American Power Conversion 240-320kW User Manual
APC Silcon
240-320kW 480V UPS
Installation Guide
Copyright ©2001 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 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!
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.
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 for the APC Silcon UPS are recyclable. Please save for later use or dispose of
them appropriately.
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2 Installation Guide APC Silcon 240-320kW 480V UPS
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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Installation Guide APC Silcon 240-320kW 480V UPS 3
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
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4 Installation Guide APC Silcon 240-320kW 480V UPS
Introduction
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.
WARNING!
Heavy equipment. To prevent personal injury or equipment damage, take extreme care when
handling and transporting UPS cabinet and equipment.
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.
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.
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
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Unpacking/Identification of Equipment
2.0 Unpacking/Identification of Equipment
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.
Copy of type label (without battery):
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6 Installation Guide APC Silcon 240-320kW 480V UPS
Unpacking/Identification of Equipment
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
NEMA 12 covers are used in locations with potential risks of liquid discharge or leakage above
UPS system.
over
Remote Display
Use remote display to monitor UPS
NOTICE!
Contact your local APC representative or APC Support if you have any questions
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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 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.
WARNING!
For safety reasons do not stand on UPS. Keep UPS cabinet surface free of any objects
3.2 Dimensions and Weight
3.2.1 Dimensions and Weight of UPS
UPS
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
Height
inch/mm
74.80/1900 in./mm wide
70.86/1800 in./mm
Width
inch/mm
Depth
inch/mm
Weight
lbs./kgs
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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
REAR
UTILITY 1
DC
OUT-
PUT
UTILITY2
COM
62.20/1580
59.44/1510
54.20/1377
51.45/1307
42.40/1077
FRONT
32.56/827
29.80/757
3.74/95
0.95/24
0
0
1.02/26
1.81/46
6.14/156
7.87/200
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30.47/774
31.50/800
25.98/660
14.37/365
15.94/405
10 Installation Guide APC Silcon 240-320kW 480V UPS
3.3.2 Conduit Entrance Plate in bottom of the system
REAR
UTILITY 1
Installation
LEFT
UTILITY 2 OUTPUT DC
0
10.14/257.5
FRONT
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.
19.78/502.5
COM
COM
RIGHT
30.39/771.9
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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
REAR
11.61/295
7.68/195
LEFT
UTILITY 1-2/ OUTPUT/ DC
COM
0
0
3.31/84
16.28/413.5
FRONT
26.12/663.5
RIGHT
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12 Installation Guide APC Silcon 240-320kW 480V UPS
External Connection
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.
WARNING!
Read warnings on page 2 of this manual before continuing.
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.
Connecting AC
and DC
power cables
UPS system with cover– doors open
1
2
4
3
UPS system without cover and doors
Connecting
communication
cables
Connecting Ground
NOTICE!
Always keep AC, DC and communication cables separate.
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External Connection
4.1.1 Connecting AC and DC Power Cables (Dual Utility Connection)
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Top bar – Utility 2 (L1, L2, L3)
Bottom bar – Output (N/E, L1, L2, L3)
Top bar – Ext. DC (X003±, X004±)
Bottom bar – Utility 1 (N, L1, L2, L3)
Connection in the
bottom of the
cabinet
14 Installation Guide APC Silcon 240-320kW 480V UPS
External Connection
Dual Utility Connection
Seen from front
E
N
L3
L2
L1
Utility 2 – X002
Output – X005
L1
N
Ext. DC
Utility 1 – X001
L3
L2
Seen from side
Utility 2
X002
Output
X005
Ext. DC
Utility 1
X001
WARNING!
Bottom cabinet connection must be grounded.
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External Connection
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.
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.
Polycarbonate
Polycarbonate
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External Connection
4.1.3 Top or Bottom Cable Entry
For top cable entry, move copper angle bar to bottom.
Angle bar
Unscrew bolt, take out the split, move the angle bar down,
insert split, and tighten the bolt
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External Connection
4.1.4 Dual and Single Utility Supply
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.
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.
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External Connection
Working Principle of Dual Utility (2 utility supplies)
Q3
Utility 2
Q10
Q1
Utility 1
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.
Working Principle of Single Utility (1 utility supply)
Utility 1/2
Q1
Utility 2
Utility 1
APC Silcon UPS
±
3.
Q3
Utility 1/2
Q2
Q2
Output
Output
APC Silcon UPS
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.
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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.
In the static switch the
following modifications
have to be made for
single utility input
1) Remove fiber bar (55322) by unscrewing bolts and by mounting copper bars as below
Fiber bar
Copper bars
2) Switch the connector in Con3 to Con1.
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20 Installation Guide APC Silcon 240-320kW 480V UPS
External Connection
CAUTION!
Ensure correct phase rotation of utility input voltage! Max. power cable size: 500 kcmil.
NOTICE!
With a 3-wire input, the UPS can only be 3-wire loaded (Phase-to-phase).
NOTICE!
If an MCCB is used in stead of external input fuses, the MCCB load capacity must be 8xIn
(nominal current) for min.10 ms.
NOTICE!
Gland plate in bottom of system must be mounted.
Wiring
Select wire size based on the data in Table 1, and the ampacities in Table 2 of this manual, a
reprint of Table 310-16 and associated notes of the National Electrical Code (NFPA 70).
See section 8.0 Appendix.
Use commercially available UL approved solderless lugs for the wire size required for your
application. Connect wire to the lug using tool and procedure specified by the lug
manufacturer.
Input, output and DC cables are routed in separate conduits.
All AC cables rated 600V.
DC cables for 480V systems rated 1000V unless otherwise stated.
CAUTION!
At a switch mode load of 100% the neutral must be rated for 173% output phase current.
NOTICE!
φ
“phase”
“risk of electric shock”
Terminal for Equipment Grounding Conductor
E
Terminal for Grounding Electrode Conductor
NOTICE!
Terminals marked and are electrically connected to the terminal marked “E”
NOTICE!
For grounding, refer to local legal regulations.
CAUTION!
Read warnings on page 2 of this manual before continuing.
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External Connection
4.1.6 Connection Terminals
Terminals – 480V
Terminal
Type
240kW M12 M12 M12 M10 M12
320kW M12 M12 M12 M10 M12
The terminals for the control & alarm cables are screw clamps for cable size AWG18 to AWG14.
All other terminals are stud terminals.
4.1.7 Torque Specifications
Stud size M6 M8 M10 M12
Torque 66/7.5 lb-in/Nm 133/15 lb-in/Nm 266/30 lb-in/Nm 443/50 lb-in/Nm
4.1.8 Grounding
4.1.8.1 System Grounding
If no UPS neutral inputs are connected to a grounded service neutral conductor according to
local NEC code reguirements, provisions must be made as follows:
a) Bonding jumper must be mounted between output terminals X005:N and X005:E
b) Output terminal X500:E, marked “Grounding electrode terminal”, must be connected by
grounding electrode conductor to a local grounding electrode according to NEC 250-26
Input
stud size
Battery
stud size
Output
stud sizePEstud size
System earth
stud size
4.1.8.2 Equipment Grounding
Terminals marked intended for equipment grounding.
Provisions must be made as follows:
Input equipment ground terminal(s) must be connected to grounding electrode(s) provided for
the service entrance(s)
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22 Installation Guide APC Silcon 240-320kW 480V UPS
E terminal
Ground terminals
External Connection
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External Connection
4.2 System Integration Interface
NOTICE!
Refer to chapter 4.1.5 Changing from dual to single utility input
Single Utility
Dual Utility
System Integration Interface (SII) is the control link between UPS and system main switches
as shown above. The purpose of the SII is to ensure correct operation of switches without losing
system output power.
WARNING!
Even with all AC and DC sources switches off, SII may receive high voltage from external alarm
and signal circuit field wiring.
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24 Installation Guide APC Silcon 240-320kW 480V UPS
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