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Related Manuals for ABB MegaFlex 1000 UL S1
Summary of Contents for ABB MegaFlex 1000 UL S1
- Page 1 — UPS INSTALLATION GUIDE MegaFlex 1000 to 1600 kW UL S1...
- Page 2 The present publication and any other documentation supplied with the UPS system is not to be reproduced, either in part or in its entirety, without the prior written consent of ABB. The illustrations and plans describing the equipment are intended as general reference only and are not necessarily complete in every detail.
- Page 3 UPS. Thank you for choosing ABB! Start-up and commissioning! An ABB Global Services Field Engineer must perform start-up and commissioning of the UPS. Please contact ABB Service Center at least two weeks prior to schedule start-up and commissioning at 1-800-292-3739.
- Page 4 While every care has been taken to ensure the completeness and accuracy of this manual, ABB assumes no responsibility or liability for any losses or damages resulting from the use of the information contained in this document.
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Page 5: Table Of Contents
5/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A Table of content Page 1 Safety rules ..................................6 Safety symbols and warnings ............................... 8 Cyber security ..................................9 2 Layout ................................... 10 Layout MegaFlex 1000 to 1600 ............................10 3 Environment ................................. -
Page 6: Safety Rules
This may require additional field marking or labelling defining appropriate level of PPE (Personal Protection Equipment) to reduce the risk of Arc-flash related injuries. Contact our ABB Service Center for product specific information. Installation This UPS must be installed and connected only by trained personnel. - Page 7 7/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A Safety instructions when working with Battery Danger! External Battery must be installed and connected to the UPS by Qualified Service Personnel. Installation Personnel must read this entire section before handling the UPS and Battery. Full voltage and current are always present at the Battery terminals.
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Page 8: Safety Symbols And Warnings
8/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A 1.1 Safety symbols and warnings Safety warnings The text of this manual contains some warnings to avoid risk to the persons and to avoid damages to the UPS system and the supplied critical loads. The non-observance of the warnings reminding hazardous situations could result in human injury and equipment damages. -
Page 9: Cyber Security
ABB Ltd and its affiliates are not liable for damages and/or losses related to such security breaches, unauthorized access, interference, intrusion, leakage and/or theft of data or information. -
Page 10: Layout
10/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A Layout 2.1 Layout MegaFlex 1000 to 1600 Fig. 2.1-3 Control Panel Fig. 2.1-1 MegaFlex 1000 to 1600 - General view µ SNMP J35DSP J35 P SNMP Fig. 2.1-4 Connectivity Rack Fig. - Page 11 3-ph SNMP/WEB plug-in adapter (option - see Fig. 2.1-4) Terminal block (see Section 4.11) Caution! Convenience test terminals are available for ABB Service Technician only. Unauthorized access to test terminals exposes to electric shock hazard risk and increases risk of UPS failure.
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Page 12: Environment
UPS packing materials must be recycled in compliance with all applicable regulations. Recycling at the end of service life! ABB, in compliance with environment protection recommends to the User that the UPS equipment, at the end of its service life, must be recovered conforming to the local applicable regulations. -
Page 13: Installation
13/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A Installation 4.1 Transport The UPS is packaged on a pallet suitable for handling with a forklift. The UPS must be moved in upright position. Do not tilt cabinets more than +/- 10° during handling. Move the UPS in its original package to the final destination site. -
Page 14: Dimensions And Weights Megaflex 1000 To 1600
14/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A 4.1.1 Dimensions and weights MegaFlex 1000 to 1600 66.93" 1700 mm 62.99" 129.92" 1600 mm 39.37" 3300mm 1000mm Fig. 4.1.1-1 MegaFlex 1000 to 1600 – UPS dimensions Dimensions (W x D x H): 129.92 x 39.37 x 86.62 inches / 3300 x 1000* x 2200 mm For seismic installations allow additional 3”... -
Page 15: Delivery
4.2 Delivery When delivered, inspect the package integrity and the physical conditions of the cabinets carefully. In case of any damage sustained during transport, immediately inform the carrier and contact your local ABB Service Center. A detailed report of the damage is necessary for any insurance claim. -
Page 16: Place Of Installation
4.4 Place of installation 4.4.1 UPS location Note! UPS installation and connection must be performed only by an ABB Service Technician! If optional cabinets and accessories are included with the UPS, please refer to those accompanying manuals for installation and operating instructions. -
Page 17: Standing Floor
17/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A 4.4.5 Standing floor Make sure standing floor (especially in case of raised floor) has sufficient weight loading capability to tolerate the UPS and extra weight that might occur from time to time. The UPS must be installed on concrete or another non-combustible surface. - Page 18 18/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A Fixing of the UPS cabinet MegaFlex 1000 to 1600 on the floor The UPS cabinet is free standing and normally does not require to be bolted to the floor. The UPS cabinet can be fixed however to the floor by bolting it with the supporting blocks to the floor. Detail A Fig.
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Page 19: Battery Location
19/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A 3 - 4 - 5 - 6 UPS 2 UPS 1 Fig. 4.4.5-5 MegaFlex 1000 to 1600 – RPA Parallel System disposition In case of Parallel System, try to place the UPS modules in sequence of their numbers (marked on the packing). -
Page 20: Ventilation And Cooling
In order to prevent overheating of the UPS, the available air intake flow rate must exceed the total air exhaust flow rate requirement of the UPS system. Contact your ABB Service Center for appropriate solutions. The below table indicates the heat dissipation at full Load at PF = 1 and charged Battery, up to 3280 ft (1000 m) altitude, for cooling air 77°F (25°C) to 86°F (30°C). -
Page 21: Unpacking
· The documentation includes the “Installation Guide & User Manual” and the “UPS Safety Rules”. Packing material recycling ABB, in compliance with environment protection, use only environmentally friendly material. UPS packing materials must be recycled in compliance with all applicable regulations. - Page 22 “Protective Foil” but only just before the first start-up of the UPS as indicated in the appropriate label! The removal of the "Protective Foil" should be performed only by an ABB Service Technician! PROTECTIVE FOIL to remove Packing material recycling!
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Page 23: Inter Cabinet Connections
23/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A 4.7 Inter cabinet connections Note! The “Power Section cabinet” and “In/Out Section cabinet” must be installed on levelled floor. Be aware of the heavy weight of the UPS cabinets, pay attention when moving the UPS cabinet. Take care not to damage the UPS cabinets when moving by forklift. -
Page 24: Cabinets Positioning And Interconnection For Electrical Safety Grounding
24/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A 4.7.1 Cabinets positioning and interconnection for electrical safety grounding Note! The “Power Section cabinet” and “In/Out Section cabinet” must be installed on levelled floor. Mechanical interconnection is essential to ensure the electrical safety grounding of the “Power Section cabinet”. -
Page 25: Bus Bars Interconnection
UPS Installation Guide / REV-A 4.7.2 Bus bars interconnection Note! All the bus bars interconnection must be performed only by an ABB Service Technician! MegaFlex 1000 to 1600 - Bus bars interconnection Rectifier bus bars (2x 80/5x310 mm) Detail showing bus bars interconnection... -
Page 26: Control Cables Interconnection
MegaFlex 1000 to 1600 UPS Installation Guide / REV-A 4.7.3 Control cables interconnection Note! All the cables interconnection must be performed only by an ABB Service Technician! MegaFlex 1000 to 1600 - Control cables interconnection F ROM PM TO EL... -
Page 27: Lower Closures With Air Inlet Grids Assembling
27/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A 4.7.4 Lower closures with air inlet grids assembling UPS is delivered with lower closures with air inlet grids to be installed on the bottom of the UPS cabinet, over standing feet. Warning! Such covers compete UPS enclosure and are essential to ensure compliance protection level against access IP2X. -
Page 28: Electrical Wiring
Ensure that the AC and DC external isolators are OFF and locked out to prevent their inadvertent operation. Do not apply power to the equipment prior to the commissioning by an ABB Service Technician. Before any other input connection, connect and check the grounding wire. -
Page 29: Input/Output Over Current Protection And Wire Sizing
29/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A 4.8.2 Input/output over current protection and wire sizing Wiring must be sized according to UPS power rating. Sizing of Circuit Breakers and cables for Input Utility, Output Load and Battery must meet the requirements of local and national electrical code and any other local regulation that may apply. -
Page 30: Data For Input/Output And Battery Over Current Protection And Wire Sizing
30/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A 4.8.5 Data for Input/Output and Battery over current protection and wire sizing Note! Please read the safety precautions at the front of this guide carefully, and thoroughly review the Battery manufacturers installation and maintenance manual before connecting the Batteries to the UPS. - Page 31 10x500 + 350 kcmil 8x500 + 250 kcmil 8x500 + 50 kcmil 14x600 + 50 kcmil MegaFlex 1600 *) for AA-8000 Aluminum cables contact ABB Service Center. Recommended two-hole cable lugs: Cable Size T&B Copper / Two holes T&B Aluminum / Two holes...
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Page 32: Installation Requirements
32/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A 4.8.6 Installation requirements Typical examples for the connection of the MegaFlex 1000 to 1600. Note! Under no circumstance’s low impedance or high impedance bonding shall be introduce inside UPS cabinet, between internal mid-point and ground. Single UPS with Common Input Utility for Rectifier &... -
Page 33: Wiring Connection
4.9 Wiring connection Note! UPS installation and connection must be performed only by an ABB Service Technician! Refer to the “Safety prescriptions - Installation” described on Chapter 1. In case of UPS equipped with options or customized parts not covered by this manual, please consult the appropriate technical documentation before proceeding with electrical connections. - Page 34 34/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A Cable conduits entry MegaFlex 1000 to 1600 openings are provided on the top and the bottom of the UPS cabinet for the connection of input and output cables. Pay attention to the position of these openings, when choosing the placement of the UPS. These openings are covered with a protective plate (A and B) which need to be prepared with appropriate cable conduits.
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Page 35: Megaflex 1000 To 1600 - Power Connection With Common Input Utility
35/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A 4.9.1 MegaFlex 1000 to 1600 - Power connection with Common Input Utility connection Load Top entry cables Bottom connection Battery - Typical installation using common NEMA two hole lugs (see Section 4.85) Battery + connection Bottom entry cables... -
Page 36: Megaflex 1000 To 1600 - Power Connection With Dual Input Utility
36/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A 4.9.2 MegaFlex 1000 to 1600 - Power connection with Dual Input Utility Top entry cables connection Load Bottom connection Battery - Typical installation using common NEMA two hole lugs Bottom entry cables (see Section 4.85) Battery + connection... -
Page 37: Use Of Megaflex 1000 To 1600 In Eboost™ Operation Mode
For systems intended to be operated in eBoost™ Operation Mode, the installation shall be protected with suitable surge protection devices (SPDs) on the AC bus feeding the UPSs. Please contact your ABB Service Centre for more information. Note! In eBoost Operation Mode the Inverter output filter is placed in parallel with the Load and combined with the Load current it contributes to the UPS input characteristic. -
Page 38: Use Of Megaflex 1000 To 1600 As Frequency Converter
Avoid high inrush current due to transformer magnetization or motor starting. Note! Only an ABB Service Technician may change a unit from Frequency Converter into a normal UPS (with Bypass) or a normal UPS to a Frequency Converter (with Bypass). -
Page 39: Rpa Parallel System Connection
UPS Installation Guide / REV-A 4.10 RPA Parallel System connection Warning! This operation must be performed only by an ABB Service Technician before the initial start-up (ensure that the UPS installation is completely powered down). Use Class 2 method for RPA cables. -
Page 40: Parallel Control Bus Connection
40/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A 4.10.2Parallel Control Bus connection In case of Parallel System, the communication between the units takes place through the Control Bus Cables. Each Parallel Unit contains the two boards “P13/P14 – IM0222 – Bus Interface Board” (mounted on top of the board “P12 –... - Page 41 41/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A J1B/1 Note! Final units, first and last, of an RPA Parallel System. On the two boards P13/P14 – IM0222 – Bus Interface Board, of J1A/1 the first and last units of a Parallel System, switches SW1-...
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Page 42: Control Bus Cable Location
UPS Installation Guide / REV-A 4.10.3Control Bus cable location Warning! This installation must be performed and verified by an ABB Service Technician before the initial start-up. Ensure that the ups installation is completely powered down. Keep SELV cables separated from high voltage cables. - Page 43 It is important that the cable J1A – J2A (1/2/3/4/5) must be the same length as cable J1B – J2B (1/2/3/4/5). Warning! Connection and commissioning of an additional UPS to an existing Parallel System must be performed only by an ABB Service Technician.
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Page 44: Xa Terminal Block
UPS Installation Guide / REV-A 4.11 XA terminal Block Warning! The connection on the XA terminal block must be performed only by an ABB Service Technician when the UPS is completely powered down! Keep SELV cables separated from high voltage cables! -
Page 45: Epo - Emergency Power Off" Command Connection
Warning! The connection of an emergency button EPO (Emergency Power Off) must be performed only by an ABB Service Technician when the UPS is completely powered down! Note! The reliability of the system depends on this contact NC (Normally Closed)! An Emergency button (Normally Closed voltage-free contact) can be connected on terminals XA / EPO-1, EPO-2. - Page 46 46/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A Note! To operationalize this function, in case that the UPS was provided with one or more cards “Customer Interface” (max. 3 - see Chapter 5), there must be on each card the following: - Remove the cable short-circuiting terminals X2 / 1, 2 (see Fig.
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Page 47: Connectivity Interface
Fig. 5-2 Connectivity Slots Note! The installation of any option board must be performed only by an ABB Service Technician. Prior to the installation, connection and cabling of any option board the UPS must be completely powered down and all the power sources that will be connected to the option board must be de- energized. -
Page 48: Serial Port J35Μp - Rs232 (Sub D, Female 9 Pin)
Serial Port J35µP - RS232 for IMV protocol Total remote management of the system using software iUPSGuard, Data Protection µ P - RS232 or ABB Service Software for system protection management systems. P - RS232 µ Fig. 5.1-1 MegaFlex 1000 to 1600 - Serial Port J35µP – RS232... -
Page 49: Customer Interface Board
49/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A 5.2 Customer interface board J1 connector– RJ45 8P8C (see Section 5.2.1) Pin 5: TX (out) Pin 6: RX (in) Pin 4: GND X1 terminal block – Output signals on voltage free contacts (see Section 9.2.2) X1 / 1, 2, 3 NO, C, NC MAINS FAILURE... -
Page 50: Connector J1 - Rj45 8P8C
In case different alarms or operating status are required, they can be configured on the same terminals via software from the Control Panel. The configuration can be changed in parameters mode by an ABB Service Technician using the appropriate “Service Code”. -
Page 51: X2 Terminal Block - "Epo - Emergency Power Off
“GENERATOR ON” on X1 / 11, 22. See Fig. 5.2-1 / X1. Since the Parameter for of the reading of the Generator function is “Service Code” protected, call the nearest ABB Service Centre for it's activation. -
Page 52: X1 Terminal Block - Aux External Maintenance Bypass
When this contact closes, eBoost operation mode is inhibited. The Parameter for the activation of such function is “Service Code” protected. Contact your ABB Service Center for its activation. This function is particularly useful for controlling eBoost operation following critical conditions on either the load side or the input utility, including generator operation when the “GENERATOR ON”... -
Page 53: Notes
53/54 MegaFlex 1000 to 1600 UPS Installation Guide / REV-A Notes 6.1 Notes Form It is recommended to note in this section Notes, with date and short description all the operations performed on the UPS, as: maintenance, components replacement, abnormal situations, etc. Date Description Done by... - Page 54 — ABB Power Protection SA Via Luserte Sud 9 6572 Quartino Switzerland abb.com/ups © Copyright 2020 ABB. All rights reserved Specifications subject to change without notice...