American Power Conversion 480kW400V User Manual
APC Silcon
480kW 400V UPS
Installation Guide
Copyright 2001 APC Japan Inc
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.
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 the “Programming” section of this guide 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.
990-4059
2 Installation Guide APC Silcon 480kW 400V UPS
Introduction
1.0 Introduction
Power regulation varies from area to area, 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.
CAUTION!
Ensure that front doors are in place and that internal front cover is fastened by screws before
attempting to lift or transport the system.
This section lists all tools and equipment required to install all UPS configurations. See also
section 4.0 of this guide for further details on connection.
Tools:
• 10mm socket
• 13mm socket-deep
• 17mm socket
• 19mm socket-deep
• 19mm combo wrench
• Small flat head/regular screwdriver
• #3 philips screwdriver
• Compression lug crimping tool
• Knock-out set (for glands)
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 cable to UPS from Service Bypass Panel
• Solid core, control cable to UPS from external batteries/external Battery
Breaker Box
990-4059
Installation Guide APC Silcon 480kW 400V UPS 3
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. Use fork lift to transport system to installation site
SKU SKU
Copy of type label
PLEASE RECYCLE
The shipping materials for the APC Silcon UPS are recyclable. Please save them for later use or
dispose of them appropriately.
990-4059
4 Installation Guide APC Silcon 480kW 400V UPS
480kW
1900 mm wide
1800 mm
APC Isolation
Transformer Module
420kW
1600 mm wide
1800 mm
?
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.)
For ventilation and service purposes allow for free space of minimum 1m above the unit or per
national and/or local codes and in front of UPS. Never install systems in direct sunlight.
NOTICE!
For reliability reasons do not stand on the UPS. Keep the UPS cabinet surface free of any
objects.
3.1.1 Cabinet Dimensions
UPS Height [mm] Width [mm] Depth [mm]
480kW 1800 1900 800
Cabinet
Installation Guide APC Silcon 480kW 400V UPS 5
990-4059
Installation
Rear
Front
Com. cable entry
Power cable entry
Rear
Power cable entry
Front
?
3.2 Footprint
3.2.1 1900mm Cabinet for 480kW UPS
3.2.2 1600mm Cabinet for 480kW Isolation Transformer
990-4059
6 Installation Guide APC Silcon 480kW 400V UPS
2 1
2 1
X005 X001
X004:- X003:+
X004:+ X003:-
Right side view
Relay board
Please refer
Battery
Front view
System Integration
Interface
Communication
Interface
Parallel Controller
to “Relay Board” section
4.0 External Connection
4.1 Connecting the UPS
External Connection
NOTICE!
Check correct phase rotation of mains input voltage!!
Max. input/output cables: 3//300 mm
If there is no neutral input Dzn0 or Dyn11 input isolation transformer is required.
CAUTION!
This UPS unit is an EN 50091-2 product and may cause radio interference in a domestic
environment. Take preventive measures in necessary.
Installation Guide APC Silcon 480kW 400V UPS 7
CAUTION!
At a switch mode load of 100% the neutral must be rated for 200% output phase current.
2
.
990-4059
External Connection
UPS External
Input
Fuses* FM
[A]
380-415V
480kW 1000 3//200 200 800 3//150
* DIN gL types
NOTICE!
All cable dimensions are recommended sizes only.
Refer to local legal regulations.
UPS External Alarm
Cable max.
[mm2]
480kW 2 30 800 3//150
PVC cables insulated to withstand ambient temperature of max. 30°C
** Must be rated as external PE cable if mains system is not supplying PE
NOTICE!
Install gland plate in bottom of unit.
External
Input Cable
[mm2]
380-415V
External System
External PE
Cable
[mm2]
Earth Cable
[mm2]**
Maximum
External
Output
Fuses*
[A]
External Battery
Breaker
[A]
Output Cable
External Battery
Cable [mm2]
External
[mm2]
990-4059
4.2 System Integration Interface
8 Installation Guide APC Silcon 480kW 400V UPS
External Connection
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. Lamps on Service
Bypass Panel and Battery Breaker Box/Battery Cabinet indicate “green light” for operation of
output switches.
SII board also integrates input facilities for emergency shut-down and temperature
compensation of charge voltage for external battery (use with battery monitor). “Battery
operation” and “Common fault” are two main SII board status relay signals.
990-4059
Installation Guide APC Silcon 480kW 400V UPS 9
External Connection
Blue
Brown
4.2.1 Connections
990-4059
10 Installation Guide APC Silcon 480kW 400V UPS
External Connection
Terminal Blocks: X003/X004 (Anxiliary Contacts)
When switching Q001, Q002, 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, 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.
• This type of auxillary contact is called a “late make” contact. (This also means that it will
“break early” when activated in opposite direction.)
• This auxillary contact is also called “NORMALLY OPEN” (NO), because the auxillary
contact will be open when the main contacts are open.
• Please note that the above term “NORMALLY” has nothing to do with NORMAL UPS
OPERATION MODE.
When switching Q003 from “OFF or 0” to “ON or 1”, the anxiliary contact has to open BEFORE
the corresponding main contacts are closed. When switching Q003 the opposite way from “ON
or 1” to “OFF or 0”, the auxillary contact has to close with a maximum delay of 0.5 seconds from
the time when the corresponding main contacts are opened.
• This type of anxiliary contact is called an “early break” contact. (This also means that it will
“make late” when activated in the opposite direction.)
• The auxiliary contact is also called “NORMALLY CLOSED” (NC), because the auxiliary
contact will be closed when the main contacts are open.
• Please note that the above term “NORMALLY” has nothing to do with NORMAL UPS
OPERATION.
X005 (Output Relays)
Battery operation signals are received with a 30-second delay. This function is inactive during
battery test. Common fault relay facility is programmable (standard factory setting: 10 sec.)
See APC Silcon User Guide for details.
Maximum nominal voltage on contact circuits is 277VAC. If two different phases are involved,
maximum phase to neutral voltage should be below 160VAC. Please note that phase L1 is
already present on the System Integration Interface board, supplied from the Service Bypass
Panel. Therefore, if a phase is needed for alarm or signal purposes, Phase L1 should be used.
990-4059
Installation Guide APC Silcon 480kW 400V UPS 11
External Connection
Parallel Board
4.3 Parallel Board
CAUTION!
Control cables must be separated from AC and DC power cables.
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.
To prepare the UPS for parallel/redundant mode, disconnect all sources of AC and DC power
supply to the UPS and connect the ribbon cable from the parallel board to the main controller
board (the ribbon cable is delivered with the UPS).
CAUTION!
DO NOT connect ribbon cable between controller and parallel card in single configurations.
Ribbon cable is for parallel operation only.
Complete the parallel system set-up by connecting the external control cables (see below).
Follow the instructions in the “Programming Parameters for Advanced Parallel” section of this
guide to execute necessary re-programming.
990-4059
12 Installation Guide APC Silcon 480kW 400V UPS
to other parallel units
UPS 1
UPS 2
UPS 3
X020:15-pin SUB-D female
X021:15-pin SUB-D female
Parallel Board
External multicore cable with 14 wires + shield
External Connection
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.
Terminals X020 and X021 for control cables located on parallel board. Connect X020 in UPS1
to X021 in UPS2, and connect X020 in UPS2 to X021 in UPS3 etc. Connect X020 in last UPS
to X021 in UPS1.
Cable is delivered with the UPS.
Power Cables
To optimize load-sharing in parallel operation, external power circuits must be “symmetrical”:
Power input and output cables to have same length and identical cross-sections.
990-4059
Installation Guide APC Silcon 480kW 400V UPS 13
External Connection
Maximum load: 8.0A – 250VAC
Minimum load: 0.05A – 6VAC
1
2
3
0.3A – 60VDC
0.05A – 6VDC
4.4 Relay Board
Relays
All relays are “fail safe”: In alarm modes, relay coil will be de-energized.
990-4059
14 Installation Guide APC Silcon 480kW 400V UPS
External Connection
4.4.1 Relay Board/Relay Functions
NOTICE
If alarm mode “Communication to controller lost” is active, ALL relays will indicate failure
Relay Number Message Alarm-trigging Events
1 ## (X002) Mains outside limits Mains voltage RMS outside limits
2 ## (X003) Bypass outside limits Bypass voltage RMS outside limits
3 ## (X004) Output outside limits Output voltage RMS value outside limits
4 (X005) System overload Output load exceeding 100%
5 (X006) Fan fault Blocked or faulty fan
6 (X007) High Equipment
Temperature or
Inverter Fuse Blown
7 (X008) MCCB battery off Battery MCCB/Fuse not closed or released
8 (X009) Normal operation UPS running in normal operation mode
9 ## (X010) Battery operation UPS running in battery operation mode
10 ## (X011) Bypass operation UPS running in bypass operation mode
11 ## (X012) Stand-by operation UPS in stand-by mode
12 (X013) Service bypass
operation
13 ## (X014) Boost charge
operation
14 (X015) Battery voltage
outside limits
15 (X016) Battery condition
fault
16 ## (X017) Common fault All alarms as mentioned above
Mains wave form (fast detector) outside limits
Mains frequency outside limits
Bypass wave form (fast detector) outside limits
Bypass frequency outside limits
Output wave form (fast detector) outside limits
Output frequency outside limits
Delta inverter current limiter active
Main inverter current limiter active
Static switch temperature too high
Main inverter failure (temperature too high or fuse blown)
Delta inverter temperature too high
Magnetic temperature too high
Isolation transformer (option) temperature too high
Battery temperature too high
(status)
(status)
(status)
(Hot stand-by - parallel systems only)
Service bypass switch active
UPS boost-charging on battery
DC voltage too high (shut down)
DC voltage below warning level
DC voltage too low (shut down)
ABM has detected weak battery condition
ABM has detected defect battery
(ABM = Advanced Battery Monitor)
(except relays 8+9+10+11)
Internal power supply fault
System locked in operation mode
Internal memory fault
Internal communication fault
## Delay programmable in configuration stack : “Common fault delay”. Settings 0,10,20,30
seconds.
990-4059
Installation Guide APC Silcon 480kW 400V UPS 15
External Connection
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.:
• Internal power supply fault
• System locked in operation mode
• Internal memory fault
• Internal communication fault
990-4059
16 Installation Guide APC Silcon 480kW 400V UPS
.
.
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
990-4059
Installation Guide APC Silcon 480kW 400V UPS 17
External Connection
Part of UPS Cabinet
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.
Serial ports
X50
X008X007
APC Silcon Triple Chassis
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.
For more information please refer to the following section.
990-4059
18 Installation Guide APC Silcon 480kW 400V UPS
External Connection
4.7 APC Silcon Triple Chassis
The APC Silcon Triple Chassis (AP9604S) 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 (AP9604SR) 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.
Do not connect a computer to any APC Silcon Triple Chassis port using a straight-through
extension cable. Use the communications cable provided with the APC Silcon Triple Chassis.
Connections using a cable made by any other manufacturer may cause damage or improper
operation of the APC Silcon Triple Chassis, the UPS, or the computer.
4.7.2 Product Description
u
x
v
w
Monitoring port
1
To UPS port
2
4.7.2.1 Monitoring Port
The Monitoring port has two functions:
• Connecting to a terminal for configuration of the chassis. For direct connection to the
Monitoring port, you must use the Monitoring cable supplied with the chassis (APC
P/N 940-0024C).
• Connecting to other APC external management peripherals in a daisy chain.
Status LED
3
Optional Power port
4
4.7.2.2 To UPS Port
The “To UPS” port connects the chassis to the UPS, using the Silcon UPS cable (APC P/N 940-
0071). The cable connector plugs into a communications port on an APC Silcon UPS.
990-4059
Installation Guide APC Silcon 480kW 400V UPS 19
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. See the APC Silcon Management Quick
Start Guide provided with your chassis or the Web/SNMP
Management Card Installation Guide on the CD for more
information.
flashing slowly
(1 time per second)
on is operating normally.
4.7.2.4 Optional Power Input
With the Optional Power input, you can power the APC Silcon Triple Chassis from an external
source, using a 24 VDC power adapter. A universal adapter (AP9505i) or a standard adapter
(AP9505) can be purchased separately from APC.
4.7.3 Installing Management Peripherals
There are two basic types of APC management peripherals that work with the APC Silcon
Triple Chassis:
• Management peripheral cards, which fit into external management peripherals that
are equipped with a card slot.
• External management peripherals, which connect to the Monitoring (or Advanced)
port of other external management peripherals.
NOTICE!
The name “Monitoring” port varies from product to product, but its purpose is the same – to
replicate the UPS communications port.
is powered on but is not communicating with the UPS.
990-4059
20 Installation Guide APC Silcon 480kW 400V UPS
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.
Management Peripheral
Card
Web/
SNMP Management
Card
Out-of-Band Management
Card
(Call-
UPS®II)
Interface Expander AP9607 Second lowest
Environmental Monitoring
Card (Measure-
4.7.3.2 Installing Management Peripheral Cards
To install management peripherals, perform the following steps.
1) Make sure that the chassis is powered off.
2) Install management peripheral cards into the housings on the rear of the chassis. See the
instructions supplied with the cards and the table above.
3) If you are daisy-chaining other APC external management peripherals to the APC Silcon
Triple Chassis: Connect the UPS cable (supplied with the management peripheral) to the
Monitoring port of the chassis and to the “To UPS” port of the other management peripheral
(Share-UPS, MasterSwitch, etc.). See “Daisy-chaining the APC Silcon Triple Chassis”.
4) Power the APC Silcon Triple Chassis and all external management peripherals.
UPS
P/N Priority Position
AP9606 Highest
AP9608 Second-highest
®
II)
AP9612T
AP9612TH
Lowest
High-numbered slot
Low-numbered slot
NOTICE!
If your configuration requires additional power, connect a 24V AC/DC power adapter available
from APC (part number AP9505 or AP9505i) for all models of Triple Chassis.
4.7.3.3 Daisy-chaining the APC Silcon Triple Chassis
If you need more than the three card slots available with the APC Silcon Triple Chassis, or if
you want to use other external management peripherals, you can daisy-chain external
management peripherals together, provided that the total amperage of all installed
management peripherals — cards and external — does not exceed the supplied amperage. (See
“Determining Power Requirements:”).
NOTICE!
When daisy-chaining Triple Chassis units, you may need to use a power adapter.
990-4059
Installation Guide APC Silcon 480kW 400V UPS 21
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.
4.7.4.1 AP9604S Power Considerations
The AP9604S model of the APC Silcon Triple Chassis receives its power from the UPS through
the power connector of the Silcon UPS cable. If the total current required by all the installed
management peripherals exceeds 500 mA, you must use a 24 VDC power adapter. To find out
whether you need additional power, see “Determining power requirements”.
4.7.4.2 Power Adapters
APC offers two models of 24 VDC power adapter.
• The standard adapter (AP9505) can provide an additional 400 mA.
• The universal adapter (AP9505i) can provide 850 mA.
4.7.4.3 Using a Power Adapter
To use the adapter, plug it into a protected power outlet and into the Optional Power port of
the APC Silcon Triple Chassis.
NOTICE!
If the power adapter loses power because of a UPS shutdown, its attached management
peripherals may not operate properly, thus adversely affecting the UPS and its protected
equipment.
4.7.4.4 AP9604SR Power Considerations
The AP9604SR model receives its power from the UPS through the supplied 24 VDC universal
adapter. The total current required by your management peripherals must not exceed the 850
mA limit of the power adapter. See ““Determining power requirements”.
4.7.4.5 Determining Power Requirements:
To determine the total amount of current required by your management peripherals, add the
individual current requirements for each management peripheral to be installed with the APC
Silcon Triple Chassis to the current requirements of the chassis itself. Refer to this table
Part # Management Peripheral Draw (mA)
AP9207 Share-UPS 8-port Interface Expander 65
AP9600 Expansion Chassis 30
AP9604 Triple Chassis 20
990-4059
22 Installation Guide APC Silcon 480kW 400V UPS
Loading...