Powerware 9125 48 Vdc Extended Battery Cabinet User s Guide www.powerware.com
FCC Part 15 Class A EMC Statements NOTE This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. ICES-003 This Class A Interference Causing Equipment meets all requirements of the Canadian Interference Causing Equipment Regulations ICES-003. Cet appareil numérique de la classe A respecte toutes les exigences du Reglement sur le matériel brouilleur du Canada. EN50091-2 Some configurations are classified under EN50091-2 as Class-A UPS for Unrestricted Sales Distribution. For these configurations, the following applies: WARNING This is a Class A-UPS Product. In a domestic environment, this product may cause radio interference, in which case, the user may be required to take additional measures. Powerware is a registered trademark of Powerware Corporation. ECopyright 2001 Powerware Corporation, Raleigh, NC, USA. All rights reserved. No part of this document may be reproduced in any way without the express written approval of Powerware Corporation.
TABLE OF CONTENTS 1 Introduction... 1 UPS Model and Battery Configurations... 1 EBC48 System Recharge Time... 1 EBC48 Battery Times... 2 2 Installation... 3 Safety Warnings... 3 Installing the EBC48... 5 Important Safeguards... 10 EBC48 Fault LED... 11 Alarm Contacts... 11 3 Specifications... 12 4 Troubleshooting... 13 Service and Support... 14 Powerware 9125 EBC48 User s Guide S Rev Awww.powerware.com i
Table of Contents ii Powerware 9125 EBC48 User s Guide S Rev Awww.powerware.com
CHAPTER 1 INTRODUCTION Thank you for your purchase of the Powerware R 48 Vdc Extended Battery Cabinet (EBC48). The Powerware EBC48 is an accessory for your Powerware 9125 UPS that extends the battery-backup run times for the UPS. The EBC48 is a 48 Vdc model with a charger. Up to three EBC48s can be attached to customize the battery run time for your application. UPS Model and Battery Configurations There are two important considerations you need to evaluate when selecting the UPS model and battery configuration for your equipment: 1. Load requirements of the equipment you want to protect. Select the UPS model that meets the power consumption requirements of the equipment you want to protect. Load Requirements explains how to determine the load requirements (refer to your Powerware 9125 User s Guide). 2. Battery protection time. During a power failure, the UPS operates on battery, providing time to complete your computing activities prior to UPS shutdown. The duration of this time period is directly related to the UPS battery configuration and the amount of load on the UPS. EBC48 System Recharge Time The following table displays the estimated minimum recharge time, after a discharge at the rated load, to return the EBC48 batteries to 90% capacity. Battery Time Used 1 Hour 2 Hours 4 Hours 8 Hours Recharge Time to >90% 17 hours 20 hours 23 hours 27 hours Powerware 9125 EBC48 User s Guide S Rev Awww.powerware.com 1
Introduction EBC48 Battery Times The following table displays the number of cabinets required for the number of hours of battery time. Battery Time Number of EBC48s Required for Battery Time (by UPS Load*) (in Hours) 2000 VA 1800 VA 1600 VA 1500 VA 1400 VA 1200 VA 1000 VA 800 VA 650 VA 3.5 1 1 1 1 1 1 1 1 1 4.0 2 1 1 1 1 1 1 1 1 4.5 2 2 1 1 1 1 1 1 1 5.0 2 2 2 1 1 1 1 1 1 5.5 2 2 2 2 1 1 1 1 1 6.0 2 2 2 2 2 1 1 1 1 6.5 2 2 2 2 2 1 1 1 1 7.0 2 2 2 2 2 2 1 1 1 7.5 2 2 2 2 2 2 1 1 1 8.0 2 2 2 2 2 2 1 1 1 8.5 3 2 2 2 2 2 2 1 1 9.0 3 2 2 2 2 2 2 1 1 9.5 3 2 2 2 2 2 2 1 1 10.0 3 3 2 2 2 2 2 1 1 10.5 3 3 2 2 2 2 2 1 1 11.0 3 3 2 2 2 2 2 1 1 11.5 3 3 3 2 2 2 2 2 1 12.0 3 3 3 3 2 2 2 2 1 *Based on load power factor of 0.70. NOTE Do not connect more than three EBC48s to the UPS. 2 Powerware 9125 EBC48 User s Guide S Rev Awww.powerware.com
CHAPTER 2 INSTALLATION Safety Warnings The following sections describe the installation and physical setup of the 48 Vdc Extended Battery Cabinet. This manual contains important instructions for your Powerware EBC48 that should be followed during installation and maintenance of the UPS and batteries. DO NOT use any other sizes or types of batteries with the EBC48. Read all of the caution and warning statements in Safety Warnings of your Powerware 9125 User s Guide before performing the installation. IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions that you should follow during installation and maintenance of the UPS and batteries. Please read all instructions before operating the equipment and save this manual for future reference. DANGER Risk of electrical shock. Installation of battery cabinets must be done by trained service personnel. Powerware 9125 EBC48 User s Guide S Rev Awww.powerware.com 3
Installation CAUTION S To reduce the risk of fire, connect only to a circuit provided with 15A maximum branch circuit overload protection in accordance with the National Electrical Code, ANSI/NFPA 70. S Never dispose of batteries in a fire. Batteries may explode when exposed to flames. In the event of a fire involving the UPS and its batteries, use only carbon dioxide fire extinguishers or those approved for use in electrical fire fighting. S Servicing of batteries should be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries. S Never open or mutilate batteries. Released electrolyte is harmful to the skin and eyes, and may be extremely toxic. S Batteries can present a risk of electrical shock or burn from high short-circuit current, fire, or explosion from vented gases. Observe proper precautions. S Proper disposal of batteries is required. Refer to your local codes for disposal requirements. S Batteries can present a risk of electrical shock or burn from high short-circuit current. The following precautions should be observed: 1) Remove watches, rings, or other metal objects; 2) Use tools with insulated handles; 3) Do not lay tools or metal parts on top of batteries; 4) Disconnect charging source prior to connecting or disconnecting battery terminals. S Determine if the battery is inadvertently grounded. If inadvertently grounded, remove source of ground. Contact with any part of a grounded battery can result in electrical shock. The likelihood of such shock will be reduced if such grounds are removed during installation and maintenance. 4 Powerware 9125 EBC48 User s Guide S Rev Awww.powerware.com
Installation Installing the EBC48 The following instructions assume you have already removed the EBC48s from the pallets according to the unloading instructions on the outside of the shipping box. Use the following procedure to set up the EBC48: 1. Place the EBC48 near the operating site. The UPS should be well ventilated and away from direct sunlight or other heat source. NOTE It is recommended to allow a minimum of 4.5I of space from the rear of the cabinet for proper ventilation. 2. If you are using only one EBC48 and want increased stability or a seismic installation, remove the mounting plates from the pallet (see Figure 1). Otherwise, skip to Step 6. Mounting Plates 5/16I Bolts Figure 1. Seismic Installation Mounting Plates 3. A seismic installation of the EBC48 requires that the mounting plates be bolted to the floor. See Figure 2 for a detailed drill and mounting pattern. Powerware 9125 EBC48 User s Guide S Rev Awww.powerware.com 5
Installation NOTE For Zone 4, it is recommended to use 5/16I self-drill bolts and hardware with 15/16I minimum embedment for 3000PSI-strength concrete. Refer to your local building codes for seismic mounting requirements. 0.44I 1.563I 8.50I 7.50I TYP 13.50I Minimum from Wall 13.00I 13.00I 7.60I from Front of Units Ø0.375I Mounting Holes Front of Unit Figure 2. Seismic Installation Mounting Pattern 4. Using customer-supplied bolts, attach the mounting plates to the floor. NOTE The floor mounting bolts are customer-supplied and should fit the 0.375I diameter mounting holes on the mounting plates. 5. Using the 5/16I bolts removed when unloading the cabinet from its pallet, resecure the EBC48 to the mounting plate. 6. Verify that the UPS is turned off. 7. Align the U-shaped mounting bracket with the two holes closest to the front of the EBC48 and secure using two of the countersink screws from the start-up kit. 6 Powerware 9125 EBC48 User s Guide S Rev Awww.powerware.com
Installation 8. Align the L-shaped mounting bracket with the two holes closest to the rear of the EBC48 and secure using two of the countersink screws from the start-up kit. NOTE The vertical section of the L-bracket must be to the left of the UPS. 9. Place the UPS on top of the EBC48, aligning the mounting brackets with the holes on the sides of the UPS chassis. Secure the brackets to the UPS using the six supplied screws. 10. Verify that the circuit breaker on all EBC48s is in the OFF (O) position (see Figure 3). Powerware 9125 EBC48 User s Guide S Rev Awww.powerware.com 7
Installation Alarm Contacts Battery Connector Charger AC Input Receptacle Charger Charger Air Exhaust Charger LED Power Switch Battery Circuit Breaker Breaker Tie Battery Output Cord Unit Rating Label Figure 3. EBC48 Rear View 8 Powerware 9125 EBC48 User s Guide S Rev Awww.powerware.com
Installation Figure 4. Maximum Configuration (UPS with Three EBC48s) 11. Plug the EBC48 battery output cord into the battery connector on the UPS rear panel. All battery connectors are polarized to prevent incorrect connection. 12. If additional EBC48s are to be used, plug the battery output cord of the second cabinet into the battery connector of the first cabinet. Follow this procedure for each additional EBC48. 13. Plug the detachable power cord into the charger AC input receptacle. Powerware 9125 EBC48 User s Guide S Rev Awww.powerware.com 9
Installation 14. Plug the other end of the power supply cord into a grounded, three-wire, AC receptacle that has been wired in accordance with NEC specifications or national wiring rules. For 240V installations, use a NEMA 6-15P/IEC 320-C13, 6-ft, detachable power supply cord that is UL-listed. Wire gauge should be #16 AWG and the insulation type should be begin with SJ, SE, or SO. NOTE DO NOT plug the AC cord from the charger into any of the UPS receptacles. NOTE The wall outlet must be within 2 meters of the equipment and accessible to the operator. 15. Verify that the charger LED on the EBC48 rear panel is illuminated, indicating the charger is on. If the charger LED is not on, turn the power switch on the EBC48rearpaneltotheONposition. 16. Remove the breaker tie from the circuit breaker on all EBC48s. 17. Switch the circuit breaker to the ON ( ) position on each EBC48. 18. The UPS may now be turned on according to your Powerware 9125 User s Guide. Important Safeguards S Do not connect or disconnect EBC48s while the UPS is operating in Battery mode. S When connecting or disconnecting EBC48s, verify the circuit breaker on all EBC48s is in the OFF (O) position. 10 Powerware 9125 EBC48 User s Guide S Rev Awww.powerware.com
Installation EBC48 Fault LED The Fault LED on the front panel of the EBC48 illuminates to indicate an over temperature condition. The Fault LED remains lit until the system cools, typically a few hours. Fault Indicator Figure 5. Fault LED Alarm Contacts A set of normally open alarm contacts is provided on the rear panel of the EBC48. The contacts will close if there is an overload or over temperature condition. Optional: To use the alarm contacts, connect alarm leads to the two contacts on the alarm contact strip. The alarm contact is rated at 1A/30 Vac or 1A/60 Vdc. Normally Open Contact Inside the EBC48 User Connection Points Figure 6. Alarm Contact Strip Powerware 9125 EBC48 User s Guide S Rev Awww.powerware.com 11
CHAPTER 3 SPECIFICATIONS Table 1. 48 Vdc Extended Battery Cabinet Technical Specifications Battery Type Expected Life Nominal Battery String Voltage Nominal Float Voltage Recharge Current Charger AC Input Circuit Protection Alarm Contact Dimensions (WxDxH) Weight Operating Environment Valve-regulated lead acid (VRLA); Hawker 12HR-300 or C & D Dynasty UPS12-270 8 years @ 20-hr rate, 25 C (77 F) 48 Vdc 2.3V/cell 5A per string, 10A total 120/240 Vac, 7/4A, 50/60 Hz (625 VA nominal); automatically selected IEC 320-C13 input connector Circuit breaker protection 1A/30 Vac or 1A/60 Vdc 17.2I x 24.6I x 28.3I (43.7 x 62.5 x 71.9 cm) Shipping weight: 750 lb (341 kg) Installed weight: 665 lb (302 kg) Temperature: 10 C to 40 C (50 F to 104 F) Recommended use: 25 C (77 F); For each 8 C (15 F) rise in temperature, the battery loses approximately 50% of its rated life. Humidity: 10 to 95% (noncondensing) Altitude: -300 to +10,000 ft Safety Conformance UL 1778, CAN/CSA C22.2, No. 107.1-M91, EN 50091-1-1 and IEC 60950 Agency Markings EMC (Class A) UL, cul FCC Part 15, EN 50091-2, ICES-003 12 Powerware 9125 EBC48 User s Guide S Rev Awww.powerware.com
CHAPTER 4 TROUBLESHOOTING The 48 Vdc Extended Battery Cabinet is shipped with the battery charged. However, it may lose some of its charge during shipping and storage. You can use the EBC48 immediately after unpacking, but it may not provide the full-rated backup time during a power failure. Upon initial startup, the EBC48 may need to operate for approximately 24 hours to fully charge the battery and provide full battery-backup time. Condition Possible Cause Action System does not provide the expected backup time. Charger LED is not on. EBC48 Fault LED is on. Alarm contact is closed. Battery Service Battery circuit breakers are in the OFF (O) position. The EBC48 is not properly connected to the UPS. Low battery capacity. Protected equipment power requirements exceed UPS capacity. EBC48 connections are not secure. Charger has failed. The EBC48 internal temperature is too high. The EBC48 internal temperature is too high or there is an overload condition. The battery may be fully discharged. The battery is not connected correctly. Switch the battery circuit breaker to the ON ( ) position for all connected EBC48s. Verify that the EBC48 cords are connected. Allow the battery to charge for 24 hours, then retest. Reduce load, then retest. Verify that the EBC48 is plugged in and turned on. Contact your service representative. Allow the unit to cool. If the condition persists, contact your service representative. Allow the unit to cool or reduce the load. If the condition persists, contact your service representative. Plug the UPS and EBC48 into a power outlet for 24 hours to charge the battery. After charging the battery, press and hold the button for 3 seconds; then check the indicator. If the indicator is still on, see UPS Maintenance in your Powerware 9125 User s Guide. Check the battery connections. Call your service representative if the problem persists. Powerware 9125 EBC48 User s Guide S Rev Awww.powerware.com 13
Troubleshooting Service and Support If you have any questions or problems with the UPS, call your Local Distributor or the Help Desk at one of the following telephone numbers and ask for a UPS technical representative. In the United States 1-800-365-4892 In Canada 1-800-461-9166 All other countries 1-919-870-3149 Please have the following information ready when you call the Help Desk: S Model number S Serial number S Version number (if available) S Date of failure or problem S Symptoms of failure or problem S Customer return address and contact information If repair is required, you will be given a Returned Material Authorization (RMA) Number. This number must appear on the outside of the package and on the Bill Of Lading (if applicable). Use the original packaging or request packaging from the Help Desk or distributor. Units damaged in shipment as a result of improper packaging are not covered under warranty. A replacement or repair unit will be shipped, freight prepaid for all warrantied units. NOTE For critical applications, immediate replacement may be available. Call the Help Desk for the dealer or distributor nearest you. 14 Powerware 9125 EBC48 User s Guide S Rev Awww.powerware.com