American Power Conversion 120-160kW User Manual

APC Silcon

120-160kW 400V UPS
User Guide

Copyright ©2000 APC Denmark ApS

Information in this document is subject to

change without notice and does not represent

a commitment on the part of the vendor

Thank You

Thank you for chosing APC Silcon. Please read this User Guide thoroughly prior to installing the
system as it provides important information on safe and efficient installation and use.

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!

WARNING!

This UPS unit contains hazardous AC and DC voltages. Only qualified electricians should connect 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 available 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 the “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, 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 on batteries.

Read and pay attention to this important information.

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 are recyclable. Please save for later use or dispose of them appropriately.

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2 User Guide APC Silcon 120-160kW 400V UPS

Contents:

1.0 Introduction 4

1.1 Display Unit 4

2.0 Stop/Start UPS and Operating the External Service Bypass Panel 5

2.1 Stop UPS (for stand-by) 5

2.2 Start UPS (from stand-by) 5

2.3 Stop UPS (for complete power down) 6

2.3.1 Switching off the UPS 6

2.4 Start UPS (from complete power down) 8

2.4.1 UPS start-up 8

2.5 Operating the External Service Bypass Switch (single systems) 10

2.5.1 Bypassing the Single System UPS 10

2.5.2 Switching the Single System UPS from External Bypass into
Normal UPS Operation 11

2.6 Operating the External Service Bypass Switch (parallel systems) 13

2.6.1 Bypassing the Parallel UPS System (All UPSs) 13

2.6.2 Switching the Parallel System from External Bypass into
Normal UPS Operation 15

2.7 Isolating one UPS in a Parallel Configuration for
Service/Maintenance 17

2.7.1 Isolating one UPS in a Parallel/Redundant System 17

2.7.2 Switching Back the UPS to Normal Rarallel/Redundant Operation 17

3.0 Operation 19

3.1 Keyboard 19

3.2 Display of Measured Values 20

3.3 Using the Remote Display 20

3.4 Economy Mode 21

4.0 Parameter Settings 22

4.1 Programming Keys 23

4.2 Switching to Bypass Operation 23

5.0 Alarms and Events 25

5.1 Displaying the Alarm Stack 25

5.2 Displaying the Event Stack 25

5.3 Possible Alarms 26

5.4 Rectifying Alarm Messages 28

5.5 Parallel Operation Alarms 28

6.0 Maintenance & Testing 29

6.1 Fan 29

6.2 Battery Monitoring Test 29

6.3 Battery Capacity Test 29

7.0 Warranty 31

7.1 APC Silcon UPS Limited Factory Warranty 31

8.0 How to Contact APC 32

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User Guide APC Silcon 120-160kW 400V UPS 3

Introduction

1.0 Introduction

This UPS system is designed to offer reliable and problem-free power supply for several years.
The system requires only a minimum of maintenance, but we recommend you follow the
maintenance guidelines described in section 6.0 Maintenance & Testing.

1.1 Display Unit

The display unit (located on the front of the UPS) is the link between the user and the UPS and
consists of a display, an alarm LED indicator and a keyboard. The display reads parameters,
measured values and alarm messages. Alarms and the pressing of keys will activate a back
light which is set to switch off automatically after 5 minutes of inactivity.

By pressing and simultaneously you increase the back light contrast. The pressing of

and simultaneously decreases the contrast.

The LED alarm is linked to an acoustic signal indicating incorrect operation. Alarms will
change the LED light from green to red. Use keyboard to program operating parameters and
to display parameters / alarm messages.

LCD-display with
back light

Alarm LED

Green: OK
Red: Alarm

Keyboard

NOTICE!

Display accuracy is ±2%, ±1digit.

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4 User Guide APC Silcon 120-160kW 400V UPS

Stop/Start UPS and Operating the External Service Bypass

2.0 Stop/Start UPS and Operating the External Service Bypass
Panel

WARNING!

AC voltage generated either from batteries or mains may be present at UPS output.

Always disconnect AC input supply source, switch off UPS, AND switch off DC.

TEST BEFORE YOU TOUCH!

Some UPS systems have a factory-set autostart feature, automatically switching on UPS
whenever mains supply is switched on (AC line). See section 4.0 Parameter settings for
instructions on how to switch off this function.

Only qualified electricians should start up or shut down APC Silcon UPS systems and
instructions in the Installation Guide should be followed. Prior to being serviced, the APC
Silcon UPS must be left in shut-down mode for a minimum of 5 minutes.

CAUTION!

Refer to the Maintenance & Testing section in this guide if the UPS is to be taken out of
operation for more than 48 hours.

Users without electrical qualifications may switch UPS to and from stand-by-mode/normal
operation, following instructions below. (In stand-by mode, the UPS has no output voltage).

2.1 Stop UPS (for stand-by)

Action

Open the front door
and activate the "ON"
and "OFF" push-button
simultaneously

CAUTION!

If the UPS system is equipped with a service bypass panel, and if the load must remain
energized by mains, refer to the Operating Service Bypass Panel sections in this guide before
proceeding

Display shows Description

System off

Alarm LED lights.
Acoustic alarm sounds
for 30 seconds

2.2 Start UPS (from stand-by)

Action

Open the front door
and activate the green
"ON" push button

Display shows

Normal operation
Load power xx%

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Stop/Start UPS and Operating the External Service Bypass

2.3 Stop UPS (for complete power down)

2.3.1 Switching off the UPS

CAUTION!

If the UPS system is equipped with a Service Bypass Panel, and if the load must remain
energized by mains, refer to the Operating Service Bypass Panel sections in this guide before
proceeding

Red / OFF

Green /ON

WARNING!
TEST BEFORE YOU TOUCH!

A special design feature switches the system into bypass operation in the event of internal power
supply failure or controller circuit failure to ensure uninterrupted output voltage.
Because of this special feature, the UPS may contain output voltage even when it is switched off.

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6 User Guide APC Silcon 120-160kW 400V UPS

Stop/Start UPS and Operating the External Service Bypass

1. Open front doors

2. Note that step 3 will interrupt output voltage and activate the alarm!
The red LED alarm below the display will light up
The acoustic alarm will sound for 30 seconds*

3. Press the green ON and the red OFF button simultaneously.
The red LED alarm below the display will light up
The acoustic alarm will sound for 30 seconds*

Display shows

**System OFF**

4. On systems with no Service Bypass Panel, switch off the mains
supply

5. The red LED alarm below the display will light up
The acoustic alarm will sound for 30 seconds

6. Switch off battery breakers F001 and F002 in the Battery Breaker
Box or battery cabinet
Refer to LED indication and labelling in Battery Breaker Box or
battery cabinet

7. To switch off mains supply, open Q001 – on systems with
Service Bypass Panel.

8. The acoustic alarm sounds

*Reset the acoustic alarm by pressing .

**System OFF**

Blank

The UPS is now isolated. Maintenance/repair, disconnection or removal can now be carried out.

CAUTION!

Recharge batteries out of service every 3 months to prevent damage.

WARNING!

Internal DC capacitor may contain energy even after the UPS has been switched off. Allow for
automatic discharge by waiting at least 5 minutes after switching off UPS and battery breakers
before working on the UPS.

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Stop/Start UPS and Operating the External Service Bypass

2.4 Start UPS (from complete power down)

2.4.1 UPS start-up

CAUTION!

Make sure all cable connections are in place prior to first start-up.

Red / OFF

Green /ON

NOTICE!

After first system start-up, check that battery temperature is displayable (press and
simultaneously on the display – it reads NV (not valid) if incorrectly installed). A battery capacity
test is recommended after the electric installation.

NOTICE!

If for any reason the start-up procedure is interrupted, wait for the display to show the step 4
message: “Stop charge DC capacitors : YES” and repeat procedure from there.

CAUTION!

Do not close the MCCBs in the Battery Breaker Box unless the display reads: “Insert fuse or
close MCCB” – otherwise the UPS may be damaged. If the display reads “DC capacitor charge
error”, do not close MCCB.
Call for assistance.

WARNING!

If “Autostart” is active the UPS will start automatically after step 9 (with a 1-minute delay)

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Stop/Start UPS and Operating the External Service Bypass

1. Check that the system has been in a stable environment for at least 12 hours enabling
any condensation to evaporate prior to start-up.

2. Open front door(s)

3. Switch on mains power by closing Q001
See notice below.

4. Wait for approx. 10 seconds

5. Press on the keyboard

6. Press on the keyboard

7. Wait for approx. 1 second

8. Wait for approx. 1 minute

9. Close MCCBs in Battery Breaker Box or Battery Cabinet

10. Press the green ON button

11. Close the front door(s)

System start-up now completed.

Display shows

System type XXX

XXX kVA - XXX

Stop charge DC

capacitors : YES

Start charge DC
capacitors : YES

Data stored

Start charge DC
capacitors : YES

Insert fuse or

close MCCB

**System OFF**

Normal operation

load power XX%

NOTICE!

One of the following display messages will appear by UPS start-up:

• “STD”: Standard (single system)

• “PAR”: Parallel System

• “ECO”: Economy mode (single or parallel systems)

(Last message has priority over the other two)

kVA size (XXX) and the voltage reads:

• XXXkVA - 400 (380 or 415 Volt)

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Stop/Start UPS and Operating the External Service Bypass

2.5 Operating the External Service Bypass Switch (single systems)

2.5.1 Bypassing the Single System UPS

Mains

Service Bypass

Switch

APC Silcon

UPS

Action

1. Press on the keyboard

2. Press or on the keyboard until

3. Press on the keyboard

4. Press on the keyboard

5. Check light indication on the bypass panel

Load

Display shows

Bypass operation

: NO

Bypass operation

: YES

Lamp indication on
Bypass Panel

Green light (H003)
above the bypass switch
handle (Q003) lights up

6. Set the external bypass switch (Q003) to position 1

7. Set the output switch (Q002) to position 0

8. Open the front door and press the green ON and
the red OFF button simultaneously

The acoustic alarm sounds for 30 seconds*

9. Set the input switch (Q001) to position 0
The red alarm LED below the display lights up and

the acoustic alarm sounds for 30 seconds*

*Use the key to reset the acoustic alarm

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Green light (H002)
above the output switch
handle (Q002) lights up

Only the light (H002)
above the output switch
handle (Q002) is now on

Display shows

**System OFF**

10 User Guide APC Silcon 120-160kW 400V UPS