMPORTANT SAFETY INSTRUCTIONS Instructions Importantes Concernant La Sécurité SAVE THESE INSTRUCTIONS Conserver Ces Instructions This manual contains important instructions for your battery system. You should follow these instructions during the installation and maintenance of the battery cabinets. Cette notice contient des instructions importantes concernant la sécurité.
ATTENTION: Une batterie peut prêsenter un risque de choc êlectrique, de brulure, ou d’incendie. Suivre les précautions qui s’imposent. • Pour le remplacement, utiliser le même nombre et modéle des batteries. • L’élimination des batteries est règlementée. Consulter les codes locaux à cet effet. General Notes About Installing Battery Cabinets Each battery cabinet is packed and crated separately for shipping.
UPS Systems Using Series 685 and Series 1085 Battery Cabinets • Powerware 9350 (30 kVA---80 kVA) • Powerware 9350 (100 kVA---160 kVA) Conventions Used in This Manual The text in this manual uses these conventions: • Bold type highlights important concepts in discussions and key terms in procedures. • Italic type highlights notes and new terms where they are defined. • Rectangular boxes containing bold type are warnings or cautions that pertain to the battery system or its electrical connections.
Table of Contents 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Typical Battery Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification of Your Battery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . For More Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Getting Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
dddddddddddddddddddddddddddddddddddddddddddddddddddddddddddddddddddddd ddddddddddddddddddddddddddddddddddddddddddddddddddddddd Figures vi List of Figure 1. Typical Battery Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Figure 2. UPS with Lineup and Match Battery Cabinet . . . . . . . . . . . . . . . . . . . . . . . . 2 Figure 3. UPS with Separate Battery Cabinets (Attached to Each Other) . . . . . . . . 3 Figure 4.
Introduction This manual describes how to install the Powerware 9350 Series 685 or Series 1085 Battery Cabinet (see Figure 1). It contains instructions for unpacking and inspecting the battery cabinet, locating the battery cabinet with respect to the UPS, and electrically connecting the battery cabinet to the UPS. The information you will use depends on the type of UPS and series of battery cabinet that you purchased.
Identification of Your Battery System Refer only to the parts of this manual that apply specifically to your system configuration. See Figures 2 and 3 to determine where to find your system installation instructions in this manual. UPS Battery Cabinet Figure 2. UPS with Lineup and Match Battery Cabinet For installation instructions, refer to “The Powerware 9350 UPS with Integral Battery Cabinets” section of Chapter 3. Refer to Chapter 2, “Unpacking Your Battery Cabinet” for unpacking instructions.
UPS Battery Cabinets Figure 3. UPS with Separate Battery Cabinets (Attached to Each Other) For installation instructions, refer to “The Powerware 9350 UPS with Separate Battery Cabinets” section of Chapter 3 or Chapter 4. Refer to Chapter 2, “Unpacking Your Battery Cabinet” for unpacking instructions. Powerware 9350 Series 685 and 1085 Auxiliary Battery Cabinets Installation Manual 164201408 Rev.
For More Information This manual describes how to install your battery cabinet. For more information about the operation and communications capabilities of your UPS system, refer to the following: 164201407 Powerwarer 9350 (100 kVA ---160 kVA) UPS Installation Describes the UPS installation procedure; discusses optional accessories, environmental considerations, weight and point loading, connection diagrams, and information on other optional cabinets.
Unpacking Your Battery Cabinet Each Powerware 9350 Series 685 or Series 1085 Battery Cabinet is shipped on a separate pallet. Use a forklift or pallet jack to move the packaged cabinets to the installation site, or as close as possible to the site, before you unload them from the pallets. Battery cabinets must be installed in accordance with all applicable codes and regulations, including the National Electrical Code (NEC), Article 480.
Inspecting and Unpacking Each Cabinet The first task in preparing for installation is inspecting and unpacking each cabinet. Cabinets arrive covered with protective packaging material, as shown in Figure 4. OUTER PACKAGING PLY---FOAM CUSHIONS Figure 4. Cabinet as Shipped, with Outer Packaging and Pallet 6 Powerware 9350 Series 685 and 1085 Auxiliary Battery Cabinets Installation Manual 164201408 Rev.
1. Carefully inspect the outer packaging for evidence of damage during transit. CAUTION: DO NOT INSTALL A DAMAGED CABINET. REPORT ANY DAMAGE TO THE CARRIER. CONTACT YOUR LOCAL SALES OR SERVICE OFFICE IMMEDIATELY. 2. Use appropriate material handling equipment to move the cabinet to a convenient unpacking area. Space is provided between the pallets to insert pallet jack blades on the bottom of the unit. DANGER: RISK OF INSTABILITY.
LEFT HAND DOOR (Step 1) FRONT SUPPORT 2 SIDE SUPPORT FOAM CUSHION 1 FLOOR PROTECTOR (Step 2) 2 2 2 1 1 (Step 3) 2 (Step 8) JACKING BOLT (Step 2) Figure 5. Removing Front and Rear Supports 3. Loosen, but do not remove, the hardware holding the foam cushions to the front and rear supports (labeled “1” in Figure 5). WARNING: SERIOUS INJURY MAY OCCUR! BATTERY CABINETS ARE EXTREMELY HEAVY. IF UNLOADING INSTRUCTIONS ARE NOT CLOSELY FOLLOWED, CABINET MAY TIP. 4.
DANGER: CABINET MAY FALL! DO NOT LOOSEN THE HARDWARE ATTACHING THE SIDE OR FRONT SUPPORTS TO THE CABINET BASE, OR THE FRONT AND SIDE SUPPORTS TO EACH OTHER, AT THIS TIME. THE CABINET MUST BE LOWERED BY THE JACKING BOLTS BEFORE THE SUPPORTS CAN BE REMOVED. 6. Carefully and evenly lower the cabinet by turning each jacking bolt consecutively two full turns (maximum) until the supports contact the floor, and the cabinet is no longer supported by the jacking bolts. 7.
NOTES: ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ___________________
Connecting to Powerware 9350 30 ---160 The method you use to install your battery cabinets depends on which UPS you have. For the purpose of discussion, this chapter uses the term UPS to refer to the UPS cabinet, and the term battery cabinet to refer to any battery cabinet. There are two different sizes of battery cabinets, but the procedure for connecting the cabinets to your UPS system is the same.
1. Make sure that the UPS is properly installed and secured with its leveling feet. 2. Roll the battery cabinet to a spot near the right-hand side of the UPS, as shown in Figure 7. 3. The field kit is attached with cable ties to the frame inside the door. Remove and retain the field kit for later use. 4. If necessary, remove the cosmetic covers and hanger brackets from the right-hand side of the UPS. Save covers, screws, and brackets for later reuse. 5.
Screw from kit Back of UPS Two small brackets go here (see detail at left) Back of 685 and 1085 Battery Cabinet Bracket from kit Existing Screw Bracket from kit Screw from kit Front of UPS Existing Screw Front of 685 Battery Cabinet UPS Cabinet Battery Cabinet Large bracket goes here (see Figure 8 for Series 1085) Existing Screw (see Figure 9 for Series 685) Bracket from kit Front of UPS Front of 1085 Battery Cabinet NOTE: When cabinets are properly aligned, all cabinet doors will be flush wit
TOP VIEW Ground Wire Ground Stud Bracket from kit Existing hinge FRONT VIEW Nut from kit Front of UPS Nut from kit Front of 1085 Battery Cabinet Figure 8. Attaching UPS Base to Series 1085 Base 12. Route the ground wire (from the field kit) from the customer ground stud in the battery cabinet, under the lower right-hand battery tray, through the access hole in the side panel of the UPS, and attach to customer ground stud in the UPS cabinet. Hardware is provided on each ground stud. 13.
TOP VIEW Ground Wire Ground Stud Bracket from kit FRONT VIEW Bracket from kit Nut from kit Nut from kit Screw from kit Front of UPS Front of 685 Battery Cabinet Figure 9. Attaching UPS Base to Series 685 Base 17. Locate the ground wire from the field kit. Route the ground wire from the customer ground stud in the battery cabinet, under the lower right-hand battery tray, through the access hole in the side panel of the UPS, and attach to customer ground stud in the UPS cabinet.
To Electrically Connect Integral Battery Cabinets Together and to the UPS: 1. All battery cabinets will arrive at your site with each battery connection string electrically disconnected. If you are installing more than one battery cabinet, perform Steps 2 through 6 for each cabinet. The battery cabinet adjacent to the UPS will be the only cabinet directly connected to the UPS. WARNING: LETHAL VOLTAGE WILL BE PRESENT WHEN PERFORMING THE REMAINING STEPS IN THIS SECTION AND SUBSEQUENT SECTIONS. 2.
BATTERY BREAKER FIXED RIGHT BATTERY POWER CONNECTOR (BLACK) STRING CONNECTORS (RED) CONNECTION FOR REMOTE MONITORING CUSTOMER CONNECTION CABINET GROUNDING (REMOTE INSTALLATION) CABINET TO CABINET TERMINAL (+) (LEFT) CABINET TO CABINET TERMINAL (---) (RIGHT) GROUNDING STUD LOCATION (2X) GROUNDING STUD LOCATION (2X) CABLE ACCESS LOCATION LEVELING FEET Figure 10. Series 685 Battery Cabinet Wiring Detail Powerware 9350 Series 685 and 1085 Auxiliary Battery Cabinets Installation Manual 164201408 Rev.
HANGER BRACKET LOCATION (SECURED WITH SCREWS) Series 685 Cabinet Series 1085 Cabinet CABINET TO CABINET CABLE ACCESS AREA (EACH SIDE) Figure 11. Series 685 and 1085 Battery Cabinet Hanger Brackets 18 Powerware 9350 Series 685 and 1085 Auxiliary Battery Cabinets Installation Manual 164201408 Rev.
BATTERY BREAKER FIXED RIGHT BATTERY POWER CONNECTOR (BLACK) STRING CONNECTORS (RED) CONNECTION FOR REMOTE MONITORING CUSTOMER CONNECTION CABINET GROUNDING (REMOTE INSTALLATION) CABINET TO CABINET TERMINAL (---) NOTE: COMPRESSION LUGS SHOWN ARE USED FOR REMOTE INSTALLATION ONLY CABINET TO CABINET TERMINAL (+) CABLE ACCESS LOCATION GROUNDING STUD LOCATION (2X) LEVELING FEET Figure 12.
Powerware 9350 UPS with Separately Located Battery Cabinets Use this procedure to wire a separately located Series 685 or Series 1085 Battery Cabinet to any Powerware 9350 UPS cabinet (see Figure 14). In this situation, the Battery cabinets are remotely loacted from the UPS and are lineup and match with each other. Figure 13. UPS with Separately Located Battery Cabinets 20 Powerware 9350 Series 685 and 1085 Auxiliary Battery Cabinets Installation Manual 164201408 Rev.
Back of Battery Cabinet #1 Screw from kit Back of Battery Cabinet #2 Two small brackets go here (see detail at left) Screw from kit Bracket from kit Existing Screw Screw from kit Bracket from kit Front of Battery Cabinet #1 Front of Battery Cabinet #2 BATTERY CABINET #1 BATTERY CABINET #2 Large bracket goes here (see Figure 15) NOTE: When cabinets are properly aligned, all cabinet doors will be flush with each other. Figure 14.
Grounding cable Ground Studs Existing hinge Bracket from kit Bracket from kit Nut from kit Front of Battery Cabinet #1 Nut from kit Screw from kit Front of Battery Cabinet #2 Figure 15. Connecting Two Series 685 Bases 3. Locate the cabinet connecting bracket and two M4×10 hex head screws from the field kit. Attach the bracket to the lower right-hand side of battery cabinet #2 using the two screws (see Figure 15). 4. Locate the large flat bracket from the field kit.
Back of Battery Cabinet #1 Screw from kit Back of Battery Cabinet #2 Two small brackets go here (see detail at left) Screw from kit Bracket from kit Existing Screw Existing Screw Bracket from kit Front of Battery Cabinet #1 Front of Battery Cabinet #2 BATTERY BATTERY CABINET #1 CABINET #2 Large bracket goes here (see Figure 17) NOTE: When cabinets are properly aligned, all cabinet doors will be flush with each other. Figure 16.
Ground Wire Ground Studs Bracket from kit Existing hinge Nut from kit Front of Battery Cabinet #1 Nut from kit Front of Battery Cabinet #2 Figure 17. Connecting Two Series 1085 Bases 3. Locate the large flat bracket from the field kit. Place the bracket over the stud on the bottom side of battery cabinet #1 lower hinge, and over the stud on the bottom side of battery cabinet #1 lower hinge. Attach the bracket with two M8 self-locking nuts from the field kit (see Figure 17). 4.
To Electrically Connect Separate Battery Cabinets to the UPS: 1. All battery cabinets will arrive at your site with each battery connection string electrically disconnected. If you are installing more than one battery cabinet, perform Steps 2 through 6 for each cabinet. Battery cabinet #1 (the left-hand cabinet) will be the only cabinet directly connected to the UPS. WARNING: LETHAL VOLTAGE WILL BE PRESENT WHEN PERFORMING THE REMAINING STEPS IN THIS SECTION AND SUBSEQUENT SECTIONS. 2.
8. Mount the side panels to the sides of the first and last battery cabinets: a. Mount the hanger brackets to the top side of the battery cabinets using M4 screws (see Figure 11). b. Hang the side panel on the hanger brackets and align it with the front and rear of the battery cabinet. c. Secure the side panel at the bottom using M4 hex head screws. 9. Secure all battery cabinets by closing and latching the doors. 10. Secure the UPS by reinstalling safety shields and closing and latching the doors.
Completing the Installation Checklist The final step in installing your battery cabinet is to complete the Installation Checklist. This checklist ensures that you have installed all hardware, cables, and other equipment. Completing all items on the checklist will ensure a smooth installation. Make a copy of the Installation Checklist before filling it out, and retain the original.
This Page Intentionally Left Blank. 28 Powerware 9350 Series 685 and 1085 Auxiliary Battery Cabinets Installation Manual 164201408 Rev.
Connecting to Powerware 9350 ---80 and 160 This chapter will explain how to electrically connect your battery cabinets to your Powerware 9350---80 or 160 UPS. Figure 18 details the Battery cabinet DC connections and control wiring connection point in a Powerware 9350---80 UPS. Figure 19 details the same connections in a Powerware 9350---160 UPS. NOTE: See Table C in Appendix A for sizing wire for separate battery configurations.
Powerware 9350---80 or 160 with Separate Battery Cabinets 1. Make sure that the UPS is properly installed and secured. 2. Roll the battery cabinets to their permanent location. 3. Attach and connect the battery cabinets to each other (refer to “The Powerware 9350 UPS with Separate Battery Cabinets” section of Chapter 3). 4. If necessary, remove the cosmetic covers and doors from the UPS. Save covers, screws, and brackets for later reuse. 5.
7. Mount the side panels to the sides of the first and last battery cabinets: a. Mount the hanger brackets to the top side of the battery cabinets using M4 screws (refer to Chapter 3, Figure 11 for location). b. Hang the side panel on the hanger brackets and align it with the front and rear of the battery cabinet. c. Secure the side panel at the bottom using M4 hex head screws. 8. Secure all battery cabinets by closing and latching the doors. 9.
Installation Checklist for Powerware 9350---160 -All packing materials and restraints have been removed from each cabinet. -Each cabinet in the battery system is placed in its correct location. -All battery cabinets are bolted together. -A ground wire is installed between all cabinets that are bolted together. -All conduits and cables are properly routed to the battery cabinets. -A ground conductor is properly installed.
Installing a Remote Battery Disconnect The remote battery disconnect is crated separately for shipping. It is enclosed in a box and is designed to be wall mounted on a surface that can support the weight and bolt pattern described in this chapter. You can install a remote battery disconnect anywhere between the remote DC supply and the UPS, according to national and local codes. Figure 20 shows the remote battery disconnect enclosure. SIDE FRONT ON OFF Figure 20.
You should read and understand these general notes before beginning installation: 34 • The material and labor for external wiring requirements is to be supplied by others. • Power cables and control wiring must be installed in separate conduit. • The ground conductor is to be sized per NEC Article 250 and local electrical code requirements. • The maximum current listed is at the minimum DC operating voltage.
E T A E T T T A A A E A E T T T E A T E Figure 21. Knockout Pattern for Remote Battery Disconnect Table A.
Table C.
Appendix A --- Customer Information The information in the appendix will help you plan for and install your battery system. The appendix contains these drawings: 164201408---1 Series 685 Battery Cabinet 164201408---2 Series 1085 Battery Cabinet 164201408---3 Remote Interface Connections 164201408---4 Series 685 / 1085 Configurations NOTE: Outline diagrams and oneline diagrams for the various UPS models are available in their respective manuals. See this manual for more information.
1. The output of the UPS is a separately derived source. Output neutral is bonded to equipment ground through the main bonding jumper. Refer to NEC Article 250 and local codes for proper grounding practices. 2. Your battery cabinet operating environment must meet the size and weight requirements shown in Table A: Table A.
Table C.
Table C.
Table C. External Wiring Requirements (UPS-to-Battery or Remote Disconnect-to-Battery) NOTE: All specified wire sizes are 90_C rated copper minimum Battery Cabinet Wire Size UPS to Battery Tool Size UPS Cabinet UPS Series/ Model Battery Cabinet Series Battery Type* 160/125 685 H20 2 Integral Supplied 3/8I hex 160/125 685 H20 2 Separate 300 kcmil 3/8I hex 2, 3, or 4 Integral Supplied 3/8I hex 42.4 (375) 3/8I hex 42.4 (375) 2, 3, or 4 Separate 300 kcmil 3/8I hex 42.
735.8 (28.97) 685 (26.97) (without decorative panels) 1870.3 (73.6) Series 685 Battery Cabinet DESCRIPTION: Dimensions are in millimeters (inches) A ---6 DRAWING NO: Series 685 Battery Cabinet (elevation) 164201408 -- 1 SHEET: 1 of 2 Powerware 9350 Series 685 and 1085 Auxiliary Battery Cabinets Installation Manual 164201408 Rev.
WALL --- NO BACK ACCESS REQUIRED TOP CABLE ENTRY LOCATION (COVER SECURED WITH SCREWS) 201.1 (7.92) Series 685 Battery Cabinet TOP VIEW 335 (13.19) 120 (4.72) 80 (3.15) 175 (6.89) 282 (11.1) 280.4 (11.04) 226.9 (8.93) 735.8 (28.97) 75 (2.95) 135 (5.32) 613 (24.14) 453 (17.83) 300.4 (11.83) 914.4 (36.00) MINIMUM CLEARANCE FOR SUBASSEMBLY REMOVAL 61.4 (2.42) 141.4 (5.57) 71 (2.80) 148 (5.83) 151 (5.95) 690 (27.17) Series 685 Battery Cabinet 530 (20.87) BOTTOM VIEW 802.7 (31.
1135.8 (44.72) 1085 (42.72) (without decorative panels) 1870.3 (73.6) Series 1085 Battery Cabinet DESCRIPTION: Dimensions are in millimeters (inches) A ---8 DRAWING NO: Series 1085 Battery Cabinet (elevation) 164201408 -- 2 SHEET: 1 of 2 Powerware 9350 Series 685 and 1085 Auxiliary Battery Cabinets Installation Manual 164201408 Rev.
Series 1085 Battery Cabinet (TOP VIEW) TOP CABLE ENTRY LOCATION (COVER SECURED WITH SCREWS) WALL --- NO BACK ACCESS REQUIRED 201.1 (7.92) 335 (13.19) 120 (4.72) 80 (3.15) 480.4 (18.91) 175 (6.89) 282 (11.1) 426.9 (16.81) 61.4 (2.42) 1135.8 (44.72) 426.5 (16.79) 141.4 (5.57) 442.9 (17.44) 250 (9.84) 1013 (39.88) 426.5 (16.79) 914.4 (36.00) MINIMUM CLEARANCE FOR SUBASSEMBLY REMOVAL 71 (2.80) 88.9 (3.5) 151 (5.95) 102 (4.02) 151 (5.95) 229.1 (9.02) 265 (10.43) 265 (10.43) 802.7 (31.
1 2 3 4 5 6 7 8 9 10 11 12 Note 2,3,4 CB1 ST (+) CB1 ST (--) CB1 AUXILIARY SWITCH (N/O) CB1 AUXILIARY SWITCH (COMM) Note 1 CB1 AUXILIARY SWITCH (N/C) CB1 ST (+) C12 CB1 ST (--) C11 CB1 AUXILIARY SWITCH (N/O) CB1 AUXILIARY SWITCH (COMM) CB1 AUXILIARY SWITCH (N/C) TB1 Note 1 Note 2,3,4 Notes: 1. Shunt trip requires 24V (150 VA instantaneous) to activate (supplied by user). 2. Auxiliary switches are rated as follows: 240 VAC @ 15A 125 VDC @ 0.3A 250 VDC @ 0.15A 3.
4 Cabinets Maximum (E4) (E5) UPS CABINET BATTERY CABINET BATTERY CABINET Powerware 9350 30 through 160 Battery Cabinets integral to UPS and connected using Manufacturer supplied wiring CONTRACTOR WIRING (1) CONTRACTOR WIRING (2) 4 Cabinets Maximum BATTERY DISCONNECT (E4) (E5) UPS CABINET BATTERY CABINET BATTERY CABINET Powerware 9350 30 through 160 Battery Cabinets located separately from the UPS NOTE: The term “Separate” refers to battery cabinets that are not physically attached to the UPS, a
This Page Intentionally Left Blank. A ---12 Powerware 9350 Series 685 and 1085 Auxiliary Battery Cabinets Installation Manual 164201408 Rev.
