Galaxy VM System Bypass Cabinet 640 kva Installation GVMSBC640KHEL 06/2016 www.schneider-electric.com
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System Bypass Cabinet 640 kva Table of Contents Important Safety Instructions SAVE THESE INSTRUCTIONS...5 Electromagnetic Compatibility...6 Safety Precautions...6 Electrical Safety...8 Symbols Used...9 Specifications... 11 Recommended Cable Sizes for Bypass and Load... 11 Copper Conductors... 11 Aluminum Conductors... 11 Recommended Bypass Upstream Protection...12 Recommended Bolt and Lug Sizes...12 Torque Specifications...12 System Bypass Cabinet Weights and Dimensions...12 Introduction...13 Overview of Supplied Installation Kits...13 Installation Kit 0M-93063...13 Installation Procedure for System Bypass Cabinet...14 Remove the System Bypass Cabinet from the Pallet...15 Prepare for Cables in a Bottom Cable Entry System...17 Prepare for Cables in a Top Cable Entry System...20 Connect the Power Cables...24 Connect Signal Cables between I/O Cabinets and System Bypass Cabinet...28 Install the Kick Plates...32 990 9709B 001 3
Important Safety Instructions SAVE THESE INSTRUCTIONS Important Safety Instructions SAVE THESE INSTRUCTIONS System Bypass Cabinet 640 kva 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. 990 9709B 001 5
System Bypass Cabinet 640 kva Important Safety Instructions SAVE THESE INSTRUCTIONS 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. Electromagnetic Compatibility NOTICE RISK OF ELECTROMAGNETIC DISTURBANCE This is a product Category 3 according to IEC 62040-2 for commercial, industrial and similar applications in the second environment - installation restrictions or additional measures may be needed to prevent disturbances. The second environment includes all commercial, light industry and industrial locations other than residential, commercial and light industrial premises directly connected without intermediate transformer to a public low-voltage mains supply. The installation and cabling must follow the Electromagnetic compatibility rules, e.g.: the segregation of cables, the use of shielded or special cables when relevant, the use of grounded metallic cable tray and supports. Failure to follow these instructions can result in equipment damage. 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. 6 990 9709B 001
Important Safety Instructions SAVE THESE INSTRUCTIONS System Bypass Cabinet 640 kva DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH The product must be installed according to the specifications and requirements as defined by Schneider Electric. It concerns in particular the external and internal protections (upstream breakers, battery breakers, cabling, etc.) and environmental requirements. No responsibility is assumed by Schneider Electric if these requirements are not respected. After the UPS system has been electrically wired, do not start up the system. Start-up must only be performed by Schneider Electric. Failure to follow these instructions will result in death or serious injury. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH The UPS system must be installed according to local and national regulations. Install the UPS according to: IEC 60364 (including 60364 4 41- protection against electric shock, 60364 4 42 - protection against thermal effect, and 60364 4 43 - protection against overcurrent), or NEC NFPA 70, or Canadian Electrical Code (C22.1, Part 1) depending on which one of the standards apply in your local area. Failure to follow these instructions will result in death or serious injury. 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. 990 9709B 001 7
System Bypass Cabinet 640 kva Important Safety Instructions SAVE THESE INSTRUCTIONS 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. HAZARD OF ARC FLASH WARNING 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. RISK OF OVERHEATING NOTICE 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. RISK OF EQUIPMENT DAMAGE NOTICE 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. 8 990 9709B 001
Important Safety Instructions SAVE THESE INSTRUCTIONS System Bypass Cabinet 640 kva Distribution Related Backfeed The upstream disconnection switch gear must be suitable for disconnection purpose. Before working on the upstream supply, the MBB must be locked in open position using the build-in lockout function. When installing the system bypass cabinet, warning labels must be posted on the load side of all upstream disconnection devices as shown in the illustration up to the transformer. The labels are supplied 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): NOTE: Three labels are provided with the system bypass cabinet. Symbols Used Stand-by Hazardous voltage Attention or consult accompanying documents Output Input OFF (power disconnection from utility/mains) or output disabled 990 9709B 001 9
System Bypass Cabinet 640 kva Important Safety Instructions SAVE THESE INSTRUCTIONS ON (power connection to the utility/mains) or output enabled Alternating current Direct current Connection for the neutral conductor on permanently installed equipment Earth (ground) 10 990 9709B 001
Specifications Specifications System Bypass Cabinet 640 kva HAZARD OF EQUIPMENT DAMAGE NOTICE Refer to the UPS installation manual for detailed specifications of the UPS system. Failure to follow these instructions can result in equipment damage. Recommended Cable Sizes for Bypass and Load NOTE: Refer to the UPS installation manual for UPS input and output cable sizes. Cable sizes in this manual are based on table 52 C4 of IEC 60364 5 52 with the following assertions: 90 C conductors An ambient temperature of 30 C Use of copper or aluminum conductors If the ambient temperature is greater than 30 C, larger conductors are to be selected in accordance with the correction factors of the IEC. NOTE: Bypass cables must be rated at minimum 90 C. Copper Conductors Parallel UPSs Capacity (kva) OCPD (A) Installation Method B1 (mm²) B2 (mm²) C (mm²) 320 500 3 x 95 3 x 120 2 x 120 400 630 3 x 120 4 x 120 2 x 150 480 800 4 x 120 3 x 150 600 1000 3 x 185 640 1000 3 x 185 Aluminum Conductors Parallel UPSs Capacity (kva) OCPD (A) Installation Method B1 (mm²) B2 (mm²) C (mm²) 320 500 3 x 120 4 x 120 2 x 185 400 630 4 x 120 2 x 240 480 800 3 x 240 600 1000 4 x 240 640 1000 4 x 240 990 9709B 001 11
System Bypass Cabinet 640 kva Specifications Recommended Bypass Upstream Protection This system bypass cabinet is rated for use on a circuit capable of delivering no more than 35 ka RMS symmetrical at 415 volts. 320 kva 400 kva 480 kva 600 kva 640 kva Breaker 1 NSX630N Mic2.3 NSX630N Mic2.3 NS800N Mic2.0 NS1000N Mic2.0 NS1000N Mic2.0 Rating(A) 500 630 800 1000 1000 Io (A) 500 630 Ir (xio) 1 1 1 1 1 Isd (XIr) 2 1.5-10 1.5-10 1.5-10 1.5-10 1.5-10 Tr 2 0.5-24 0.5-24 0.5-24 Recommended Bolt and Lug Sizes Cable Size Terminal Bolt Diameter Cable Lug Type 70 mm 2 M10 KST TLK70 12 95 mm 2 M10 KST TLK95 12 120 mm 2 M10 KST TLK120 12 150 mm 2 M10 KST TLK150 12 185 mm 2 M10 KST TLK185 12 240 mm 2 M10 KST TLK240 12 Torque Specifications Bolt size M4 M5 M6 M8 M10 M12 M14 Torque 1.7 Nm (1.25 lb-ft) 2.5 Nm (1.84 lb-ft) 5 Nm (3.69 lb-ft) 17.5 Nm (12.91 lb-ft) 30 Nm (22 lb-ft) 50 Nm (36.87 lb-ft) 75 Nm (55.31 lb-ft) System Bypass Cabinet Weights and Dimensions Weight kg Height mm Width mm Depth mm System bypass cabinet (GVMSBC640KHEL) 328 1970 712 859 1. Or other breaker with equivalent electronic trip unit for the rating 2. Isd and Tr must be set by the installer based on the installation coordination 12 990 9709B 001
Introduction Introduction System Bypass Cabinet 640 kva Overview of Supplied Installation Kits Installation Kit 0M-93063 Part Used in Number of Units Cable relief Connect the Power Cables, page 24 19 Cable ties for power cables 200 Cable ties for signal cables Connect Signal Cables between I/O Cabinets and System Bypass Cabinet, page 28 20 Cable tie for signal cables 30 M6 x 16 RLX screw Install the Kick Plates, page 32 20 Kick plates for front and rear sides of cabinet 2 Kick plates for right and left sides of cabinet 2 M6 clipping on nut Spare parts 20 990 9709B 001 13
System Bypass Cabinet 640 kva Installation Procedure for System Bypass Cabinet Installation Procedure for System Bypass Cabinet 1. Remove the System Bypass Cabinet from the Pallet, page 15. 2. Prepare for cables. Follow one of the procedures: Prepare for Cables in a Bottom Cable Entry System, page 17. Prepare for Cables in a Top Cable Entry System, page 20. 3. Connect the Power Cables, page 24. 4. Connect Signal Cables between I/O Cabinets and System Bypass Cabinet, page 28. 5. Install the Kick Plates, page 32. 14 990 9709B 001
Remove the System Bypass Cabinet from the Pallet System Bypass Cabinet 640 kva Remove the System Bypass Cabinet from the Pallet 1. Remove the bolts from the front and rear. Front View of the System Bypass Cabinet 2. Slide out the plate from below the cabinet. Front View of the System Bypass Cabinet 990 9709B 001 15
System Bypass Cabinet 640 kva Remove the System Bypass Cabinet from the Pallet 3. Lift the cabinet with a pallet jack or a forklift. Front View of the System Bypass Cabinet 4. Remove the two bolts from the right side and the two bolts from the left side and slide out the pallet parts. 5. Lower the cabinet onto the floor. Front View of the System Bypass Cabinet 16 990 9709B 001
Prepare for Cables in a Bottom Cable Entry System System Bypass Cabinet 640 kva Prepare for Cables in a Bottom Cable Entry System DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Do not drill or cut holes for cables with the gland plates installed and do not drill or cut holes in close proximity to the UPS system. Failure to follow these instructions will result in death or serious injury. 1. Open the front door of the system bypass cabinet. 2. Loosen the screws and remove the cover. Front View of the System Bypass Cabinet 990 9709B 001 17
System Bypass Cabinet 640 kva Prepare for Cables in a Bottom Cable Entry System 3. Loosen the screws and remove the cover with the SIB and MBB handles in the open position. Front View of the System Bypass Cabinet 4. Loosen the screws and remove the bottom cover. Front View of the System Bypass Cabinet 5. Drill or cut holes for power and signal cables in the bottom cover. 18 990 9709B 001
Prepare for Cables in a Bottom Cable Entry System System Bypass Cabinet 640 kva 6. Reinstall the bottom cover and fasten with the screws. Front View of the System Bypass Cabinet DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Ensure that there are no sharp edges that can damage the cables. Failure to follow these instructions will result in death or serious injury. 990 9709B 001 19
System Bypass Cabinet 640 kva Prepare for Cables in a Top Cable Entry System Prepare for Cables in a Top Cable Entry System DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Do not drill or cut holes for cables with the gland plates installed and do not drill or cut holes in close proximity to the UPS system. Failure to follow these instructions will result in death or serious injury. 1. Open the front door of the system bypass cabinet. 2. Loosen the screws and remove the cover. Front View of the System Bypass Cabinet 20 990 9709B 001
Prepare for Cables in a Top Cable Entry System System Bypass Cabinet 640 kva 3. Loosen the screws and remove the cover with the SIB and MBB handles in the open position. Front View of the System Bypass Cabinet 990 9709B 001 21
System Bypass Cabinet 640 kva Prepare for Cables in a Top Cable Entry System 4. Swap the top and bottom covers of the system bypass cabinet. a. Loosen the screws and remove the two bottom covers. b. Loosen the screws and remove the top cover and install it in the bottom of the system bypass cabinet. Front View of the System Bypass Cabinet 5. Drill or cut holes for power and signal cables in the larger of the two covers that were installed in the bottom of the system bypass cabinet. 22 990 9709B 001
Prepare for Cables in a Top Cable Entry System System Bypass Cabinet 640 kva 6. Install the two covers on the top of the system bypass cabinet and fasten with the screws. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Ensure that there are no sharp edges that can damage the cables. Failure to follow these instructions will result in death or serious injury. 990 9709B 001 23
System Bypass Cabinet 640 kva Connect the Power Cables Connect the Power Cables Front View of the System Bypass Cabinet 1. Connect the PE cable. 2. Connect the UPS output cables to the UPS output terminals. 3. Connect the load cables to the load terminals. 4. Connect the bypass cables to the bypass terminals. 24 990 9709B 001
Connect the Power Cables System Bypass Cabinet 640 kva 5. Fasten the cables with the provided cable reliefs. NOTE: In the event of a down stream low impedance short circuit the cabinet must be inspected for dislocation of cable anchoring. Side View of the System Bypass Cabinet in a Top Cable Entry System Side View of the System Bypass Cabinet in a Bottom Cable Entry System 990 9709B 001 25
System Bypass Cabinet 640 kva Connect the Power Cables 6. Fasten the cables with the provided cables ties to the cable support in the bottom of the cabinet. The cable support can be moved vertically if needed. Front View of the System Bypass Cabinet 26 990 9709B 001
Connect the Power Cables System Bypass Cabinet 640 kva 7. Reinstall the cover and fasten with the screws. Front View of the System Bypass Cabinet 8. Route the signal cables that are connected to the MBB and the SIB in the right side (front view) of the system bypass cabinet and connect to the printed circuit board 640 6507. a. Connect the cable 0W98694 from the MBB to the J3866 terminal. b. Connect the cable 0W98693 from the SIB to the J3850 terminal. 990 9709B 001 27
System Bypass Cabinet 640 kva Connect Signal Cables between I/O Cabinets and System Bypass Cabinet Connect Signal Cables between I/O Cabinets and System Bypass Cabinet 1. Route the signal cables from the I/O cabinets through the top or the bottom of the system bypass cabinet to the printed circuit board 640 6507 in the bottom of the system bypass cabinet. Top Cable Entry System Bottom Cable Entry System 2. Fasten the signal cables with the provided cable ties. 3. Remove the jumpers from J5608 on the printed circuits boards 640 3635 in the I/O cabinets before wiring. 28 990 9709B 001
Connect Signal Cables between I/O Cabinets and System Bypass Cabinet System Bypass Cabinet 640 kva 4. Depending on the number of parallel UPS units, connect the below signal cables between the system bypass cabinet and the I/O cabinet of each specific UPS: NOTE: The signal cables must have a minimum rating of 600 V Class II. UPS 1 Signal Cables UPS 2 Signal Cables 990 9709B 001 29
System Bypass Cabinet 640 kva Connect Signal Cables between I/O Cabinets and System Bypass Cabinet UPS 3 Signal Cables UPS 4 Signal Cables 30 990 9709B 001
Connect Signal Cables between I/O Cabinets and System Bypass Cabinet System Bypass Cabinet 640 kva UPS 5 Signal Cables 5. Reinstall the cover and fasten with the screws. Front View of the System Bypass Cabinet 990 9709B 001 31
System Bypass Cabinet 640 kva Install the Kick Plates Install the Kick Plates 1. Install the kick plates on the front and rear of the system bypass cabinet. Fasten the kick plates with the provided screws. Front View of the System Bypass Cabinet 2. Install the kick plates on the sides of the system bypass cabinet. Fasten the kick plates with the provided screws. 32 990 9709B 001
Schneider Electric 35 rue Joseph Monier 92500 Rueil Malmaison France + 33 (0) 1 41 29 70 00 www.schneider-electric.com As standards, specifications, and design change from time to time, please ask for confirmation of the information given in this publication. 2015 2016 Schneider Electric. All rights reserved. 990 9709B 001