AIS
®
3000 and
XR Battery Enclosure
10-40kVA
400V
Operation Manual
AIS3000® & XR Battery Enclosure 10-30kVA, 208V, Operation Manual – 990-1962 1
AIS
®
3000 and XR Battery Enclosure
10-40kVA 400V
Operation Manual
IMPORTANT SAFETY INSTRUCTIONS - SAVE THESE INSTRUCTIONS
This manual contains important instructions that should be followed during
installation and maintenance of the UPS and Batteries
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Contents
AIS® 3000 & XR Battery Enclosure 10-40kVA, 400V, Operation Manual – 990-2259 i
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 1
Warning/note symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Environmental symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
The AIS 3000 Family Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
352mm Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
523mm Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Start-Up (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Voltage confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bypass operation (or static bypass operation) . . . . . . . . . . . . . 8
Mechanical bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
The Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Menu-driven user functions . . . . . . . . . . . . . . . . . . . . . . . . 11
Basic display navigation principles . . . . . . . . . . . . . . . . . . . 12
Control functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Status views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Clock set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Alarm threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Display setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Diagnostics screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ii AIS® 3000 & XR Battery Enclosure 10-40kVA, 400V, Operation Manual – 990-2259
Front Panel Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air Filter Inspection/Replacement. . . . . . . . . . . . . . . . . . . . . . . 20
Air filter inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
General safety prior to module replacement . . . . . . . . . . . . 23
Removal of Battery Securing Brackets (if applicable) . . . . . . . 24
Battery Module removal . . . . . . . . . . . . . . . . . . . . . . . . . . 25
How to install a Battery Module . . . . . . . . . . . . . . . . . . . . 25
Network Management Card with Environmental Monitor. . . . . 27
Network Management Card replacement . . . . . . . . . . . . . . 27
How to Obtain Replacement Parts . . . . . . . . . . . . . . . . . . . . . . 28
Orderable parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Total-Power-Off Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Display Messages/Troubleshooting . . . . . . . . . . . . . . . . . . . . . 31
Display messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Mechanical Bypass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Mechanical Bypass Lever . . . . . . . . . . . . . . . . . . . . . . . . . 34
Turn into mechanical bypass . . . . . . . . . . . . . . . . . . . . . . . 34
Turn into normal operation (from bypass operation) . . . . . . . 35
Maintenance Bypass Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Operation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
LIMITED FACTORY WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . 37
APC product covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Terms of warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Non-transferable warranty extends to first purchaser for use . 37
Assignment of warranties . . . . . . . . . . . . . . . . . . . . . . . . . 37
Drawings, descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Warranty claims procedure . . . . . . . . . . . . . . . . . . . . . . . . 38
Exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
AIS® 3000 & XR Battery Enclosure 10-40kVA, 400V, Operation Manual – 990-2259 iii
Appendix ...............................................................40
UPS Components and Options. . . . . . . . . . . . . . . . . . . . . . . . . 40
352mm Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
523mm Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
System sizes, part Nos., number of Battery Modules and
weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Part number coding: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Battery Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Front Panel overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Stabilizing Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
User interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Battery Securing Bracket and Floor Anchoring . . . . . . . . . . . 45
Conduit Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Extended Run Battery Enclosure (XR Enclosure) and Battery
Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Part Numbers for XR Enclosures . . . . . . . . . . . . . . . . . . . . . 47
Part Number for Battery Module . . . . . . . . . . . . . . . . . . . . 47
Maintenance Bypass Panels with Power Distribution Capability 48
AIS® 3000 & XR Battery Enclosure 10-40kVA, 400V, Operation Manual – 990-2259 1
IMPORTANT SAFETY INSTRUCTIONS
This guide contains important instructions that should be followed when handling the UPS, Battery
Enclosures, and Batteries.
Warning/note symbols
Environmental symbols
WARNING!
Risk of electric shock.
CAUTION!
Read this information to avoid equipment damage.
Note
Indicates important information.
Indicates that more information is available on this subject in a different section of this
manual.
See als
o
Indicates that more information is available on the same subject in a different manual.
Temperature Ventilation
requirements
Humidity Dust/Fumes Altitude
IMPORTANT SAFETY INSTRUCTIONS
2 AIS® 3000 & XR Battery Enclosure 10-40kVA, 400V, Operation Manual – 990-2259
General safety
Two people to lift a component weighing between 18 - 32 kg.
Indicates that a switch or current protection device is ON.
Indicates that a switch or a breaker is OFF.
Note
For configurations including customer-supplied external batteries, refer to
manufacturers battery installation and maintenance instructions.
AIS® 3000 & XR Battery Enclosure 10-40kVA, 400V, Operation Manual – 990-2259 3
Introduction
Welcome to the Operation Manual covering the AIS
®
3000 UPS and the Extended Run Battery
Enclosure (XR Enclosure). This manual provides you with a detailed description of start-up,
operation, and troubleshooting.
Note
The UPS manuals:
Receiving and Unpacking - part # 990-1961
Site Planning and Electrical Installation - part # 990-2258 – are provided in the
documentation storage area at the top right corner on the UPS (behind the Front Panel).
The XR Battery Enclosure (option) – Electrical Installation Manual – part #990-2195 is
provided behind the Front Panel of the XR Battery Enclosure.
Note
For information on Maintenance Bypass Panels, see product specific manual.
Note
For more details on APC products and services, visit us at www.apc.com
10/100Base-T
Probe
AP9619 Network Management Card EM
!
Reset
Output
Pwr
Zone
10/100
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Documentation
storage
4 AIS® 3000 & XR Battery Enclosure 10-40kVA, 400V, Operation Manual – 990-2259
The AIS 3000 Family Range
352mm Enclosures
523mm Enclosures
10/10
0
Ba
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P
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AP9619 Network Management C
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Reset
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www.apc.com
www.apc.com
Front view Rear view Front view without cover
10-20kVA
www.apc.com
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10
/100
Bas
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AP96
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/100
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
M
o
del:
S
er
ial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
S
er
ial:
BATTERY UNIT
10/100Base-T
P
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AP96
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:
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Mode
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BATTERY UNIT
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BATTERY UNIT
M
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Serial:
BATTERY UNIT
Mod
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Serial
:
BATTERY UNIT
Mod
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:
S
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:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Mo
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BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
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BATTERY UNIT
Model:
Seri
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:
BATTERY UNIT
M
o
del:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Front view Rear view
Front view without cover
10-20kVA
Front view without cover
30-40kVA
Blind plates
cover
empty battery
bays
The AIS 3000 Family Range
AIS® 3000 & XR Battery Enclosure 10-40kVA, 400V, Operation Manual – 990-2259 5
WARNING!
Only trained persons familiar with the construction and operation of the equipment,
including the electrical and mechanical hazards involved, may install and remove
system components.
Note
Details on the UPS sizes, runtime, weight etc. are available in the Appendix under UPS
sizes, weights, and runtime configurations.
Note
Most illustrations show 523mm Enclosures but apply to both Enclosure sizes. Any
differences between the two Enclosure sizes will be addressed in the manual.
6 AIS® 3000 & XR Battery Enclosure 10-40kVA, 400V, Operation Manual – 990-2259
Start-Up (if applicable)
Power application
Set the utility breaker to ON.
If your installation includes an XR Enclosure with a DC disconnect switch, turn the DC
disconnect switch ON.
Note
Start-up is included with the UPS, and the start-up procedure described here is only
applicable if the UPS requires a subsequent start-up.
WARNING!
Only trained personnel familiar with the construction and the equipment may carry out
the start-up procedure.
Note
Wait approximately 30 seconds for the system to boot up and carry out self test.
Model
:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
S
e
rial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Se
rial:
BATTERY UNIT
10/100Base-T
Probe
A
P
961
9
Network Mana
gem
e
nt
Ca
rd EM
!
Res
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Output
P
w
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Zo
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10/100
ON
OFF
Model:
Serial:
BATTERY UNIT
M
odel:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model
:
S
erial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model
:
S
erial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Mo
d
e
l
:
S
eria
l
:
BATTERY UNIT
Mo
del:
Serial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Model:
S
e
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ial:
BATTERY UNIT
Model:
Serial:
BATTERY UNIT
Mo
del:
Serial:
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XR Enclosure
Mains
breaker
UPS
Start-Up (if applicable)
AIS® 3000 & XR Battery Enclosure 10-40kVA, 400V, Operation Manual – 990-2259 7
After system boot-up, the display will atuomatically prompt you on how to confirm/select voltage
and frequency as shown in the following.
Voltage confirmation
At the initial start-up, the display will prompt you through the following screens:
•When the Confirm Voltage prompt appears on the screen, use the arrow key on the display to
select desired voltage, and press ENTER.
When the prompt Apply load appears, select Yes if you want the UPS to provide a load output
now. (If you do not want a UPS load output at this point, select No).
LOAD ON LED is now lit, and the display will show the Confirm Status Screen.
prompt you on how to confirm/ select volta ge and frequency as shown in the following.
See display introduction under The Display.
Note
The UPS is now ready to support the load.
Confirm Voltage
Use 400V
Yes, use 400V
No, select another
Apply load?
Yes
No
Chrg xxx% ||||||||||
Load xxx% ||||||||||
xxx Vin xxxVout xxHz
Runtime: xxhr xxmin
Status screen
8 AIS® 3000 & XR Battery Enclosure 10-40kVA, 400V, Operation Manual – 990-2259
Operation Modes
In a stand-alone installation, the UPS has four different operation modes. If the installation includes a
Maintenance Bypass Panel test mode will also be available.
Normal operation
During normal operation, the UPS converts mains power to conditioned power for the connected
load.
Battery operation
During battery operation, the UPS provides power to the connected load from its internal and (if
applicable) external batteries for a finite period. The UPS transfers to battery operation if the supply
of mains power fails, or is outside pre-defined limits.
Bypass operation (or static bypass operation)
Static bypass operation can either be obtained by user request or automatically, as the UPS will
switch into bypass operation if both the normal and battery operation modes are unavailable. During
static bypass operation, the mains power is sent through internal Radio Frequency Interference (RFI)
filters to the connected load, bypassing the internal power converters. The UPS transfers to bypass
operation following a command received via the display, or after a short or heavy overload on the
output of the UPS. Battery back-up is not available in bypass operation.
Mechanical bypass
In mechanical bypass, mains power is sent directly to the connected load through a mechanical
breaker, bypassing all internal UPS functions and filters. Mechanical bypass is obtained by the
operation of the mechanical bypass breaker lever located behind the front cover. Mechanical bypass
is a feature designed to keep the load supplied with mains power during maintenance of the UPS
power sections. All major maintenance operations can be performed with the UPS running in
mechanical bypass, and with the load being supplied directly with unconditioned mains power.
Operation Modes
AIS® 3000 & XR Battery Enclosure 10-40kVA, 400V, Operation Manual – 990-2259 9
Maintenance bypass
The UPS can be connected to an external Maintenance Bypass Panel. When activated, this panel
bypasses the entire UPS Enclosure (only possible with an optional APC Maintenance Bypass Panel),
feeding mains power directly to the load. An activated wrap-around Maintenance Bypass Panel
completely isolates the UPS and allows all kinds of maintenance to be performed – including a
replacement of the entire UPS.
10 AI 3000 & XR Battery Enclosure 10-40kVA, 400V, Operation Manual – 990-2259
The Display
Introduction
CAUTION!
The display provides access to more functions than described in this manual. Those
functions should not be accessed without the assistance of APC Customer Support in
order to avoid unwanted load impacts. For APC World-wide Customer Support, refer to
rear cover of this manual.
LOAD ON
When the green LED is on, the UPS provides power to the load equipment.
ON BATT When the yellow LED is on, power to the load flows from the batteries to the
Power Module.
BYPASS When the yellow LED is on, power to the load is supplied through the static
bypass switch or mechanical bypass.
FAULT When the red LED is on, a fault condition exists.
LCD Screen Displays alarms, status data, instructional help, and configuration items.
UP and DOWN
navigation keys
Selects menu items and accesses information.
HELP key Launches context-sensitive help.
ENTER key Opens menu items and input changes to system parameters.
ESC key Returns to previous screen displayed.
?
ESC
Chrg 100%
Load 000%
230Vin 000Vout 50Hz
Runtime: 00hr 30m
LOAD ON
ON BATT
BYPASS
FAULT
Four Light Emitting Diode (LED)
indicators report the operational
status of the UPS.
Liquid Cystal
Display (LCD)
Screen
Five navigation keys are used to select and open
menu items, to access information, change system
parameters, and to launch context-sensitive help.


AIS® 3000 & XR Battery Enclosure 10-40kVA, 400V, Operation Manual – 990-2259 11
Navigation
Menu-driven user functions
If you get beyond the functions described in the menu tree, do not proceed. Press ESC to go back.
Overview
Main Menu
Control
Status
Setup
Logging
Control
Turn load off
UPS into
bypass
Iin lbyp Iout
Status
Vin Vbyp Vout
Load & Bat
Frequencies
Alarm
thresholds
Setup
Logging
Clock
Display
Settings
View log
View statistics
Beeper setup
Logging
Display setup
Diags
Diagnostics
Faults and
Diagnostics
Chrg xxx%
Load xxx%
xxxVin
Runtime
kVA & kW
Display
Diags
Help
Batteries
Navigation
12 AI 3000 & XR Battery Enclosure 10-40kVA, 400V, Operation Manual – 990-2259
Basic display navigation principles
On the display, press ESC until you get to the Overview Screen, which provides you with basic
system status information.
Press UP, DOWN arrows to navigate the selector arrow and view all sub-menu screens.
Press ENTER to open the Main Menu screen. From here, you command, configure, and monitor the
system.
Control functions
From the Control Screen on the Main Menu, you can select the following functions:
1. Turn Load OFF/ON
2. Switch the UPS into Bypass/out of Bypass
Turn load OFF (disconnect the UPS output to the load equipment).
1. From the Main Menu, select Control and press ENTER
2. Use UP/DOWN key to navigate to Turn Load OFF, and press ENTER
3. Select YES, Turn Load FF
Chrg 100%
Load 000%
230Vin 000Vout 50Hz
Runtime: 0hr 0m
Overview Screen
Control
Status
Setup
Logging
Display
Diags
Help
Main Menu
WARNING!
Disconnecting the UPS output to the load, does NOT de-energize the UPS! Always
follow the Total-Power-OFF procedure if you need to de-energize the UPS in
emergency situations!
Control
Status
Setup
Logging
Display
Help
Diags
Main Menu
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