1 Installation Manual GE FLYWHEEL CE Version GE Consumer & Industrial SA Via Cantonale 50 CH-6595 Riazzino, Switzerland October 2016
2 Table of Contents List of Figures... 3 List of Tables Important Safety Instructions General Safety Precautions Ensuring a Safe Work Area Fire Prevention Grounding Practices Earthquake Safety Life Support Statement General Information Applicable Standards and Certification Patents Site Preparation Space Requirements Floor Loading and Leveling Environmental Considerations Auxiliary Input Power Requirements Wiring Considerations Handling and Unpacking Inspecting the System Moving and Handling Removing the Shipping Skid Internal Inspections Installation Installation Guidelines System Anchoring System Wiring Route 1 - DC Bus Terminal Connections Grounding Route 4 Auxiliary Control Power Terminal Connections Route 2 and 5 CB1 Controls and Optional Customer Interface Board (CIB) CB1 Controls (J10) Customer Interface Board (CIB) Optional Remote Emergency Power Off (REPO) Technical Support Options Installation Drawings GE Flywheel, Standard and Enhanced, Installation Manual 2
3 List of Figures Figure 1 Moving the flywheel with a forklift Figure 2 Shipping Configuration Figure 3 Lifting the flywheel off the pallet with a forklift Figure 4 Flywheel Cabinet Figure 5 Anchoring the Flywheel Figure 6 System Wiring Block Diagram (ref.) Figure 7 Location of Field Wiring Terminals Figure 8 DC Terminal Connections Figure 9 Ground Terminal Connections Figure 10 Auxiliary Power Terminal Connections Figure 11 Enhanced Flywheel Nameplate (sample) Figure 12 CB1 Controls and Optional Customer Interface Board (CIB) Connections Figure 13 Remote Emergency Power Off Connections (Optional) List of Tables Table 1 Auxiliary Input (AC Input) Table on Nameplate... 5 Table 2 Auxiliary Input Power Requirement Table 3 Component Connections and Torque levels Table 4 Auxiliary Control Voltage and Appropriate Circuit Breaker Ratings Table 5 Installation Drawings Provided with the manual GE Flywheel, Standard and Enhanced, Installation Manual 3
4 1. Important Safety Instructions SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during the installation of the GE flywheel energy storage system. Personnel installing or maintaining GE equipment must read and understand this manual before operation of the equipment. It is the user s responsibility to read and obey all safety procedures, become familiar with these procedures and know how to safely operate this equipment. WARNINGS Utilize extreme care when handling the GE flywheel energy storage system to prevent equipment damage or injury to personnel. By no means should the GE flywheel energy storage system be removed or dismounted while the flywheel system is turned ON and/or the flywheel rotor is spinning. Failure to obey all safety precautions and general instructions may cause personal injury and/or damage to the equipment. In the event of fire involving electrical equipment, the use of carbon dioxide fire extinguishers or other equipment appropriate for extinguishing electrical fires must be utilized. Utilize extreme care when servicing the equipment as hazardous AC and DC voltages may be present. This product must be installed and serviced by GE factory-authorized service personnel only, in accordance with national and local regulatory requirements. Before servicing the equipment, even after the flywheel has stopped spinning, personnel should wait at least five (5) minutes and check for both AC and DC voltages with appropriately rated voltage testers. Regardless of the type of shutdown, make sure all input power is OFF and use extreme caution as high voltage capacitors and power circuits may still have voltage present. Utilize extreme care when the GE Flywheel has input power present (AC and/or DC). Ensure that both the operator and any test equipment are isolated from direct contact with the earth ground or the enclosure frame. Any contact between floating circuits and the enclosure frame is a lethal shock hazard given that some components within the enclosure are not connected to the enclosure frame. Extreme caution must be used such that any test equipment exterior does not make contact either physically or electrically with the frame or GE equipment enclosure. Potentially lethal electrical voltages and currents are present in the system which could cause shock, burn, or death. Turn OFF power and follow appropriate lockout/ tag-out procedures before servicing. NOTE The AC and DC input voltage setting is factory set. Contact GE if incorrect. GE Flywheel, Standard and Enhanced, Installation Manual 4
5 WARNING The AC input voltage setting is factory set and is indicated on the nameplate located on the inner door (see Table 1). If the AC input voltage setting is changed in the field, the nameplate must be modified accordingly to notify and alert future service personnel of the change. Table 1 Auxiliary Input (AC Input) Table on Nameplate AC Input, (L L) 50/60 Hz, 2-WIRE + GND AC Input Configuration Volts, VAC Current, Amps NOTE Changes to the AC input voltage must be performed by certified GE personnel. Safe and efficient operation can only be achieved if the equipment is properly operated, maintained and serviced. GE Flywheel, Standard and Enhanced, Installation Manual 5
6 DANGER / DANGER / PERICOLO / GEFAHR / PELIGRO May cause death or serious injury. HIGH VOLTAGE! Risk of Electric Shock Service to be performed by qualified personnel ONLY. Do NOT install equipment not approved by the manufacturer in this cabinet. Multiple and/or remote sources of power may be present. Disconnect all sources of power before servicing. Peut causer de graves blessures, voire mortelles. HAUTE TENSION! Risque de choc électrique L entretien doit être effectué par du personnel qualifié. NE PAS installer l'équipement non approuvé par le fabricant dans ce cabinet. Plusieurs sources de puissance, distantes ou non, peuvent être présentes. Débranchez toutes les sources d'alimentation avant l'entretien. Può provocare morte o gravi lesioni. ALTA TENSIONE! Rischio di scosse elettriche La manutenzione deve essere eseguita da personale qualificato. NON installare apparecchiature non approvate dal costruttore in questo quadro. Sorgenti di alimentazione multiple e/o remote possono essere presenti. Aprire tutte le sorgenti di alimentazione prima della manutenzione. Hochspannung! Gefahr eines elektrischen Schlags Lebensgefahr, kann schwere Verletzungen verursachen. Arbeiten dürfen nur von qualifiziertem Personal durchgeführt werden. NICHT installieren Geräte vom Hersteller nicht in diesem Schrank zugelassen. Es können mehrere oder rückspeisende Quellen vorhanden sein. Trennen Sie alle Stromquellen vor der Wartung. Puede causar la muerte o lesiones graves. ALTO VOLTAJE! Riesgo de descarga eléctrica Servicio para ser realizado ÚNICAMENTE por personal cualificado. NO instale equipos no autorizados por el fabricante en este gabinete. Múltiples y/o remotas fuentes de energía pueden estar presentes. Desconecte todas las fuentes de energía antes de dar servicio. GE Flywheel, Standard and Enhanced, Installation Manual 6
7 WARNING / AVERTISSEMENT / ATTENZIONE / WARNUNG / ADVERTENCIA AC and/or DC voltages terminate inside this equipment. Each circuit must be disconnected individually. Service to be carried out by trained personnel only. Makes sure devices have discharged fully before servicing. Des tensions AC et/ou DC sont raccordées à l'intérieur de cet équipement. Chaque circuit doit être déconnecté individuellement. L Entretien doit être effectué par du personnel qualifié uniquement. Assurez-vous que les dispositifs soient entièrement déchargés avant l'entretien. Entrambe le tensioni AC e/o DC sono presenti all'interno di questa apparecchiatura. Ogni circuito deve essere scollegato singolarmente. La manutenzione deve essere eseguita solo da personale qualificato. Assicurarsi che i dispositivi siano completamente scarichi prima della manutenzione. Innerhalb dieses Gerätes sind AC und / oder DC-Spannungen vorhanden. Jeder Stromkreis muss individuell getrennt werden. Service nur durch geschultes Personal. Stellen Sie sicher, dass die Geräte vor Arbeitsbeginn ordnungsgemäß entladen sind. CA y / o tensiones de CC se terminan dentro de este equipo. Cada circuito debe desconectar individualmente. Servicio por personal capacitado. Hace que los dispositivos estén correctamente dados de alta antes del servicio. WARNING / AVERTISSEMENT / ATTENZIONE / WARNUNG / ADVERTENCIA To reduce the risk of fire, only replace fuses with others of the same type and rating or equivalent fuses. Pour réduire le risque d'incendie, remplacez les fusibles par des fusibles de même type ou équivalent. Per ridurre il rischio di incendio, sostituire i fusibili solo con fusibili dello stesso tipo o equivalenti. Um die Brandgefahr zu reduzieren, ersetzen Sie Sicherungen nur mit solchen gleichen Typs oder gleichwertigen Sicherungen. Para reducir el riesgo de incendio, reemplace los fusibles sólo por otro del mismo tipo y calificación o fusibles equivalentes. GE Flywheel, Standard and Enhanced, Installation Manual 7
8 DANGER / DANGER / PERICOLO / GEFAHR / PELIGRO Before Servicing: Hazardous voltage Risk of shock, burn or explosion. Capacitors inside. Verify no voltage is present using a correctly rated tester. After servicing: Replace all devices, doors, and covers before powering this equipment. Failure to follow instructions may result in death or serious injury. This equipment must only be installed and serviced by qualified personnel. Avant l'entretien: Tension dangereuse Risque de choc, brûlure ou d'explosion. Condensateurs présents à l'intérieur. Vérifier qu'aucune tension n'est présente en utilisant un appareil correctement calibré. Après un entretien: Replacez tous les dispositifs, les portes et les couvercles avant de mettre en marche cet équipement. Le non-respect des instructions peut entraîner des blessures graves, voire mortelles. Cet équipement doit être installé et entretenu uniquement par un personnel qualifié. Prima della manutenzione: Tensione pericolosa Rischio di shock, ustioni o esplosioni. I condensatori all'interno. Verificare con un tester correttamente tarato che la tensione non sia presente. Dopo la manutenzione: Riposizionare tutti i dispositivi di sicurezza, le porte e gli involucri prima di accendere questa apparecchiatura. La mancata osservanza delle istruzioni può provocare gravi lesioni o la morte. L installazione e la manutenzione di questa apparecchiatura devono essere eseguite solo da personale qualificato. Vor der Wartung: Gefährliche Spannung Gefahr von Stromschlag, Verbrennungen oder Explosion. Achtung Kondensatoren. Überprüfen Sie die Spannungsfreiheit mit einem dafür vorgesehenen Messgerät. Nach der Wartung: Schließen Sie alle Geräte, Türen und Abdeckungen vor dem Einschalten der Stromversorgung an diesem Gerät. Nichtbefolgen der Anweisung kann zum Tod oder schweren Verletzungen führen. Diese Geräte dürfen nur durch qualifiziertes Personal installiert und gewartet werden. Antes del servicio: Tensión peligrosa Riesgo de descarga eléctrica, quemadura o explosión. Los condensadores en el interior. Verifique que no haya tensión con un comprobador nominal adecuado. Después de servicio: Vuelva a colocar todos los dispositivos, las puertas y las cubiertas antes de energizar el equipo. No seguir las instrucciones puede provocar la muerte o lesiones graves. Este equipo debe ser instalado y reparado por personal cualificado. GE Flywheel, Standard and Enhanced, Installation Manual 8
9 WARNING / AVERTISSEMENT / ATTENZIONE / WARNUNG / ADVERTENCIA Comply with the manufacturer s instructions when selecting current elements and setting switches. If the switch trips, current-carrying components in the controller (CB1) should be examined and replaced if damaged. CAUTION Risk of electric shock, it takes a minimum of 1 hour before the capacitor discharge to a level below 50 V DC. Les Instructions du fabricant pour la sélection des éléments de courant et le réglage des interrupteurs doivent être respectées. Si l'interrupteur s'est déclenché, les pièces conductrices de courant du disjoncteur (CB1) doivent être examinées et remplacées si elles sont endommagées. ATTENTION Risque de choc électrique, il faut un minimum de 1 heure avant la décharge du condensateur à un niveau inférieur à 50 V DC. Rispettare le istruzioni del produttore per la selezione e la configurazione degli interruttori automatici. Se l'interruttore è scattato, gli elementi conduttori sotto carico dell interruttore automatico (CB1) devono essere esaminati e sostituiti in caso di danneggiamento. ATTENZIONE Rischio di scosse elettriche. Ci vuole minimo 1 ora prima della scarica del condensatore ad un livello inferiore a 50 V DC. Die Anweisungen des Herstellers für die Auswahl und die Einstellung der Sicherungen und Trenner müssen befolgt werden. Wenn der Trenner ausgelöst hat, stromführende Komponenten der Steuerung (CB1) prüfen und ggf. ersetzen, wenn sie beschädigt sind. VORSICHT Gefahr eines elektrischen Schlags, es dauert mindestens 1 Stunde bevor die Kondensatorentladung ein Niveau unterhalb von 50 V DC erreicht. Las instrucciones del fabricante para la selección de los elementos actuales y fijar los interruptores deben ser seguidas. Si el interruptor se ha disparado, con corriente componentes del controlador (CB1) deben ser examinados y reemplazados si están dañadas. PRECAUTION Riesgo de choque eléctrico, se necesita un mínimo de 1 hora antes de la descarga del condensador a un nivel por debajo de 50 V DC. GE Flywheel, Standard and Enhanced, Installation Manual 9
10 1.1. General Safety Precautions Read and follow the instructions in this manual thoroughly before carrying out any work on the GE Flywheel. Please take note of all the safety precautions outlined in this manual. o Normal safety precautions are necessary while the system is operating under typical operating conditions with all cabinet doors closed. o Unique safety instructions are required for handling, installation and maintenance of this equipment. Please refer to the particular sections that apply to the work you will be performing on this equipment. o Keep the area around the system free from puddles of water, excess moisture, or debris. o Perform maintenance with at least one other qualified personnel who is also familiar with the hazards associated with the specific tasks being performed. Due to the possible presence of high voltages, do not work alone. One person should monitor the controls and indicators while the other person performs the maintenance procedure. Always have another person within sight in case of an emergency. o Only test equipment designated for the GE Flywheel system should be used for troubleshooting. This unit contains several circuits that are energized with high voltage. Even when the power is turned OFF, dangerously high potentials may exist on the AC, DC bus and/or at the capacitor banks. Always check with an appropriately rated AC and DC voltmeter to ensure no voltage is present before making any contact or using tools within the equipment. o Do not allow unauthorized personnel on or around the system during maintenance. o Protective glasses and/or other protective equipment should be worn as applicable. o Do not wear loose articles of clothing or jewelry that can get entangled on controls or other parts of the system. o Unless other instructions are provided, perform maintenance on the equipment once the system is stopped, disconnected from input power and the equipment is properly locked and tagged out. o Do not attempt to repair the equipment if the issue(s) are not understood adequately. o Repair or replace the damaged component(s) with the appropriate tools. o Remove all tools and any loose items before restarting the system. GE Flywheel, Standard and Enhanced, Installation Manual 10
11 Ensuring a Safe Work Area WARNING Modifying the equipment, overriding or failing to follow the safety precautions or recommended procedures could expose service personnel to hazardous conditions. Always follow the safety precautions and recommended procedures. Observe all applicable codes. Hazard alert labels and protective guards on potentially dangerous areas of this system protect personnel from exposure to hazards during normal operation and maintenance. Personnel must know how to recognize and avoid hazardous and potentially hazardous conditions associated with this equipment. The consequences of improper or careless operation of GE systems can be serious. These systems must be operated and maintained only by trained and qualified personnel. All personnel installing, servicing and maintaining GE systems must be trained in regulatory requirements and Lockout/Tag-out procedures. Lockout/Tag-out procedures are required to control and eliminate the potential for harm to service personnel and/or equipment resulting from the accidental startup of equipment or release of stored energy. The Lockout/Tag-out procedures include attaching a Do Not Operate warning tag to the controls before the system is serviced. Attach the warning tags to the system and to each operator control station. Only personnel trained in electrical safety and hazards specific to the system should perform service and maintenance on this equipment as high voltages may be present. WARNING Hazardous conditions could exist while servicing the system. Do not service the system alone. Make use of other personnel who are familiar with the system hazards and are within visual sight in case of an emergency Fire Prevention Keep the equipment in an area that is ventilated appropriately. Keep the floor clean of debris or any flammable materials around or on the equipment. Lubricants and flammable materials are to be stored in properly marked protective containers in a safe location. No smoking is permitted in areas that contain flammable material. Wiring must be properly routed, maintained in good condition and securely attached. The wiring should be inspected periodically to check for any signs of wear or deterioration. The wiring and cabling within the equipment or directly connected to the equipment must be of the recommended gauge size. All the connections must be secure as required by the connection type and gauge size to prevent arcing or sparks. Bypassing fuses and/or circuit breakers is prohibited Grounding Practices Proper grounding is required to avoid the risk of electrocution and the extreme hazards associated with high voltages and currents. Refer to Section 2. - Site Preparation for details. Proper grounding is also required to maintain system performance and reliability. Failure to properly ground the equipment may result in unpredictable electrical circuits and electrical activity that may potentially damage associated electronics and communications. All grounds should be inspected periodically to ensure that they are secured, as required by the connection type and gauge size, and are free from corrosion. GE Flywheel, Standard and Enhanced, Installation Manual 11
12 Earthquake Safety A key aspect associated with the use of industrial equipment is the ability to withstand damage caused by seismic events. Many geographic locations where GE Flywheel systems will be installed are in active seismic zones. The Uniform Building Code rates geographic seismic zones on a scale of 0 through 4. Industrial equipment is susceptible to various types of damage as a result of an earthquake, which include but are not limited to: Water damage Toppling or overturning Equipment especially susceptible to toppling over are those with an aspect ratio of greater than 2:1. That is, if the equipment s height is greater than twice its width or depth, it is prone to toppling or overturning. Sliding against and striking other equipment and items Large or heavy equipment has significant momentum attached to it if it starts to move. Once it breaks inertia and begins to slide, it has the potential to cause serious damage to personnel and anything it strikes. Misalignment of components Refer to 2. - Site Preparation for details intended to securely fasten the GE Flywheel in its intended location for operational safety and seismic requirements Life Support Statement GE does not advocate the utilization of its products in any life support applications where a malfunction or failure of its products can potentially result in adverse effects to life support equipment or adversely affect the reliable operation and safety of life support equipment. By no means will GE intentionally sell its products into life support applications unless reassurance is provided in writing that appropriate measures have been taken to ensure that the risks associated with malfunction or failure of its products have been minimized, that the customer assumes all associated risks and that the liability of GE is safeguarded under such circumstances. GE Flywheel, Standard and Enhanced, Installation Manual 12
13 1.2. General Information Applicable Standards and Certification For distribution in Europe, the GE Flywheel is designed in accordance with the following Directives: 2004 / 108 / EC: The Electromagnetic Compatibility Directive and its amending directives 2006 / 42 / EC: The Machinery Directive and its amending directives (95/16/EC) has been designed and manufactured to the following specifications: o EN :2007 Electromagnetic compatibility (EMC) - Part 6-4: Generic Standard - Emission Standard for Industrial Environments o EN :2005 Electromagnetic compatibility (EMC) - Part 6-2: Generic Standards - Immunity Standard for Industrial Environments o EN :2010 Safety of Machinery Electrical Equipment of Machines - Part 1: General Requirements o EN ISO 12100:2010 Safety of Machinery - General Principles for Design - Risk assessment and risk reduction The GE Flywheel is designed in accordance with the pertinent sections of the requirements outlined in the following: National Fire Protection Association (NFPA) National Electric Code (NEC) National Electrical Manufacturer s Association (NEMA) Occupational Safety & Health Administration (OSHA) CAUTION This unit complies with the limits for a Class A digital device, pursuant to Part 15 Subpart J of the FCC rules. These limits provide reasonable protection against harmful interference in a commercial environment. This unit generates, uses and radiates radio frequency energy and, if not installed and used in accordance with this instruction manual, may cause harmful interference to radio communications. Operation of this unit in a residential area may cause harmful interference that the user must correct at his own expense Patents The GE Flywheel may be covered by one or more of the following VYCON U.S. patents: Patent 6,727,617 Patent 6,700,258 Patent 5,315,197 Patent 5,514,924 Patent 5,111,102 Patent 6,897,587 GE Flywheel, Standard and Enhanced, Installation Manual 13
14 2. Site Preparation Minimal site preparation is required for installation of the FLYWHEEL. Before installation, consideration must be given to: Wiring and cabling to UPS and other equipment Service access Exhaust requirements Floor mounting Be sure to review this section, along with the installation drawings provided with this manual and listed in Section 7. - Installation Drawings, prior to installation Space Requirements The flywheel requires 0.63 m 2 of floor space. A 914mm clearance in front is required for service, 305mm clearance above the unit is required for cooling. The unit accommodates top or bottom entry for power and control cables; this must be taken into consideration while planning for product installation Floor Loading and Leveling The flywheel should be mounted on a finished surface, such as concrete, block or brick. The floor must be strong enough to support the equipment load and must be suitable for anchoring. The floor must be within 3 degrees of being level: ±64mm over a 1.2 m span. Raised floor installations must utilize a suitable floorstand contact the factory for more information. The floor mounting pattern for anchoring is detailed in the Floor Mounting Details Environmental Considerations Clean, dust-free environment. Install away from overhead water lines. Ambient operating temperature range is -10 C to +40 C. Minimum cold start temperature is 0 C. Relative humidity must be less than 90%, non-condensing. Note that room ventilation is necessary, but air conditioning may not be required. Maximum ambient operating temperature is 40 C without de-rating Auxiliary Input Power Requirements Protected AC power is required for proper operation of the flywheel. System control power is derived from this protected AC source; it also provides power for the cooling fans and the vacuum pump. The protected AC power (Auxiliary Control Power) must come from the critical bus of a UPS system, such that when the UPS is placed on maintenance bypass, control power is still available. The flywheel can accommodate 208 or 240 VAC L1, L2, & G, 50/60Hz. Table 2 Auxiliary Input Power Requirement AC Input Configuration AC (L L) 50/60 Hz, 2-WIRE + GND Volts, VAC Current, Amps GE Flywheel, Standard and Enhanced, Installation Manual 14
15 2.5. Wiring Considerations A qualified electrician must perform all electrical connections. All external wiring (DC & AC Power, Control and Grounding) are to be provided by the electrical contractor. All wire sizes and installation must comply with all applicable local, regional and national electrical codes. Verify that all incoming high and low voltage power circuits are de-energized and locked out before installing the cables and making connections. The Floor Mounting Details identifies the locations of the cable access areas. The flywheel can accommodate bottom or top access. Remove and punch the conduit landing plates and re-install prior to connecting any wiring. Do not cut or punch the conduit landing plates while attached to the flywheel. After reattaching the landing plates, ensure there are no metal shavings, wire fragments, etc., inside the unit. Each cable group must be run in a separate grounded rigid metal conduit to prevent control signal interference. Please refer to the Interconnect Diagram. Additional wiring may be required specific to the connected UPS model. Consult with your UPS technical representative. GE Flywheel, Standard and Enhanced, Installation Manual 15
16 3. Handling and Unpacking The flywheel has sensitive electrical and mechanical components that have been calibrated prior to shipment and as such, the equipment is shipped in an air ride truck. The flywheel is designed to be handled using either a forklift or a pallet jack. Overhead lifting equipment may also be used in conjunction with straps. Care must be taken to prevent damage or personnel injury while handling or unpacking the equipment Inspecting the System Upon delivery of the flywheel, inspect the equipment and shipping skid for any signs of damage or mishandling. Shock and tilt gauges indicate excessive shock and/or tilt. If any damage is noted, file a claim with the shipping agency within 24 hours and notify your GE sales representative of the damage and condition of the equipment. Do not attempt to install any equipment suspected of damage during shipment Moving and Handling NOTE The flywheel with shipping material weighs up to 816 kg. It must be handled with care and maintained in an upright position, paying particular attention to the center of gravity of the equipment. Arrows on the packing equipment indicate the upright position. Check and verify the capacity of the forklift or pallet jack is sufficient for the weight of the flywheel. When transporting using a forklift or pallet jack, check and verify the forks extend beyond the full depth of the cabinet (see Figure 1). Using straps, an overhead lifting device may be used to transport the flywheel. Check and verify the capacity of the overhead lifting device and straps are sufficient for the weight of the equipment. The flywheel has sensitive electrical and mechanical components that have been calibrated prior to shipment. When transporting, maintain minimum tilt from vertical at all times and do not subject the equipment to excessive shock and/or vibration. The unit must not be subjected to more than 15 degrees of tilt. Exhibit care when handling the flywheel to avoid equipment damage or personnel injury. Figure 1 Moving the flywheel with a forklift GE Flywheel, Standard and Enhanced, Installation Manual 16
17 3.3. Removing the Shipping Skid The flywheel is shipped on a skid and is fixed using four sets of hardware (see Figure 2). Figure 2 Shipping Configuration Remove the hardware that holds the flywheel to the shipping skid. The flywheel may now be moved to the appropriate location. The mounting channels must be removed to roll the flywheel on uneven floors. When the flywheel is set in place, re-install the mounting channels. Use a forklift to lift the flywheel off the shipping skid (see Figure 3). An overhead lifting device may also be used with appropriate straps. NOTE Use extra caution when maneuvering the forklift into place for lifting the flywheel, as rubber isolation mounts for the flywheel housing are exposed and can potentially be damaged by the forklift. Ensure that the forks are placed directly underneath the base flanges to prevent damage. Figure 3 Lifting the flywheel off the pallet with a forklift GE Flywheel, Standard and Enhanced, Installation Manual 17
18 3.4. Internal Inspections Open the door and open the internal door (see Figure 4). Inspect the flywheel for visible signs of damage during shipment. All internal wiring should be intact and all major components should be secured in place. Check for broken torque seals, loose connections and loose hardware within the unit. Refer to Table 2 for a list of major components that should be checked for proper connections. Check the torque seal on components indicated with an X in the Check Seal column; re-torque any loose connections using the recommended torque levels as guidelines. Table 3 Component Connections and Torque levels Component Ch C Recommended Flywheel X Magnetic Bearing X Flywheel Assembly X X 27 n-m Vacuum Pump X Power Stack (DC X X 10 n-m Power Stack (AC X X 10 n-m Terminal Blocks X Control Circuit X CB1 X X 31 n-m TB4 X X 31 n-m K1 & K3 Relays X X 11 n-m Auxiliary AC X X 4 n-m Inductors X X 10 n-m Figure 4 Flywheel Cabinet GE Flywheel, Standard and Enhanced, Installation Manual 18
19 4. Installation 4.1. Installation Guidelines Install your flywheel in accordance with the instructions, guidelines and drawings included with this manual, following all procedures. CAUTION Only qualified personnel must perform the initial system check-out and startup to ensure proper equipment operation. Failure to do so may void your warranty. Contact your GE Service Representative to arrange for system check-out and startup. Select a location away from overhead water lines to prevent water damage in case of accidental leaks. Route cables such that runs are as short as possible. Locate the flywheel for easy connection of inputs, outputs and auxiliary equipment. Allow enough space to service the flywheel. Raised floor installations must utilize a floorstand. Call factory for information NOTE Refer to Section 2. - Site Preparation for service clearance requirements for the flywheel. No side or rear access is necessary for maintenance, allow a minimum of 4 mm between units when placing side-by-side. Ensure air circulation is sufficient to expel heat produced by the flywheel. Protect against moisture and excessive humidity (not to exceed 90% non-condensing). Protect against excessive dust and other particulate matter. Ensure installation is in compliance with fire prevention regulations and practices. Install in an area that provides an operating environment temperature of -10 C to +40 C. Avoid placing the unit in direct sunlight or other heat sources. Make sure that the floor can support the weight of the flywheel. If the flywheel will not be immediately installed, store indoors in a clean, dry area where the temperature will be between -20 C to +70 C and the humidity does not exceed 90% (non-condensing). GE Flywheel, Standard and Enhanced, Installation Manual 19
20 4.2. System Anchoring The following tools and equipment are required for floor anchoring: Transport/handling equipment such as a forklift or pallet jack. Before moving, check and verify to ensure the handling equipment is capable of supporting the weight of the flywheel. Open-end wrench Socket wrench with appropriate ratchet handle Drill and masonry drill bit Hammer and/or mallet Expansion bolts Installation Procedure The following procedure is for the use of expansion anchors; other methods may be used. Prepare a clean, level finished surface, free of obstructions, cracks and seams in the vicinity of the installation. Ensure all clearances are maintained and the area for bottom entry (if used) is clear. Locate the position for the mounting holes; see the Floor Mounting Details. Drill mounting holes large enough for the expansion anchors. Drop expansion anchors in the mounting holes, using a mallet, as necessary, to make sure the expansion anchors are flush with the floor. Using a mallet or hammer, tap the setter rod (if any) to set the expansion anchors in place. Remove the setter rod. Using a forklift or a pallet jack, move the flywheel into place; straps can also be used to lift the unit and set it in place. Place the unit such that the holes in the C channel align with the mounting holes. Level the flywheel using the leveling feet. The flywheel cabinet must be within 3 of vertical; add shims at the mounting channels as necessary. Insert Anchor Bolts and tighten (see Figure 5). Figure 5 Anchoring the Flywheel GE Flywheel, Standard and Enhanced, Installation Manual 20
21 4.3. System Wiring Refer to Section 7. - Installation Drawings for location of terminals and cable routing information. Additional wiring may be required specific to the connected UPS model. Consult with your UPS technical representative. All wire sizes and installation must comply with local, regional and national electrical codes. Verify that all incoming high and low voltage power circuits are de-energized and locked out before installing the cables and making connections. Each cable group must be run in a separate grounded rigid metal conduit to prevent control signal interference. See the Interconnect Diagram. Figures 6 and 7 illustrate typical connection and terminal locations within the flywheel cabinet. Figure 6 System Wiring Block Diagram (ref.) 1 DC Input V DC +, -, GND + - GND TB4 + TB4 - GND Plate Aux Power Input 200, 240VAC, GND, 50/60 Hz L1 L2 GND TB1 4 Protected AC Power from System Critical Bus UPS GE Flywheel Standard and Enhanced UVR UVR Ret 24 DC UVR is used for TLE and SG kva No UVR for SG up to 150 kva 3 NO 4 5 J14 Com NC Optional CIB Form C Contacts J1, 2, 3, 6, 7, 8 5 Optional Customer Connections for remote monitoring Figure 7 Location of Field Wiring Terminals Auxiliary Power Input Ground DC Power Optional Customer Interface Board (CIB) Circuit Breaker Controls (J14) Optional REPO GE Flywheel, Standard and Enhanced, Installation Manual 21
22 4.4. Route 1 - DC Bus Terminal Connections In the GE Flywheel, the DC power cables are terminated, shown in Figure 8 (also see the Floor Mounting Details). TB4 can accommodate one (1) 13 mm mm 2 per pole. After the cables are in place, Torque the lugs to 31 n-m. Figure 8 DC Terminal Connections Refer to your UPS installation documentation for termination of the DC power cables within the UPS. The DC power cables must be sized so that the maximum voltage drop (due to cable resistance) between the UPS and the flywheel is 2 volts at rated power. CB1 is rated at 250A 500V DC. WARNING Identify and verify polarity (plus (+) and minus (-)) prior to making electrical connections (positive to positive and negative to negative). Improper connections may result in failure or equipment damage. The field-supplied DC power cabling provided by the electrical contractor must be rated 600V and in accordance with local, regional and national electrical codes. Connect the DC power cables according to the table in the Interconnect Diagram. GE Flywheel, Standard and Enhanced, Installation Manual 22
23 4.5. Grounding The flywheel must be effectively connected to the UPS ground terminal. The ground connection must be as short as possible. The DC power ground lug can accommodate one (1) 13 mm 2 to 125 mm 2 (see Figure 9). Figure 9 Ground Terminal Connections Wire sizes and installation must comply with applicable local, regional and national electrical codes. Connect the ground wires according to the table in the Interconnect Diagram. GE Flywheel, Standard and Enhanced, Installation Manual 23
24 4.6. Route 4 Auxiliary Control Power Terminal Connections The AC power wires are terminated at TB1 inside the flywheel (see Figure 10). TB1 can accommodate one (1) 2 mm 2 to one (1) 5 mm 2 cable per terminal. Figure 10 Auxiliary Power Terminal Connections The AC power can be VAC, single-phase, 50 or 60 Hz AC that must come from the critical bus of a UPS system. The required AC value has been identified prior to shipment so the proper internal settings have been made by the factory. The product nameplate identifies the factory setting. (See Figure 11) Table 4 Auxiliary Control Voltage and Appropriate Circuit Breaker Ratings Auxiliary Input Voltage, Volts AC Current, Amps 6 5 Circuit Breaker NOTE The AC power is a factory-set feature. If the available power is different from the voltage marked on the nameplate, call your GE Service Representative. The field-supplied AC power wiring provided by the electrical contractor must be in accordance with local, regional and national electrical codes. Connect the AC power cables according to the table in Interconnect Diagram. Figure 11 Enhanced Flywheel Nameplate (sample) GE Flywheel, Standard and Enhanced, Installation Manual 24
25 4.7. Route 2 and 5 CB1 Controls and Optional Customer Interface Board (CIB) CB1 Controls (J10) The control wires are terminated at J10 shown in Figure 12. The control wiring allows basic communication between the other equipment and the flywheel. J10 pin 1 is at the top for +24 UVR; pin 2 is for UVR return; pins 3, 4, & 5 are for CB1 Auxiliary contacts, NO, COM and NC respectively. J10 can accommodate one (1) 0.4 mm 2 to 5 mm 2 per terminal. Route control wires as far away from power cables as possible to minimize interference Customer Interface Board (CIB) The CIB consists of six relays that allow for remote monitoring of the following signals: Warning (Summary); Shutdown; Alarm (Summary); Ready; Charging; and Discharging. These are potential free Form C contacts; see Technical Reference, CIB for more information. Figure 12 CB1 Controls and Optional Customer Interface Board (CIB) Connections Optional CIB - Form C Contacts J1 Warning J2 Shutdown J3 Alarm J6 Ready J7 Charging J8 Discharging J14 for CB1 Control (24 VDC UV) and CB1 Aux Contacts GE Flywheel, Standard and Enhanced, Installation Manual 25
26 4.8. Optional Remote Emergency Power Off (REPO) Optional REPO This option is intended to activate an Emergency Power Off (EPO) from a remote location. The EPO interface requires a Normally Open (N.O.) contact. When the contact is closed it invokes an EPO command, the flywheel goes into a shutdown mode and opens the main Circuit Breaker. Figure 13 Remote Emergency Power Off Connections (Optional) Optional REPO Control When this option is purchased, a Normally Open isolated contact must be used. Connections are made to the DIN rail Terminal block shown. GE Flywheel, Standard and Enhanced, Installation Manual 26
27 5. Technical Support GE is dedicated to providing high-quality products to the owners and users of every flywheel. Your flywheel should operate free from trouble. If you require maintenance support, spare parts or other technical assistance, please contact your local Sales/Service organization for assistance. You may also contact GE Customer Service at or by at Please have the following information available: Location / Customer Name System Model Number System Serial Number Connected UPS Manufacturer Connected UPS Model GE Flywheel, Standard and Enhanced, Installation Manual 27
28 6. Options The following options are available for the GE Flywheel: Customer Interface Board (CIB); VYCON Part Number The Customer Interface Board allows the customer to monitor the status of the flywheel by providing dry, potential free Form C (NO, Com, NC) contacts. These contacts may be used in a variety of applications including connection to Remote Status Panels; Building Management Systems, or directly to a UPS. This option can be factory or field installed. Remote Emergency Power Off (REPO); VYCON Part Number The REPO option allows for remotely activating the Emergency Power Off function of the flywheel. This option requires a potential free Normally Open (NO) contact. This option can be factory or field installed. Modbus RTU Interface; VYCON Part Number MODBUS is an industry accepted serial communication protocol generally used with Building Maintenance Systems. GE s implementation of MODBUS uses the RS-485 protocol and provides information to monitor system performance. This option can be factory or field installed. GE Flywheel, Standard and Enhanced, Installation Manual 28
29 7. Installation Drawings Table 4 provides a list of installation drawings provided with this manual, including drawing numbers and titles. Table 5 Installation Drawings Provided with the manual Drawing Title Floor Mounting Details Floor Mounting Details, Seismic Interconnect Diagram System Power Diagram GE Flywheel, Standard and Enhanced, Installation Manual 29
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