User`s Handbook for - Critical Power Group
Contents
1. Battery Wiring SCNGMales act cc iat ok e n 18 Form No 003 2359 Rev A FirstLine Extended Run Time Battery Cabinet 10 KVA SECTION 1 Introduction The FirstLine extended run time battery cabinet is used in conjunction with the FirstLine uninterruptible power supply UPS to prevent loss of valuable electronic information and minimize equipment downtime During brownouts blackouts and other power interruptions batteries provide emergency power to safeguard operation Figure 1 shows the FirstLine extended run time battery cabinet which can be outfitted with one or two strings of batteries See Table 1 for part numbering system 2225 565 0mm 31 94 811 2mm I 6 00 152 4mm MIN WALL CLEARANCE FOR VENTILATION VENTILATION HOLES 46 00 1168 4mm Jo er LEO FRONT ACCESS PANEL FUSES CIRCUIT BREAKER AND BATTERIES CUSTOMER POWER AND CONTROL CONNECTIONS ON REAR lt LEVELING FEET 4 LISTED Figure 1 The FirstLine Extended Run Time Battery Cabinet FirstLine Extended Run Time Battery Cabinet Part Number System Number of DC Bus pup usar Strings Voltage FLU BAT 10 1 B 1 408 VDC FLU BAT 10 2 B 2 408 VDC FLU BAT 12 1 B 1 432 VDC FLU BAT 12 2 B 2 432 VDC Note 12 units are not part of2. Service The batteries must only be serviced by authorized service personnel Before any battery service is attempted the batteries must be disconnected by unplugging the cables to the battery trays Before removing the cables the connections should be marked in a way that no confusion will exist when it is time to reconnect the cables see Figures 6 and 10 The batteries are mounted in slide out trays that permit access to the battery to battery connections when the trays are withdrawn from the cabinet If batteries are being replaced only use the same manufacturer and battery type and rating as the battery removed It is very important that only one tray at a time be extended from the cabinet If more than one tray is extended the cabinet can become unstable and topple over After each tray is installed or serviced it must be fully inserted and secured using the supplied threaded fasteners before attempting to install or service another tray If the trays are to be removed always remove the highest tray first The battery trays are very heavy and it will be necessary to use a lifting device to support the trays as they are removed When the trays are to be reinstalled use the procedure in the following paragraph The battery trays are very heavy and it will be necessary to use a lifting device to support the trays as they are installed Do not take away the external support until the extension limit tabs on the upper sides of the batte
3. UL Listing and are used with the FLU 10S 22 UPS models only Table 1 Part Numbering System Form No 003 2359 Rev A 1 FirstLine Extended Run Time Battery Cabinet 10 KVA SECTION 2 Safety Warnings IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions that you should follow during installation and maintenance of the Battery Cabinet Please read all instructions before operating the equipment and save this manual for future reference f g READ AND FOLLOW ALL SAFETY INSTRUCTIONS Do not use outdoors Do not route wiring across or near hot surfaces Do not install near gas or electric heaters Use caution when servicing batteries Battery acid can cause burns to skin and eyes If acid is spilled on skin or in eyes flush acid with fresh water and contact a physician immediately Equipment should be installed where it will not readily be subjected to tampering by unauthorized personnel The use of accessory equipment not recommended by the manufacturer may cause an unsafe condition Do not use this equipment for other than intended use Table 2 Symbols Danger Risk of Electric Shock Caution Risk of Explosion Note Ground Connection A A AA A Electrostatic Sensitive Device Form No 003 2359 Rev A 2 gt FirstLine Extended Run Time Battery Cabinet 10 KVA This Battery Cabinet contai
4. program REPLACEMENT BATTERY Manufacturer Cat Number Quantity Required China Storage Battery HRL1280W 34 per string China Storage Battery HR1290W 34 Per string REPLACEMENT BATTERY Suitable for computer room applications Manufacturer Cat Number Quantity Required China Storage Battery HR1280WFR 34 Per string China Storage Battery HR1290WFR 34 Per string RECOMMENDED REPLACEMENT INTERVALS Batteries 2 to 5 years Note Batteries suitable for computer rooms are good for all applications 1 FLU BAT 12 Battery cabinet contains 36 batteries per string Note 12 units are not part of UL listing 2 Battery life is highly dependent on the ambient temperature and the number and depth of discharge cycles A discharged battery should be recharged as soon as possible If the battery is left in a discharged state irreversible sulfation occurs reducing the capacity run time of the battery Form No 003 2359 Rev A 17 FirstLine Extended Run Time Battery Cabinet 10 KVA 110 OILVIN3HOS 8 2 NI 7OH1NOO uxpivaug Quvoa8 39VJHU31NI e uaxvaus LINDYIO AuaLiv8 1 7 XXX LIA Leto sey SHO193NNOO SHOLO3NNOO AdaLlvg AHallvg indino
5. to MBS 1 Verify that the bypass source is available Bypass lamp on UPS mimic display is green 2 Perform a manual transfer to bypass mode on the UPS by pressing and holding the ESC key while simultaneously pressing the UP ARROW key Form No 003 2359 Rev A 14 4 FirstLine Extended Run Time Battery Cabinet 10 KVA Verify that the UPS output is ON BYPASS by observing that the lamp associated with the bypass line at the static switch block on the mimic display is green and that the lamp associated with the inverter is not lit Operate the MBS to put it in bypass mode It is now safe to turn off the UPS and close the battery breaker s Restart the UPS To transfer back to normal mode Ts Verify that the UPS is still ON BYPASS by observing the mimic display If not perform a manual transfer to bypass as described above Operate the MBS to put it in normal mode Enable automatic transfer by pressing and holding the ESC key while simultaneously pressing the DOWN ARROW key After a few seconds the mimic display should show that the static switch has transferred the load to inverter CAUTION The battery cabinet circuit breaker must be closed before starting the UPS Switch the circuit breaker On while the UPS is operating can cause equipment damage that is not covered by the equipment warranty Form No 003 2359 Rev A 15 FirstLine Extended Run Time Battery Cabinet 10 KVA SECTION 6 Battery Removal Installation and
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7. The FIRSTLINE EXTENDED RUN TIME BATTERY CABINET 10 KVA User s Manual ERAS PRODUCTS CO 301 Gaddis Boulevard Dayton Ohio 45403 U S Toll Free 866 261 1191 937 253 1191 Fax 937 253 1723 Web site www stacoenergy com Form No 003 2359 Rev A 07 23 2010 FirstLine Extended Run Time Battery Cabinet 10 KVA Form No 003 2359 Rev A FirstLine Extended Run Time Battery Cabinet 10 KVA CONTENTS DLL IM LL INL EIE 1 1 FirstLine Extended Run Time Battery Cabinet Part Number 1 2 Safety Warnings ae 2 4 Battery Cabine oct AERE e E EM A M ELA Lt 4 Inispecting He ete exe 4 Floor koadig PER LUE 4 Clearance MT A 4 Unloading th Cabin ti A 5 LNG m SOOO 4 oca an cierto DP ONE dde deed 8 Electrical Installation Er 8 8 Connecting FirstLine Battery 10 FirstLine UPS Part Number SySIOITI iunio i
8. d ui 3 8 Lag bolts 6 each side and 4 Upper in front _ Forklift fork channel Shipping bracket 1 this side and opposite side Front guard Remove 3 4 19mm spacer Figure 2 Extended Run Time Battery Cabinet Form No 003 2359 Rev A 5 FirstLine Extended Run Time Battery Cabinet 10 KVA Shipping bracket X Remove and discard 3 8 bolt and washers 8 places Figure 3 Shipping Bracket 8 Remove the 8 3 8 bolts mounting the shipping brackets to the cabinet and remove the brackets see figure 3 Roll the cabinet to the desired location 10 Do not move the cabinet to another location by forklift as the cabinet is heavy and may fall Form No 003 2359 Rev A 6 FirstLine Extended Run Time Battery Cabinet 10 KVA Placing The Cabinet Once the cabinet has been rolled into position remove the front panel to access the front leveling feet by lifting the panel up and off the cabinet see figure 5 Adjust the leveling feet as shown in figure 4 l Lower the leveling foot to the floor to secure the cabinet in position Figure 4 Leveling foot being adjusted down to the floor Form No 003 2359 Rev A 7 FirstLine Extended Run Time Battery Cabinet 10 KVA SECTION 4 Electrical Installation A WARNING Only qualified service personnel such as a licensed electrician should perform the Bat
9. e equipment warranty See the procedure below for stopping the rectifier Before connecting the cables between the UPS and the Extended Run Time Battery Cabinet the UPS must be powered down On the Extended Run Time Battery Cabinet the front outer panel must be removed and the circuit breaker placed in the Off position See Section 4 Connecting to the FirstLine Battery Cabinet to connect the cables Stopping the Rectifier in the UPS Before connecting any batteries to the UPS the rectifier must be stopped The rectifier is stopped whenever the UPS is OFF All breakers should be closed when the UPS is started Generally the only reason to open any of the battery disconnect devices is to perform service which requires that the UPS be turned off It is best to close the disconnect devices before starting the UPS and leave them closed during operation In the event of an emergency condition that requires opening a disconnect device it will be necessary to stop the rectifier in order to restore the system to normal configuration The simplest way to stop the rectifier is to turn off the UPS by pressing the power line circle button on the front panel This will remove power from the load Once the battery breaker s has have been closed the UPS can be restarted by pressing the power button If the UPS is connected to the load using a Maintenance Bypass Switch MBS the load can be maintained when the UPS is turned OFF To transfer
10. ent has been damaged during shipment keep the shipping and packing materials for the carrier or place of purchase and file a claim for shipping damage If you discover damage after acceptance file a claim for concealed damage To file a claim for shipping damage or concealed damage 1 File with the carrier within 15 days of receipt of the equipment 2 Send a copy of the damage claim within 15 days to your service representative Floor Loading When planning the installation consider the battery cabinet weight for floor loading The strength of the installation surface must be adequate for point and distributed loading The approximate weights are shown in the following table Table 3 Model Floor Loadings STANDARD MODEL FLOOR LOADING Battery Cabinet Model Maximum Weight Point Loading FLU BAT 10 1 B 757 Lbs 343 kg 241 Ib in 17 kg cm FLU BAT 10 2 B 1289 Lbs 585 kg 410 Ib in 29 kg cm Clearances The following clearances are recommended for the FirstLine Extended Run Time Battery Cabinet From Front of Cabinet 36 91 4 cm working space From Back of Cabinet 6 15 2 cm From Left Side of Cabinet to UPS Minimum 24 61 cm The right side of the UPS needs 24 of clearance for service access if the UPS is a 42 44 or model If the battery cabinet is placed on the left side of the UPS no minimum clearance is required Form No 003 2359 Rev A 4 FirstLine E
11. ex XL C OR Ue e uta Ra Ed 13 SODIOB 14 Stopping the Rectifier the UPS 14 SOGIIOI Duc onus uU NR II 16 Battery Removal Installation and Service 16 ete 17 Part Numbering 3SySlelfi 2 5 Pe a coll oc dtu ede d 1 Table 2 Symbols MM 2 Table Model Floor 2 4022224 0 000 4 Table 4 FirstLine UPS Part Numbering 13 Figure 1 The FirstLine Extended Run Time Battery 1 Figure 2 Extended Run Time Battery 5 Figure 3 Shipping BACK OU seas ipu tem iden cu ee tenete 6 Figure 4 Leveling foot being adjusted down to the floor 7 Figure 5 Removing the Cabinet Front 22 2040 9 Figure 6 Balleflgs ooa erae peii Ide Aptent Pss EG Arana ides 10 Figure T CONMECIOIS A 12 Figure 8 UPS deti tete cnp ded een indue deme einn 13 Figure 9 Battery infensa ette 17 Figure 10
12. hown in figure 7 connectors Red connectors Black connectors White connectors Red connectors Black connectors Fuses Figure 6 Batteries Form No 003 2359 Rev A 10 FirstLine Extended Run Time Battery Cabinet 10 KVA 3 Remove the top screw holding the left input connector cover on the rear panel and loosen the bottom screw of this cover Rotate the cover down Replace the top screw and tighten both screws as shown in figure 7 4 With the supplied 10 foot long power cable Staco part number 817 0368 connect from the left input battery power terminals on the rear of the cabinet to the similar connector on the rear of the UPS Ensure that the positive red connector of the cable connects to the positive red connector on the rear of the cabinets See figure 7 Never connect the positive red to the negative black Severe damage and injury could result 5 Once the power cable is connected place the connect
13. ix Notes Isolation Transformer Isolation transformer required for use with delta 3 wire input Standard is K20 rated 220V Models are not listed to UL CUL or CSA i O Xo N External battery UH circuit breaker control connector UPS REAR VIEW Figure 8 UPS Connections Form No 003 2359 Rev A 13 FirstLine Extended Run Time Battery Cabinet 10 KVA SECTION 5 Special Considerations for Connecting Batteries to the FirstLine UPS including Extended Run Time Battery Cabinets It is never safe to work within either the UPS or the extended battery cabinet while the UPS is powered The batteries produce a lethal voltage whether or not the UPS is powered or running Always work with extreme caution No service work should be performed unless the personnel are properly trained and appropriate tools and equipment are available All batteries must be connected to the UPS prior to starting the rectifier The rectifier runs whenever the UPS is on If a battery is disconnected while the rectifier is running for example if the circuit breaker on an extended battery cabinet is opened while the UPS is running it must not be closed without first stopping the rectifier Connecting a battery while the rectifier is running will cause equipment damage that is not covered by th
14. ns LETHAL VOLTAGES All repairs and service should be performed by AUTHORIZED SERVICE PERSONNEL ONLY There are NO USER SERVICEABLE PARTS inside the Battery Cabinet WARNING This Battery Cabinet contains its own energy source batteries Hazardous voltage may be present even when the battery cabinet is not connected to a power source To reduce the risk of fire or electric shock install this battery cabinet in a temperature and humidity controlled indoor environment free of conductive contaminants Do not operate near water or excessive humidity 95 maximum CAUTION Batteries can present a risk of electrical shock or burn from high short circuit current Observe proper precautions Servicing should be performed by qualified service personnel knowledgeable of batteries and required precautions Keep unauthorized personnel away from batteries Risk of explosion if batteries are replaced by an incorrect type Replace with same type and rating only Proper disposal of batteries is required Refer to your local codes for disposal requirements Never dispose of batteries in a fire Batteries may explode when exposed to flame Form No 003 2359 Rev A 3 FirstLine Extended Run Time Battery Cabinet 10 KVA SECTION 3 Battery Cabinet Setup This SECTION describes Equipment inspection Floor loading and clearances Removing and replacing the cabinet panels Unloading the cabinet Inspecting The Equipment If any equipm
15. or clamping brackets over the connectors as shown in figure 7 and lock in place with the 6 32 screws 6 With the supplied 10 foot long 6 pin Mini DIN cable Staco part number 273 0413 connect from the left input circuit breaker control connector on the rear of the cabinet to the similar connector on the rear of the UPS See figure 8 7 Switch the circuit breaker to the On position 8 Replace the front panel of the battery cabinet CAUTION If the circuit breaker trips the internal batteries of the UPS are still connected and providing power to the UPS 9 Additional battery cabinets connect to the Battery Power Out connector on the first or previous battery cabinet instead of the UPS Similarly the Circuit Breaker Control Out connection is made from the first or previous battery cabinet to the Circuit Breaker Control In of the next or following cabinet Form No 003 2359 Rev A 11 E E Form No 003 2359 Rev A FirstLine Extended Run Time Battery Cabinet 10 KVA Remove this screw and replace after cover is rotated Connector covers EET Ex ae FPS ol o o lo am UNDER LOAD CIRCUIT BREAKER CONTROL Loosen this screw but do n
16. ot remove Tp 1 4 pey J J rs Cee ee Se C m Battery Connector 2 N e POWER CABLE connections TOP VIEW in s e e Rotate cover down and tighten screws If cable is removed cover must be rotated our CIRCUIT BREAKER CONTROL back over the opening l and locked in place T with screws Connector clamping bracket N REAR VIEW 2 E 44 connections BNO Power Cable 4 2 4 8 pa LEFT SIDE VIEW Figure 7 Connectors 12 FirstLine Extended Run Time Battery Cabinet 10 KVA The following FirstLine UPS models are to be used with this battery cabinet FirstLine UPS Part Number System Table 4 FirstLine UPS Part Numbering System Full Part Number Output Basic Part Battery Other Input Voltage Voltage No Option Options 480 208Y 120 FLU 10S 42 480 480Y 277 FLU 10S 44 1 10 208Y 120 208Y 120 FLU 10S 20 2 208Y 120 208Y 120 FLU 10S 20 1 I 220Y 127 220Y 127 FLU 10S 22 1 220Y 127 220 127 FLU 10S 22 2 Battery Option 1 string 2 2string 0 Without Batteries Other Options Suff
17. ry tray are inserted past the notches on the upper edge of the battery shelf see figure 9 Always install the lowest battery tray first After it is inserted fully into the support shelf secure the tray with the supplied threaded fasteners After all of the trays are reinstalled and secured reconnect the cables using the markings as a guide WARNING Never connect the two cables from a battery tray or from a battery string two trays together as severe damage will occur resulting in fire and or injury Battery connections should only be made by a person wearing eye and hand protection It is advised that eye wash be available If there are any doubts about the proper connections do not proceed Form No 003 2359 Rev A 16 FirstLine Extended Run Time Battery Cabinet 10 KVA Extension limit tab Notch Battery tray x 1 Y d Tray mounting screw 2 Battery shelf Cutaway side view of battery tray batteries not shown for clarity Figure 9 Battery Tray Maintenance The FirstLine Extended Run Time Battery Cabinet is designed to be virtually user maintenance free requiring only the occasional wipe with a damp cloth or non abrasive cleaner Spare kits are available for the FirstLine Battery Cabinet series please contact Staco Energy Products Co service center for details For maximum availability of the UPS the batteries should be replaced as part of a comprehensive preventive maintenance
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19. tery Cabinet installation and initial startup Risk of electrical shock Wiring Preparation To begin wiring the Battery Cabinet Te Verify that the electrical connections to the installation site have been properly installed Wire the FirstLine UPS per the User s Manual form number 003 2258 Switch off utility power to the distribution point where the UPS is connected Be absolutely sure there is no power Removing and replacing the front panel see figure 5 Lift the panel up and off the cabinet To replace the panel gt Lower the shoulder screws on the rear of the panel into the keyhole slots on the cabinet gt Press the panel downward until the panel is firmly mounted in place Switch the circuit breaker to the Off position Remove the inner front cover by removing the 8 eight screws mounting it to the enclosure Form No 003 2359 Rev A 8 FirstLine Extended Run Time Battery Cabinet 10 KVA KEYHOLE SLOT y 9 M SHOULDER SCREW Figure 5 Removing the Cabinet Front Panel Form No 003 2359 Rev A 9 FirstLine Extended Run Time Battery Cabinet 10 KVA Connecting To The FirstLine Battery Cabinet To be performed by authorized service personnel 1 Inspect battery trays for signs of damage Verify that all terminal connections are sound See figure 6 2 Use a voltmeter to verify that the battery string is above 408 VDC at the battery input connector s
20. xtended Run Time Battery Cabinet 10 KVA Unloading the Cabinet The following tools are required for unloading the cabinet AN Wrenches for 3 8 bolts Forklift For removing the cabinet from the truck and to separate the lower pallet from the upper pallet and cabinet only Once removed from the truck remove the cabinet from the pallet as stated below DO NOT move to final location by forklift CAUTION The Battery Cabinet is heavy see Table 3 Unloading the cabinet requires at least two people to safely remove the cabinet from the pallets To remove the Battery Cabinet from the shipping pallets 1 2 Remove all banding wrapping and foam protectors With a forklift lift the cabinet and upper pallet using the forklift channels see figure 2 from the lower pallet by 1 to 2 inches Slide the lower pallet completely away from the cabinet Lower the upper pallet and cabinet to the floor Remove the 12 3 8 lag bolts securing the shipping brackets to the pallet and the 4 3 8 lag bolts securing the front guard board in place see figure 2 Remove the guard board and 3 4 wood spacers under each of the shipping brackets Ensure that the four 4 leveling feet are raised so that they will not touch the floor when the cabinet is placed on the floor Slowly roll the cabinet forward off the pallet Once the cabinet is fully off the pallet slide the pallet completely away from the cabinet C id Remove and discar
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