APC Silcon 240-320kW 400V UPS Installation Guide Copyright 2000 APC Denmark ApS This manual is subject to change without notice and does not represent a commitment on the part of the vendor
Thank You! Thank you for chosing the APC Silcon Series 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.
Contents 1.0 Introduction 1.1 Tools and Equipment 5 2.0 Unpacking 6 3.0 Installation 7 3.1 3.1.1 3.2 3.2.1 3.2.2 3.2.3 Requirements on Site Cabinet Dimensions Footprint 1600mm Cabinet for 240-320kW UPS 825mm Cabinet for Isolation Transformer or Switch Gear 1600mm Cabinet for Isolation Transformer 7 7 8 8 8 8 4.0 External Connection 9 4.1 4.2 4.2.1 4.3 4.4 4.4.1 4.5 4.5.1 4.6 4.7 4.7.1 4.7.2 4.7.3 4.7.4 4.7.5 4.7.6 4.8 4.9 4.9.1 4.9.2 4.9.
6.3 6.4 6.4.1 6.4.2 6.4.3 6.5 6.5.1 6.5.2 6.5.3 6.5.4 6.5.5 6.5.
Introduction 1.0 Introduction Power regulation varies from country to country, and information given in this installation guide can therefore only be of a general nature. Electricians should therefore always refer to national and local electrical codes prior to installing the UPS system. 1.1 Tools and Equipment CAUTION! Heavy equipment. To prevent personal injury or equipment damage, take extreme care when handling and transporting UPS cabinet and equipment.
Unpacking 2.0 Unpacking NOTICE! Unless otherwise specified by the shipping company use a fork lift to unload equipment from pallet 1. To unpack UPS unit, remove top and bottom screws from side plates of packaging and lift up side plates 2. Verify compliance between type label on reverse side of front door and system ordered. Check input and output voltage 3. Copy type label data to label copy below for easy identification of system 4.
Installation 3.0 Installation 3.1 Requirements on Site All system parts are accessible from front or top of UPS. Cable entries are accessible from bottom. A 1-metre free space on all sides should be allowed during installation. After installation of the UPS, leave a free space of 600 mm to the right for system access. (As per applicable national and/or local codes.
Installation 3.2 Footprint 3.2.1 1600mm Cabinet for 240-320kW UPS Power cable entry Rear com. cable entry Front 3.2.2 825mm Cabinet for Isolation Transformer or Switch Gear Rear Power cable entry 3.2.
External Connection 4.0 External Connection 4.1 Connecting the UPS Right side view Relay board Please refer to “Relay Board” section Battery Front view System Integration Interface Communication Interface Parallel Controller NOTICE! Check correct phase rotation of mains input voltage!! Max. input/output cables: 3//300 mm2. If there is no neutral input Dzn0 or Dyn11 input isolation transformer is required.
External Connection CAUTION! At a switch mode load of 100% the neutral must be rated for 200% output phase current. UPS External Input Fuses* FM [A] 380-415V External Input Cable [mm2] 380-415V External PE Cable [mm2] Maximum External Output Fuses* [A] External Output Cable [mm2] 240kW 500 2//120 95 400 2//95 320kW 630 2//185 150 500 2//150 * DIN gL types NOTICE! All cable dimensions are recommended sizes only. Refer to local legal regulations. UPS External Alarm Cable max.
External Connection 4.2 System Integration Interface NOTICE! Consistent use of designations (Q001, Q002, Q003, H002, H003) in diagrams simplifies information exchange. System Integration Interface (SII) is the control link between UPS and system main switches as shown in above diagram. The purpose of the SII is to ensure correct operation of switches without losing system output power. Auxiliary contacts on the main switches transmit the SII board inputs.
External Connection 4.2.
External Connection Terminal Blocks: X003/X004 (Anxiliary Contacts) When switching Q001, Q002, Q010, Battery Breaker 1 or Battery Breaker 2 from “ON or 1” to “OFF or 0”, the anxiliary contact has to be open BEFORE the corresponding main contacts are opened. When switching Q001, Q002, Q010, Battery Breaker 1 or Battery Breaker 2 the opposite way from “OFF or 0” to “ON or 1”, the anxiliary contact has to close with a maximum delay of 0.5 seconds from the time the corresponding main contacts are closed.
External Connection The built-in parallel board connects two or more UPS systems in parallel, either to obtain increased system reliability or to obtain higher output power. The parallel board also ensures correct load-sharing between paralled systems. NOTICE! For reliability reasons, APC recommends separate battery packs in redundant/parallel conigurations.
External Connection Parallel Board X021:15-pin SUB-D female X020:15-pin SUB-D female External multicore cable with 14 wires + shield to other parallel units UPS 1 UPS 2 UPS 3 External Control Cables External multicore cable is equipped with 15-pin SUB-D plug at either end. Connect pin 1 to pin 1, and pin 2 to pin 2 etc. up to pin 15 - with the exception of pin 8, which is not to be connected. Shield is connected to plug cover at both ends.
External Connection 4.4 Relay Board 1 2 3 Maximum load: 8.0A – 250VAC 0.3A – 60VDC Minimum load: 0.05A – 6VAC 0.05A – 6VDC Relays All relays are “fail safe”: In alarm modes, relay coil will be de-energized.
External Connection 4.4.
External Connection ## Delay programmable in configuration stack : “Common fault delay”. Settings 0,10,20,30 seconds. Maximum cable size: 2mm2 See section 5.2: System configuration NOTICE! Alarm Trigging Events 1-2-3-9-10-11-13 activates the corresponding alarm relay after the delay. Alarm Trigging Events 4-5-6-7-8-12-14-15 activates the corresponding alarm relay momentarily. Common fault relay 16 is activated at the same time as relay 1-2-3-4-5-6-7-12-13-14-15, or in any of the below situations.
External Connection 4.5 Communication Interface Board The 3-port ComInterface is used to establish an interaction between UPS and e.g. a computer system. Main purpose: To ensure a controlled computer shut-down in case of a mains supply failure. 4.5.1 Connections . .
External Connection 4.6 Connecting of APC Silcon Tripel Chassis The enclosed Triple Chassis must be connected to the serial port on the Communication Interface Board, and to the 24V supply (cables included). Terminal locations shown below. 240/320kW Serial ports X50 Front view of UPS Cabinet (doors open) X50 is a 24V supply for Triple Chassis. Only to be used for this purpose. Not suitable for telephone equipment. Triple Chassis must be connected to both X50 and a serial port.
External Connection 4.7 APC Silcon Triple Chassis The APC Silcon Triple Chassis is an American Power Conversion (APC) external management peripheral that allows you to use monitoring and control management peripherals with your APC Silcon series UPS. The retrofit model is for use with Silcon series UPSs that are not equipped with a 24 VDC power port. 4.7.1 Safety Warnings Use the APC Silcon Triple Chassis only in conjunction with an APC Silcon UPS.
External Connection 4.7.2.3 LEDs The APC Silcon Triple Chassis status LED provides important information concerning operation of the chassis. Refer to the table below for a description of the conditions indicated by the LED. IF the LED is… THEN the Silcon Triple Chassis… off is not receiving power. flashing quickly (5 times per second) has not been configured.
External Connection 4.7.3.1 Order of Management Peripheral Cards Because UPS signals are passed between management peripherals, you must install management peripheral cards in the correct order for them to work together properly. The card slots are numbered 1 to 3, from left to right, as viewed from the rear of the chassis. The following table lists the management peripheral cards, their priority, and proper position.
External Connection To add card slots, you can daisy-chain the APC Silcon Triple Chassis with the standard Triple Chassis (AP9604) management peripheral, installing the APC Silcon Triple Chassis closer to the UPS. 4.7.4 Powering the APC Silcon Triple Chassis The APC Silcon Triple Chassis supplies power to the installed management peripheral cards and to the Monitoring port, allowing you to power multiple management peripherals. 4.7.4.
External Connection AP9604S[R] APC Silcon Triple Chassis 90 AP9606 Web/SNMP Management Card 110 AP9607 Interface Expander 45 AP9608 Out-of-Band Management Card (Call-UPS II) 35 AP9612 Environmental Monitoring Card (Measure-UPSII) 60 AP9825i Isolated Extension Cable 50 AP9830 Remote Power-Off Device 35 4.7.
External Connection 4) Pack the APC Silcon Triple Chassis carefully in its original packaging, if possible. Do not use polystyrene beads for packing. Damage sustained in transit is not covered under the warranty. Enclose a letter in the package with your name, address, RMA number, a copy of the sales receipt, daytime phone number, and payment (if applicable). 5) Mark the RMA number clearly on the outside of the shipping carton. The factory will not accept any materials without this marking.
External Connection Normally Open Line Fail Signal Normally Open Low Battery Signal Normally Closed Line Fail Signal Common UPS Shut Down RS-232 Input or Advanced Mode RS-232 Data RX In Line Fail RS-232 Output or Advanced Mode RS-232 Data TX Out Unregulated +24 VDC Output Chassis 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 27
External Connection 4.7.6.2 Power, Physical, and Environmental Specifications. Item Specification Power Turn on voltage: > 22 VDC Turn off voltage: < 16 VDC Current draw (normal operation): 90 mADC Current draw (voltage < 16 VDC): < 1 mADC Physical Size (H xW x D): 1.75 x 17.0 x 5.0 in (44 x 432 x 127 mm) Weight: 4.02 lb (1.81 kg) Shipping weight: 8.12 lb (3.
External Connection 4.8 APC Silcon Battery Cabinets IMPORTANT SAFETY INSTRUCTIONS a The installation of battery drawers in UPS cabinets requires battery knowledge and should be made or supervised by qualified personnel only. Keep unauthorized personnel away from batteries. b Use identical battery types and numbers when replacing batteries. See battery supplier manual for further details. c CAUTION - Do not dispose of batteries in a fire. Battery may explode.
External Connection 4.8.0.6 Installation of Batteries See Installation Guide for Battery Cabinet for: • Preparing Batteries and UPS • Dimensions and Weight • Connecting Batteries WARNING! Before proceding, ensure that power supplies have been disconnected from UPS for a minimum of 5 minutes. CAUTION! Follow “Start-up Procedure” in APC Silcon User Guide.
External Connection 4.9 Battery Breaker Box/Fuse-box CAUTION! Batteries connected to a UPS out of service for a period exceeding 8 days may be damaged. Refer to Section 7.0 Power Disconnection in this guide. Battery Breaker Box/Fuse-box provides overcurrent and short-circuit protection for UPS installations with external batteries. NOTICE! If battery has been disconnected, refer to Section: - UPS Start Up in the APC Silcon User Guide.
External Connection 4.9.1 Battery Breaker Box UPS Ampere Rating [A] Connection Cable [mm2] Max.
External Connection UPS Battery 2 UPS Battery 1 Battery 2 Battery 1 4.9.
External Connection 4.9.
Programming Parameters 5.0 Programming Parameters Below table shows operating parameters programmable from keyboard. Only qualified users should re-set programming parameters. 5.1 Parameters Parameter Setting* Comments Bypass operation YES, NO YES will switch the system into bypass mode Language GB, D, F DK, S, SF NL, PL, CZ E, P, SK, H Language of text in display Autostart YES, NO Automatic restart by mains return (1 min.delay).
Programming Parameters 5.1.1 Programming Keys NOTICE! Display accuracy is + 1%, + digit.
Programming Parameters 5.1.2 Programming Example - Switch to Bypass Operation NOTICE! Do not leave in by-pass mode for extended periods in order not to affect battery capacity. Return to normal operation Follow same procedure to program other parameters. 5.2 System Configuration System configuration parameters are vital for correct system operation and are passwordprotected.
Programming Parameters System Configuration Parameters (password protected) Parameter Setting* Comments Isolation Transformer Input YES, NO YES if optional input isolation transformer is available IsolationTransformer Output YES, NO YES if optional output isolation transformer is available Delta Soft Start Time 1, 10, 20, 40 sec. Input current switching in ramp function.
Programming Parameters 5.2.1 Programming Example - Change Charge Voltage to 446 NOTICE! Change charge voltages, battery warning limit, shut down voltage and high battery temperature limit by entering the actual value. See example above.
Programming Parameters 5.2.2 Programming Example - Change to Output Isolation Transformer available NOTICE! Change parameters by pressing the key once or several times. See example above.
Programming Parameters 5.3 Programming Parameters for Advanced Parallel Operation To use the advanced parallel functions, the following parameters must be programmed: 1. “Station number” 2. “Highest station address” 3. “Advanced power management” 4. “APM test mode active” 5. “Battery connection” 5.3.1 Description of Settings 1. “Station number” • Valid station numbers: 1-9 stating the UPS parallel address in system. 2.
Programming Parameters 5.3.2 Programming example Example with four systems in parallel with separate batteries. • Programme the station addresses 1-4: 1 for UPS 1, 2 for UPS 2, 3 for UPS 3, and 4 for UPS 4. • All UPS systems have to be programmed to “Highest station address”:4. • If APM is not to be tested, “APM test mode active” must be “NO”. • If a system is isolated due to service, the station numbers must be reprogrammed for the remaining active systems starting with number 1 and ending with maximum.
Options/Accessories 6.0 Options/Accessories Please contact your local APC representative for information on options/accessories available in your region. See “How to Contact APC” in this guide. 6.1 Service Bypass Panel for Single Operation UPS External System Input Fuse [A] Max. Prospective ShortCircuit Current [kA] System Input/ UPS Input Cable [mm2] ** System Output/ UPS Output Cable [mm2] ** 240kW 500 45 2x120 320 kW 630 45 2x185 Max.
Options/Accessories 6.1.1 Wiring up UPS with SBP in TN-C-S Network 6.1.
Options/Accessories 6.1.3 Operating The External Service Bypass Switch Action 1. Press on the keyboard Display shows 2. Press or Bypass operation :NO 3. Press on the keyboard 4. Press on the keyboard on the keyboard until Bypass operation :YES Lamp indication on Service Bypass Panel 5. Check lamp indication on the Service Bypass Panel The Green lamp (H003) above the bypass switch handle (Q003) lights 6.
Options/Accessories 6.1.3.1 Switching from External Bypass to Normal UPS Operation Action Display shows 1. Turn the input switch (Q002) to position ”0“ ** System OFF ** 2. Open the UPS front door and press the green "ON” key Normal operation load power % 3. Press on the keyboard 4. Press or 5. Press on the keyboard 6. Press on the keyboard on the keyboard until Bypass operation :NO Bypass operation : :YES Lamp indication on Servive Bypass Panel 7.
Options/Accessories 6.
Options/Accessories 6.2.
Options/Accessories 6.2.
Options/Accessories 6.2.3 Operating External Service Bypass Switch for Parallel Systems 6.2.3.1 Bypassing Parallel UPS Systems H002a CAUTION! Batteries connected to a UPS out of service for a period exceeding 8 days may be damaged.
Options/Accessories Action Step 1-4 can be carried out with any of the parallel systems, however this will switch all systems into bypass operation. Display shows 1. Press on the keyboard 2. Press or 3. Press on the keyboard 4. Press on the keyboard Bypass operation :NO on the keyboard until Bypass operation :YES Bypass operation All systems will transfer to bypass operation Do not switch off any of the UPS systems until step 5-8 has been completed. Lamp indication on bypass panel 5.
Options/Accessories 6.2.3.
Options/Accessories Action Display shows 1. Check that output switch (Q004) is in position “0” 2. Check that all output switches (Q002) are in position “0” 3. Turn input switches (Q001) to position “1” ** System OFF ** 4. Open the UPS front door and press the green “ON” push-botton Normal operation load power 0% 5. Press on the keyboard 6. Press or 7. Press on the keyboard 8.
Options/Accessories The following can be carried out on any UPS Display shows 13. Press on the keyboard Bypass operation :YES 14 Press or Bypass operation :NO 15. Press on the keyboard 16. Press on the keyboard on the keyboard until All the systems will transfer to normal operation. Normal operation load power xx% No lamps on the bypass panel lights any longer 6.2.
Options/Accessories H002a 6.2.5 Switching Back to Normal Parallel/Redundant Operation 1. Turn input switch (Q001) and output switch (Q002) to position “1” 2. Charge capacitor, connect battery and start up UPS UPS will automatically switch to normal operation and start load-sharing with other parallelled UPS(s). WARNING! System will discharge built-in capacitors, but check terminal voltage before proceding.
Options/Accessories 6.3 Intersystem Synchronization Unit Intersystem Synchronization Unit System (ISU System) The ISU system consists of inter-connected ISUs. One ISU system may consist of up to 5 ISUs, regardles of ISU configuration. The ISU system synchronizes the voltage of parallel operation systems running in battery operation. The ISU system may also include one or more external synchronization sources, e.g. a gen-set or a non-APC Silcon UPS system.
Options/Accessories 6.4 Remote Display With the remote display unit data may be displayed at distances of up to 25 m from UPS. For extended communication distance, see section below. Remote display may easily be connected to UPS via one of the two serial communication ports on the communication interface board. To obtain a transmission distance of up to 3.2 km normal RS232C signal levels must be converted to a long distance communication standard. The converter must be placed outside the UPS cabinet. 6.4.
Options/Accessories 6.4.1.1 Connections Without Converter Connect a 25-pin female Sub-D and a 9-pin male Sub-D connector with a 3-wire shielded cable, as shown in the table below. Connect shield at one end only. Pin Connection for Interconnection Cable (without converter): Host (DTE) Remote Display (DTE) 25-pin female pin No. 9-pin male pin No. 2 (TXD) 2 (RXD) 3 (RXD) 3 (TXD) 7 (GND) 5 (GND) House (shield) No Connection 6.4.1.
Options/Accessories 6.4.2 Remote Display Installation 6.4.2.1 Connecting RS232C and Mains Adapter CAUTION! Wiring for alarm and signal circuit field to be rated 300V (minimum). Rear view Rear view Front view 1. Turn 180° to loosen the 4 screws 2. Remove front cover 3. Mont back plate 4. Connect cables DP9-F Cable entry from bottom and rear Mains adapter 6.4.2.2 Remote Display Power Supply The remote display is supplied by normal AC power with no battery back-up.
Options/Accessories 6.4.3 Remote Display Use The remote display is an inactive unit unable to influence the operation of the UPS: Some of the alarms visible on the internal display are also available on the remote display (See the Alarm section in the APC Silcon User Guide). 6.4.3.1 Initiating the Remote Display After having connected the supply the display will show: Remote Display: “APC Silcon UPS” 6.4.3.
Options/Accessories 6.5 Isolation Transformer 1800mm 1600 mm wide APC Isolation Transformer module 320-480kW UPS Height [mm] Width [mm] Depth [mm] Weight [kg] 240kW 320kW 1800 1800 800 1600 800 800 1240 1470 Example of Transformer Configuration (Yyno) PE PE NOTICE! APC isolation transformers are available in various configuration. Contact your local APC representative for further information. See “How to Contact APC” in this guide.
Options/Accessories 6.5.1 Connecting Isolation Transformer UPS External Input Fuses* FM [A] 380-415V External Input Cable [mm2] 380-415V External PE Cable [mm2] External Output Cable [mm2] External Temp. Switch Cable Max.
Options/Accessories NOTICE! If an MCCB is used in stead of external input fuses, the MCCB load capacity must be 8xIn (nominal current) for minimum 10 ms. NOTICE! Check correct phase rotation of mains input voltage! Maximum input/output cables: 3//300 mm2. If input neutral is not available, an optional Dzn0 or Dyn11 input isolation transformer must be used. NOTICE! All external cable dimensions are recommended sizes only. Refer to local legal regulations.
Options/Accessories Isolation Transformer External Input Fuses* FM [A] 380-415V External Input Cable [mm2] 380-415V External PE Cable [mm2] External Output Cable [mm2] External Temp. Signal Cable Max.
Options/Accessories 6.5.2 Wiring up UPS with External Yyn0 Isolation Transformer at Output WARNING! Isolation transformer provides galvanic isolation between mains supply and load. Load will loose galvanic isolation if isolation transformer is bypassed NOTICE! Refer to local legal regulation for wiring information.
Options/Accessories 6.5.3 Wiring up UPS with External Yyn0 Isolation Transformer at Input WARNING! Isolation transformer provides galvanic isolation between mains supply and load. Load will loose galvanic isolation if isolation transformer is bypassed. NOTICE! Refer to local legal regulation for wiring information.
Options/Accessories 6.5.4 Wiring up UPS with External Optional Dzn0 Isolation Transformer at Input WARNING! Isolation transformer provides galvanic isolation between mains supply and load. Load will loose galvanic isolation if isolation transformer is bypassed. NOTICE! Refer to local legal regulation for wiring information.
Options/Accessories 6.5.5 Wiring up UPS with External Optional Dzn0 Isolation Transformer at Output WARNING! Isolation transformer provides galvanic isolation between mains supply and load. Do not bypass isolation transformer in order to avoid damaging circulation currents and to prevent load from loosing galvanic isolation. NOTICE! Refer to local legal regulation for wiring information.
Options/Accessories 6.5.6 Wiring up UPS with External Optional Dyn11 Isolation Transformer at Input WARNING! Isolation transformer provides galvanic isolation between mains supply and load. Do not bypass isolation transformer in order to avoid damaging circulation currents and to prevent load from loosing galvanic isolation. NOTICE! Refer to local legal regulation for wiring information.
System Specifications 7.0 System Specifications 7.1 Technical Data Voltage Input Output Voltage tolerance Normal operation Bypass operation +15% +10% (standard) +4, 6, 8% (programmable) Frequency 50Hz/60Hz +6 standard +0.5-8% (programmable) Input power factor load 25% minimum 0.97 load 100% minimum 0.99 Current distortion Max. 5% Voltage 3x380/400/415V Voltage tolerance +1% static symmetrical load +3% static symmetrical load +5% 0-100% load step Voltage distortion max. 3% linear load max.
Warranty 8.0 Warranty 8.1 APC Silcon Series Limited Factory Warranty APC warrants that the unit, when properly installed and commissioned by APC or APC authorized service personnel, shall be free from defects in materials and workmanship for a period of (1) year from the date of installation or maximum 18 months after manufacturing.
Appendix 9.0 Appendix 9.1 Table 1. Installation Planning Data Q3 Service Bypass Panel Main Input Breaker * Output Breaker * Q2 Q1 UPS Module Field Wiring* Field Wiring * Battery Bank** * Not supplied by APC ** Internal Batteries available for 40kW units and smaller Installation Planning Data APC Silcon Series AC Input Power rating Source Nom. Max.
Appendix Notes: 1. Nominal input current based on rated load. 2. Maximum input current based on rated load + full battery recharge. Full battery recharge assumed to increase input current with 10%. 3. Nominal power consumption (column 1c) based on nominal input current (1e) and the corresponding input voltage (1a). 4. Maximum power consumption (1d) based on maximum input current (1f) and the corresponding input voltage (1a). 5.
How to Contact APC 10.0 How to Contact APC APC Corporate 132 Fairgrounds Road West Kingston, RI 02892 USA APC Australia Level 27, 100 Miller St.
