APC 990-1378 User Manual

APC BC300 Series 10kW 208/450/480V
Installation Guide
Copyright ©2002 APC Denmark ApS
This manual is subject to change without
notice and does not represent a commitment
Thank You
Thank you for choosing the APC BC300 Series. Read this Installation Guide before you install and use 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.
IMPORTANT SAFETY INSTRUCTIONS – SAVE THESE INSTRUCTIONS
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 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.
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.
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2 Installation Guide APC BC300 Series 10kW 208/450/480V UPS
Contents:
1.0 Introduction 4
1.1 Tools and Equipment Needed 4
2.0 Receiving, Unpacking, Moving and Storing the UPS and Batteries 5
2.1 Receiving, Unpacking and Moving to Site 5
2.2 Storing the UPS and Batteries 5
3.0 Installation 6
3.1 Requirements on Site 6
3.1.1 UPS Footprint (measurements in inches & mm) 7
3.2 Installing the Conduit Connection Kit 7
3.2.1 Conduit Connection Kit Contents 8
3.2.2 Installing Pedestals 8
3.2.3 Installing Conduit Box and Base Covers 8
3.3 Installing the Maintenance Bypass Panel and UPS 9
3.3.1 Component Overview (door open) 14
3.3.2 Wire Terminals 15
3.3.3 Wiring Diagram for BC300 16
3.3.4 Single Line Diagram for BC300 17
3.3.5 External Connection Board 21
3.3.6 Communication Interface Board (Option) 22
3.4 Smart Slot and Connection of Triple Chassis 23
3.5 APC BC300 Triple Chassis 24
3.5.1 Safety Warnings 24
3.5.2 Product Description 24
3.5.3 Installing Management Products 25
3.5.4 Powering the APC BC300 Triple Chassis 26
3.5.5 Troubleshooting 27
3.5.6 Product Specifications 28
3.6 Installation of External Batteries and Battery Breaker 30
3.6.1 Battery Installation 30
3.6.2 Battery Replacement 33
4.0 Initial Start-up and Phase Check 34
4.1 Initial Start-up and Phase Check (Internal Batteries) 34
4.2 Initial Start-up and Phase Check (External Batteries) 35
5.0 Clearing the Events Log 37
6.0 Start-up and Shutdown Procedure 38
6.1 Start-up from Maintenance Bypass 38
6.2 Shutdown Procedure 39
7.0 Technical Specifications 40
7.1 APC BC300 Series 10kW Technical Data 40
7.2 Battery Specifications 41
7.3 Dimensions/Weight 42
8.0 How to Contact APC 43
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Installation Guide APC BC300 Series 10kW 208/450/480V UPS 3
Introduction
1.0 Introduction
This Installation Guide provides information on UPS installation, wiring, start-up and shut­down procedures along with Maintenance Bypass Panel phase check and external battery installation. Electricians should always refer to national and local electrical codes prior to installing the UPS system.
1.1 Tools and Equipment Needed
This section lists all tools and equipment required to connect the UPS to the Maintenance Bypass Panel.
Insulated Tools and Other Equipment Needed:
• Torque wrench in inch-pounds or newton-meters
• Standard U.S. and metric wrenches
• Petroleum jelly or conductive grease
• Brush (for applying petroleum jelly or conductive grease to battery terminals)
• Mallet
• Volt-Ohm meter (True RMS - Digital)
• Pliers
• Ratchet and sockets
• Electrical tape
• Standard and Phillips screwdrivers
• Torx head screwdriver set
• APC BC300 User Guide
• Phase rotation meter
Cables and interconnection hardware not provided by APC.
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4 Installation Guide APC BC300 Series 10kW 208/450/480V UPS
Receiving, Unpacking, Moving and Storing the UPS and Batteries
2.0 Receiving, Unpacking, Moving and Storing the UPS and Batteries
2.1 Receiving, Unpacking and Moving to Site
CAUTION!
Heavy equipment. To prevent personal injury or equipment damage, use caution when handling and transporting UPS cabinet and equipment.
1. While the UPS system is still on the truck, inspect the equipment and shipping container(s)
for any signs of damage. Do not install the system if damage is apparent. If damage has occurred, notify APC as soon as possible.
2. Compare the shipment with the bill of lading. Report any missing items to the carrier and
to APC immediately.
3. Remove the screws on the bottom part of the packaging side plates.
4. Remove the packing materials from the unit.
5. Verify compliance between type label on reverse side of UPS front door and system ordered.
Check input and output voltage.
6. Unbolt the unit from the pallet.
7. Remove the unit from the pallet with a forklift.
8. Use a forklift or hand truck to transport the unit to the installation or storage site. Study
the footprint to decide how to move the UPS through doorways and into position.
PLEASE RECYCLE
The shipping materials are recyclable. Please save for later use or dispose of them appropriately.
2.2 Storing the UPS and Batteries
Store the APC BC300 Series UPS between -4 and 104° F (-20 and 40° C). However, APC recommends that the unit and batteries be stored between 59 and 77° F (15 and 25° C). This temperature range, or cooler, allows batteries a longer shelf life. Recharge stored batteries every 90 to 120 days. See the section “Requirements on Site” in this Installation Guide for further details.
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Installation Guide APC BC300 Series 10kW 208/450/480V UPS 5
Installation
3.0 Installation
3.1 Requirements on Site
A 3-foot free space on all sides should be allowed during installation. Place the UPS in a clean, dust-free environment, free of contaminants. Allow air circulation around the UPS cabinet and any battery cabinets or racks.
• Ambient temperature range: 32 to 104° F (0 to 40° C). Ideal temperature: 77° F (25° C)
NOTE: At 92° F (33° C), battery life would be approx. 50% compared to storage at a
normal temperature of 77° F (25° C). At 113° F (45° C). Battery life will be reduced to some 25%. Make sure that the floor can support the weight of the UPS, external batteries, and any other necessary equipment.
• Never install systems in direct sunlight or near heat sources.
• Service access from front and top of unit. Cable entry from bottom of unit.
• Do not operate the UPS or batteries in a sealed room or container.
NOTICE!
Allow a minimum clearance of 3 foot (914mm) for service in front of and above the UPS and 6 inches (152mm) at the back.
NOTICE!
Do not stand on the UPS. Keep the UPS cabinet surface free of objects.
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6 Installation Guide APC BC300 Series 10kW 208/450/480V UPS
Installation
3.1.1 UPS Footprint (measurements in inches & mm)
23.6
(600)
20.1
(510)
Conduit
Connection
Box
Cable Entry
19.8
(504)
27.9
(708)
31.7
(804)
Top View
36.0
(914)
Minimum
Service
Clearance
55.1
(1400)
AA
Front View
36.0
(914)
Recommended
Cooling
Clearance
Notes:
1. All dimensions are in inches (millimeters).
2. Minimum cooling and service clearance 36.00 (914).
3. Conduit entry is bottom of unit.
4. Unit weight = 1BPI 1111lbs (504kg) 2BPI 1331lbs (604kg).
5. Installation must comply with all applicable national and local codes.
View from inside cabinet, looking down
Section A-A
31.7
(804)
Side View
Figure 1
3.2 Installing the Conduit Connection Kit
Insulated and other tools required
• 13 mm ratchet or wrench
• T20 torx screwdriver
• Greenly punch
• Equipment suitable for lifting heavy UPS off the ground
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Installation Guide APC BC300 Series 10kW 208/450/480V UPS 7
3.2.1 Conduit Connection Kit Contents
For Pedestals:
• 23 pedestals
• 4 M8 x 100 mm bolts
• 4 M8 lock washers
• 4 M8 flat washers
• 4 M8 nuts
For Conduit Box:
• 1 Conduit Box
• 1 Conduit Box Cover
• 11 M5 x 12 mm T20 Torx screws
• 11 M5 lock washers
• 11 M5 flat washers
For Base Covers:
Installation
• 2 Side Base Covers
• 2 Front/Rear Base Covers
• Hook and loop fasteners
3.2.2 Installing Pedestals
CAUTION!
Heavy Equipment. Use caution and appropriate equipment to safely lift the UPS several inches above the floor when installing pedestals.
1) Remove brackets mounted to the UPS feet during shipping
2) Lift the UPS off the floor and place the pedestals under UPS feet where the holes of pedestals and holes in UPS feet are aligned
3) With caution lower the UPS feet into pedestal
4) Fasten but DO NOT TIGHTEN bolts, washers and nuts on the four corner feet of UPS
NOTICE!
Place flat washer under the bolt head and the lock washer under the nut.
5) Move the UPS to the installation site
Tighten the bolts
3.2.3 Installing Conduit Box and Base Covers
1) Punch conduit holes in the back of the conduit box
2) Place the conduit box between the center leg and right leg of the unit, with the open side facing the front of the unit
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8 Installation Guide APC BC300 Series 10kW 208/450/480V UPS
Installation
3) Use four T20 torx screws and washers to fasten the conduit box to the front legs of the UPS
NOTICE!
Place flat washer, lock washer and screw in this particular order.
4) After all UPS wiring has been completed, attach conduit box cover to the front of the conduit box
5) Use hook and loop fasteners to attach the base covers to the UPS
3.3 Installing the Maintenance Bypass Panel and UPS
IMPORTANT!
If you do not have an APC Maintenance Bypass Panel, you must provide overcurrent protection and a UPS input AC disconnect means. APC strongly recommends that a means of bypassing the UPS from the critical load be provided for maintenance.
Follow these guidelines when installing the Maintenance Bypass Panel and UPS:
• Install the Maintenance Bypass Panel within sight of the UPS. When installing the Maintenance Bypass Panel, see illustrations under any instructions provided with the Maintenance Bypass Panel.
• Install all wiring in accordance with applicable electrical codes. Use 75° C copper conductors.
• Install the AC input and UPS output in separate conduits. UPS output circuits
must be installed in dedicated conduit systems and separate from other
electrical circuits.
• Control wiring must be installed in a separate conduit.
• Good ground connections are necessary to reduce electrical noise and make the operation of the UPS and the loads safe. Follow the grounding guidelines in the installation wiring diagram. Refer to the National Electrical Code (NEC), appropriate IEEE documents, and all applicable codes.
• For systems with non-linear, neutral-connected loads, standard practice is to size the neutral conductor for 1.732 times the phase current.
• When installing the AC wiring, refer to the illustration
BC300
and to any additional diagrams provided with the UPS. The illustration
shows typical installations . Your installation may be different.
• See
Component Overview
Wiring Termination
terminations. Refer to illustration external connection board. See illustration for information on the optional communication interface board. If you have any questions, contact APC Technical Support for assistance.
illustration for a view of the UPS with covers removed. See
or
Component Overview
External Connection Board
Communication Interface Board (Option)
Wiring Diagram for BC300
Single Line Diagram for
illustrations for UPS wiring
for information on the
and
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Installation Guide APC BC300 Series 10kW 208/450/480V UPS 9
7
3
U
11
15
19
20
16
12
8
4
U
U
U
U
Maintenance
Bypass Switch
Contacts marked "U"
closed in "UPS".
Contacts marked "BP"
closed in Bypass.
Contacts are Make
before Break.
AC Output from UPS
F1
F2
F3
N
TO CRITICAL
LOAD CENTER
AC Output
to Critical Load
L1
L2
L3
N
G
L1
L2
L3
N
GRD
1
5
13
9
10
14
6
1718
2
BP
BP
BP
BP
BP
G
G
Uninterruptible Power Supply
L1
L1
L2
L2
L3 L3
N
N
G
AC Input
to UPS
L1
L2
L3
UPS Input
Disc. Switch
Shown in Open
Position
1
2
4
6
5
3
AC Line
Input
F4
F5
F6
L1
L2
L3
N
GRD
Notes:
1. 208V F1, F2, F3 = 35A
2. 480V F1, F2, F3 = 15A
3. 208V F4, F5, F6 = 45A
4. 480V F4, F5, F6 = 20A
5. All AC power cabling is 3- or 4-wire + Ground at 208VAC / 480VAC 3-phase.
6. Installation must comply with all applicable national and local codes.
Installation
Figure 2 - SBP Electrical Schematic 208V & 480V
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10 Installation Guide APC BC300 Series 10kW 208/450/480V UPS
Installation
UPS Input
Disconnect
Switch
On-Off
1
3
5
F1A
6
12345
CNN
DC
Auxiliary Switch Circuit
2
4
6
1A
F1-F2-F3
G L1 L2 L3 G L1 L2 L3
AC Output
to Critical Load
AC Output from UPS
F4-F5-F6
GL1L2L3
AC Line Input
UPS Maintenance
Bypass Switch
UPS Bypass
2
1
BYP
4
3
UPS
6
5
BYP
8
UPS
7
10
9
BYP
12
11
UPS
14
13
BYP
15
16
UPS
18
17
BYP
20
19
UPS
2
1
BYP
4
3
BYP
6
5
BYP
8
7
UPS
GL1L2L3
AC Input to UPS
Notes:
1. F1, F2, F3 = 15A
2. F4, F5, F6 = 25A
3. All AC power cabling is 3 wire + Ground at 450VAC 3-phase.
4. Installation must comply with all applicable national and local codes.
440, 450, 480
VAC Primary
H1 H3H2H4
X1
120 VAC
Secondary
XFMR 1
Relay
R
13
14
9
1
"UPS in Static Bypass" Ind. Light
G
"UPS in Maintenance Bypass" Ind. Light
R
Keyed Solenoid Lock Release Switch
Release
Lock
0X
14
13
X0
21
22
X0
31
32
0X
43
44
Solenoid Lock
Mechanism
N
(Energize to Unlock)
440, 450, 480
VAC Primary
H4
H3 H2
H1
X2
X2
X1
120 VAC
Secondary
XFMR 2
120 VAC
+
X
-
120 VDC
5A
Figure 3 - SBP Electrical Schematic 450V
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Installation Guide APC BC300 Series 10kW 208/450/480V UPS 11
L1 L2 L3 N G
L1 L2 L3 N G
L1 L2 L3 N GNL3L2L1
L1 L2 L3
AC Output to Critical Load
AC Output
from UPS
AC Line Input
AC Input
to UPS
UPS Con NC
AUX Switch
10.00 (254)
Switches Mounted at
Both Ends for Stability
Removable
Bottom Plate
Terminal Blocks
Mounted on Hi Hat
20.00 (508)
16.00 (406)
Mounting Dimension
20.00 (508)
21.00 (533)
Mounting Dimension
All Inputs and Outputs to Terminals
Padlock
5.75
(146)
10.50 (267)
Notes:
1. All dimensions are in inches (millimeters)
2. Minimum cooling and service clearance 36.00 (914) from front of unit.
3. Installation must comply with all applicable national and local codes.
Installation
Figure 4 - SBP Electromechanical 10kW 208V and 480V
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12 Installation Guide APC BC300 Series 10kW 208/450/480V UPS
Installation
L1 L2 L3 N GNL3L2L1
24.00 (610)
20.00 (508)
Backpanel 22’’ Square
AC Line Input
25.00 (635)
Mounting Dimension
24.00 (610)
Lock Release
L1 L2 L3 N G
AC Output to Critical Load
2.00 (51)
4.00
(102)
3.00 (76)
L1 L2 L3 N G
AC Output from UPS
Mounting Dimension
Notes:
1. All dimensions are in inches (millimeters)
2. Minimum cooling and service clearance 36.00 (914) from front of unit.
3. Installation must comply with all applicable national and local codes.
Figure 5 - SBP Electromechanical 10kW 450V
L1 L2 L3
AC Input
to UPS
Fuses/Locks are Under Hi Hat
4’’ Tall Hi Hat With Terminals
Removable Bottom Plate
UPS Con NC
AUX Switch
12.00 (305)
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Installation Guide APC BC300 Series 10kW 208/450/480V UPS 13
3.3.1 Component Overview (door open)
DC fuse F001-F003
AC fuse F007-F009
ON/OFF buttons
Controller Board
Display unit
Communication
Interface
Battery Connection
Input/Output Terminal Blocks
Utility RFI/ Fuse Board
Installation
Figure 6 Component Overview
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14 Installation Guide APC BC300 Series 10kW 208/450/480V UPS
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