American Power Conversion 240-320kW User manual

Brand: American Power Conversion

Model: 240-320kW

Category: Power supply units

Type: User manual

APC Silcon

240-320kW 480V UPS

Installation Guide

This manual is subject to

change without notice and does not represent

a commitment on the part of the vendor.

2 Installation Guide APC Silcon 240-320kW 480V UPS

990-4049

Thank You!

Thank you for chosing an APC Silcon UPS. Please read this Installation Guide thoroughly prior to

installing the system. It provides important information on safe and efficient installation.

The installation and use of this product must comply with national, federal, state, municipal and

local codes.

Safety Symbols used in this manual

WARNING!

Indicates a hazard which, if not avoided, could result in injury or death.

CAUTION!

Indicates a hazard which, if not avoided, could result in damage to

the product or other property.

NOTICE!

Read and pay attention to this important information.

WARNING!

This UPS unit contains hazardous AC and DC voltages. Only qualified electricians should install the

UPS, AC line and external batteries, and must be familiar with batteries and battery installation.

Before installing, maintaining or servicing the UPS, shut off the UPS and disconnect all sources of AC

and DC power.

As the UPS has no built-in disconnection devices to switch off external AC and DC input power, ensure

that disconnection devices are provided as separate parts in connection with the installation!

The installer must provide each external disconnecting device for this UPS system with labels with the

following text:

“Isolate the Uninterruptible Power Supply (UPS) as instructed in this guide before working on circuit”.

AC and/or DC voltage will always involve a potential risk of AC voltage at UPS output generated from

either batteries or utility. To avoid equipment damage or personal injury, always assume that there

may be voltage at UPS output.

This system is equipped with an auto-start function. If activated the system may start without warning.

Refer to “Programming” section for information on de-activation.

TEST BEFORE YOU TOUCH!

To reduce the risk of fire or electric shocks, install the UPS and external batteries in a temperature and

humidity controlled indoor area, free of conductive contaminants.

UPS batteries are high-current sources. Shorting battery terminals or DC terminals, DC busbars can

cause severe arcing, equipment damage and injury. A short circuit can cause a battery to explode.

Always wear protective clothing and eye protection and use insulated tools when working on batteries.

CAUTION!

This unit contains components sensitive to electrostatic discharge (ESD). If you do not follow the ESD

procedures, you may cause severe damage to electronic components.

PLEASE RECYCLE

The shipping materials for the APC Silcon UPS are recyclable. Please save for later use or dispose of

them appropriately.

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Installation Guide APC Silcon 240-320kW 480V UPS 3

Contents:

1.0 Introduction 5

1.1 Tools and Equipment 5

2.0 Unpacking/Identification of Equipment 6

3.0 Installation 9

3.1 Requirements on Site 9

3.2 Dimensions and Weight 9

3.2.1 Dimensions and Weight of UPS 9

3.3 Footprints 10

3.3.1 UPS Cabinet Footprints 10

3.3.2 Conduit Entrance Plate in bottom of the system 11

3.3.3 Top Cable Entry 12

4.0 External Connection 13

4.1 Connecting the UPS 13

4.1.1 Connecting AC and DC Power Cables (Dual Utility Connection) 14

4.1.2 Seperation of AC from DC1 and DC2 16

4.1.3 Top or Bottom Cable Entry 17

4.1.4 Dual and Single Utility Supply 18

4.1.5 Switching from Dual to Single Utility Input 20

4.1.6 Connection Terminals 22

4.1.7 Torque Specifications 22

4.1.8 Grounding 22

4.2 System Integration Interface 24

4.2.1 Connecting the System Integration Interface Board (SII-board) 25

4.3 Parallel Board 29

4.4 Relay Board 31

4.4.1 Relay Board Functions 31

4.4.2 Cable Sizes 33

4.5 Communication Interface / Smart Slot 34

4.5.1 Connections 34

4.6 SmartSlot for APC Silcon 240-320kW UPS 34

4.6.1 SmartSlot Accessories 35

4.6.2 Multiple SmartSlot Installation - introduction 35

4.6.3 APC Silcon Battery Cabinets 37

4.7 Battery Breaker Box 39

4.7.1 Interconnection 40

4.7.2 Mounting and Connection of Battery Breaker Box 40

4.7.3 UPS with External Battery via Battery Breaker Box 41

4.8 UPS Installations in Computer Rooms 41

4.8.1 EPO Principle 42

4.8.2 Emergency Power Off (EPO) for UPS 44

5.0 Programming 46

5.1 Parameters 46

5.1.1 Programming Keys 47

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5.1.2 Programming Example - Switch to Bypass Operation 47

5.2 System Configuration 49

5.2.1 Programming Example - Change Boost Charge Voltage to 446V 50

5.2.2 Programming Example - Change to Output Isolation

Transformer Available 51

5.3 Programming Parameters for Advanced Parallel Operation. 52

5.3.1 Description of Settings. 52

5.3.2 Programming Example 52

5.4 Battery Monitor 53

6.0 Options/Accessories 54

6.1 Diagrams for Service Bypass Panel for Single Operation,

Single and Dual Utility 54

6.2 Seismic Anchoring 62

6.2.1 Mounting Seismic Anchoring 63

6.3 NEMA 12 Cover (IP31) 64

6.3.1 Mounting NEMA 12 Cover 64

6.4 Remote Display 65

6.4.1 Extension of Remote Display Communication Distance 65

6.4.2 Remote Display Installation 67

6.4.3 Remote Display Use 68

6.5 Isolation Transformer Module 69

6.5.1 Requirements on Site 69

6.5.2 Cabinets and Dimensions 70

6.5.3 Footprints 70

6.5.4 Connecting Isolation Transformer 70

6.5.5 Recommended Cable Lugs and Crimping Tools 70

6.5.6 Isolation Transformer - Diagram Delta WYE configuration (Dyn11) 71

6.5.7 Isolation Transformer Grounding 71

6.5.8 Principale Diagrams for Isolation Transformer 72

6.6 Intersystem Synchronization Unit 74

7.0 System Specifications 75

7.1 Technical Data 75

8.0 Appendix 76

8.1 Table 1. Installation Planning Data 76

8.2 Table 2 – Table 310-16 77

9.0 Warranty 79

9.1 APC Silcon Series® Limited Factory Warranty 79

10.0 How to Contact APC 80

Introduction

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Installation Guide APC Silcon 240-320kW 480V UPS 5

1.0 Introduction

Power regulation varies from country to country, and the information given in this installation

guide can therefore only be of a general nature. Electricians should always refer to national and

local electrical codes prior to installing the UPS system.

1.1 Tools and Equipment

This section lists all tools and equipment required to install all UPS configurations. See also

section 4 for further details on connection.

Tools:

• 10mm socket

• 13mm socket-deep

• 17mm socket

• 3/4” or 19mm socket-deep

• 3/4” or 19mm combo wrench

• Small flathead/regular screwdriver

• #3 philips screwdriver

• Compression lug crimping tool

• Knock-out set (for conduit)

Equipment:

• Compression lugs for cable terminations

• Cable to Service Bypass Panel from system feeder

• Cable to UPS input from service bypass panel

• Cable to Service Bypass Panel from UPS output

• Cable from Service Bypass Panel to customer distribution

• Cable to UPS input from external batteries/external Battery Breaker Box

(systems = with external battery)

• Solid core, control wire to UPS from Service Bypass Panel

• Solid core, control wire to UPS from external batteries/external Battery Breaker Box

• Conduit necessary for above listed cabling

WARNING!

Heavy equipment. To prevent personal injury or equipment damage, take extreme care when

handling and transporting UPS cabinet and equipment.

WARNING!

Ensure that front doors are in place and that internal front cover is fastened by screws before

attempting to lift or transport the system.

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Unpacking/Identification of Equipment

2.0 Unpacking/Identification of Equipment

Copy of type label (without battery):

NOTICE!

Unless otherwise specified by the shipping company, use a fork lift to unload equipment from

pallet.

1. Unpack system.

2. Verify compliance between type label on reverse side of front door and system ordered.

Check input and output voltage.

3. Copy the type label data to label copy below for easy identification of the system.

4. Use a fork lift to transport the system to installation site.

Unpacking/Identification of Equipment

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Main UPS system

The UPS is a battery back-up system. Unconditioned power is fed to UPS input. The UPS

supplies conditioned power.

Service Bypass Panel

AC utility power for critical load is led through the service bypass panel while UPS is shut

down for maintenance

Battery Breaker Box

The APC Battery Breaker Box is required if the UPS is installed with an external battery. The

Battery Breaker Box provides overcurrent and short-circuit protection.

Battery Cabinet

For storage and protection of battery bank.

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Unpacking/Identification of Equipment

Isolation Transformer

Isolation Transformers are used for galvanic isolation of utility power and conditioned power.

Seismic Anchoring

Seismic anchoring stabilizes the UPS in seismic areas.

NEMA 12 C

over

NEMA 12 covers are used in locations with potential risks of liquid discharge or leakage above

UPS system.

Remote Display

Use remote display to monitor UPS

NOTICE!

Contact your local APC representative or APC Support if you have any questions

Installation

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Installation Guide APC Silcon 240-320kW 480V UPS 9

3.0 Installation

3.1 Requirements on Site

All system parts are accessible from front or top of UPS. Cable entries are accessible from top

or bottom. The system may be installed close to walls as long as free space is allowed for system

doors to open.

For ventilation and service purposes allow for free space of a minimum of 3 foot above and in

front of UPS. Never install systems in direct sunlight.

3.2 Dimensions and Weight

3.2.1 Dimensions and Weight of UPS

WARNING!

For safety reasons do not stand on UPS. Keep UPS cabinet surface free of any objects

UPS

Height

inch/mm

Width

inch/mm

Depth

inch/mm

Weight

lbs./kgs

240kW 480V 70.86/1800 74.80/1900 31.50/800 4432/2014,5

320kW 480V 70.86/1800 74.80/1900 31.50/800 4432/2014,5

Cabinet

74.80/1900 in./mm wide

70.86/1800 in./mm

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Installation

3.3 Footprints

3.3.1 UPS Cabinet Footprints

NOTICE!

Dimensions indicated in inches / milimeters and lbs. / kgs

74.80/1900

73.85/1876

71.05/1805

70.86/1800

62.20/1580

59.44/1510

54.20/1377

51.45/1307

42.40/1077

32.56/827

29.80/757

3.74/95

0.95/24

1.02/26

1.81/46

6.14/156

7.87/200

14.37/365

15.94/405

25.98/660

30.47/774

31.50/800

REAR

COM

UTILITY 1

OUT-

PUT

UTILITY2

FRONT

Installation

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Installation Guide APC Silcon 240-320kW 480V UPS 11

3.3.2 Conduit Entrance Plate in bottom of the system

Cable entries need to be punched in the UPS cabinet. Follow diagram for correct orientation of

power and control cables to be led into the UPS.

10.14/257.5

19.78/502.5

30.39/771.9

FRONT

COM

UTILITY 1

UTILITY 2 OUTPUT DC

LEFT

RIGHT

REAR

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Installation

3.3.3 Top Cable Entry

Cable entries need to be punched in the UPS cabinet. Follow diagram for correct orientation of

power and control cables to be led into the UPS.

17.72/450

11.61/295

7.68/195

3.31/84

16.28/413.5

26.12/663.5

REAR

FRONT

RIGHT

LEFT

UTILITY 1-2/ OUTPUT/ DC

COM

External Connection

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4.0 External Connection

4.1 Connecting the UPS

Prior to connecting the UPS, refer to section 6: Options and Accessories to ensure that UPS

options are correctly interphased.

To access cable terminals, open front door, remove screws and lift off the 4 front covers

(remember earth wire on rear side). Power cable entry at bottom: Remove front covers 2 and 3.

Power cable entry at top: Remove front covers 1 and 2. Remove cover 4.

WARNING!

Read warnings on page 2 of this manual before continuing.

NOTICE!

Always keep AC, DC and communication cables separate.

Connecting AC

and DC

Connecting Ground

Connecting

communication

UPS system without cover and doors

cables

power cables

UPS system with cover– doors open

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External Connection

4.1.1 Connecting AC and DC Power Cables (Dual Utility Connection)

Top bar – Utility 2 (L1, L2, L3)

Bottom bar – Output (N/E, L1, L2, L3)

Bottom bar – Utility 1 (N, L1, L2, L3)

Top bar – Ext. DC (X003±, X004±)

Connection in the

bottom of the

cabinet

External Connection

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Installation Guide APC Silcon 240-320kW 480V UPS 15

WARNING!

Bottom cabinet connection must be grounded.

Utility 2 – X002

Output – X005

Ext. DC

Utility 1 – X001

Utility 1

X001

Ext. DC

Utility 2

X002

Output

X005

Dual Utility Connection

Seen from front

Seen from side

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External Connection

4.1.2 Seperation of AC from DC1 and DC2

Use the 2 pieces of polycarbonate (supplied with the UPS) to separate AC from DC1 and DC2.

Standard length of polycarbonate adjusted for top cable entry. Adjust length of polycarbonate

to fit bottom entry where applicable.

WARNING!

Supply the UPS from grounded 3-wire/4-wire WYE service.

NOTICE!

Ensure correct phase rotation of input voltage.

NOTICE!

Keep UPS input and output conductors in separate conduits.

NOTICE!

Keep AC and DC conductors in separate conduits.

NOTICE!

Keep batteries 1 and 2 (DC conductors) in separate conduits.

WARNING!

Keep UPS power conductors and UPS control wiring in separate conduits.

Polycarbonate

External Connection

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Installation Guide APC Silcon 240-320kW 480V UPS 17

4.1.3 Top or Bottom Cable Entry

For top cable entry, move copper angle bar to bottom.

Unscrew bolt, take out the split, move the angle bar down,

insert split, and tighten the bolt

Angle bar

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External Connection

4.1.4 Dual and Single Utility Supply

The UPS is fitted with dual utility input as standard. If dual utility is not available or not

needed, a small modification has to be made. See section 4.1.5 switching from dual to single

utility input.

WARNING!

UPS units contain hazardous AC and DC voltages. Only qualified electricians should install UPS,

AC line and external batteries, and must be familiar with batteries and battery installation.

Before installing, maintaining or servicing the UPS, shut off the UPS and disconnect all sources

of AC and DC power.

As the UPS has no built-in disconnection devices to switch off external AC and DC input power,

ensure that disconnection devices are provided as separate parts in connection with the

installation!

The installer must provide each external disconnecting device for this UPS system with labels

with wording as follows:

“Isolate the Uninterruptible Power Supply (UPS) as instructed in this guide

before working on circuit”

AC and/or DC voltage will always involve a potential risk of AC voltage at UPS output generated

from either batteries or utility. To avoid equipment damage or personal injury, always assume

that there may be voltage at UPS output.

This system is equipped with an auto-start function. If activated the system may start without

warning. Refer to “Programming Parameters” for information on de-activation.

TEST BEFORE YOU TOUCH!

To reduce the risk of fire or electric shocks, install the UPS and external batteries in a

temperature and humidity controlled indoor area, free of conductive contaminants.

UPS batteries are high-current sources. Shorting battery terminals or DC terminals or DC

busbars can cause severe arcing, equipment damage and injury. A short circuit can cause a

battery to explode. Always wear protective clothing and eye protection and use insulated tools

when working with working near batteries.

CAUTION!

This unit contains components sensitive to electrostatic discharge (ESD). If you do not follow the

ESD procedures, you may cause severe dammage to electronic components.

External Connection

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Installation Guide APC Silcon 240-320kW 480V UPS 19

Working Principle of Dual Utility (2 utility supplies)

Working Principle of Single Utility (1 utility supply)

NOTICE!

Max. phase shift between utility 1 and 2: less than

Refer to section 7.0 System Specifications for frequency tolerance of utility 1 and 2, and voltage.

Utility 1 supports the load in normal operation. Utility 2 supports the load through the static and

service bypass switch.

NOTICE!

Refer to section 7.0 System Specifications for frequency and voltage tolerance of utility 1.

Utility 1 or 2 supports the load in normal operation or through the static service bypass switch.

Q10

Utility 2

Output

Utility 1

Utility 2

APC Silcon UPS

Output

APC Silcon UPS

Utility 1/2

20 Installation Guide APC Silcon 240-320kW 480V UPS

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External Connection

4.1.5 Switching from Dual to Single Utility Input

Follow steps 1 and 2 to switch from dual to single input.

1) Remove fiber bar (55322) by unscrewing bolts and by mounting copper bars as below

2) Switch the connector in Con3 to Con1.

In the static switch the

following modifications

have to be made for

single utility input

Fiber bar

Copper bars

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American Power Conversion 240-320kW User manual

Brand: American Power Conversion

Model: 240-320kW

Category: Power supply units

Type: User manual

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American Power Conversion 240-320kW User manual

American Power Conversion 240-320kW User manual

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