American Power Conversion AIS 5000 User Manual
AIS 5000
10–100 kVA
400 V
Installation Manual
®
Contents
Safety ..................................................................... 1
IMPORTANT SAFETY INSTRUCTIONS
- SAVE THESE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1
IMPORTANT SAFETY INSTRUCTIONS
— SAVE THESE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1
Symbols used in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
User Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General Information ................................................3
About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Site Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Receiving and inspecting the UPS . . . . . . . . . . . . . . . . . . . . . . . 4
Moving the equipment to site: . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fitting the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air filter sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Enclosure dimensions and footprint . . . . . . . . . . . . . . . . . . . . . 8
External Connection ..............................................12
Connecting the UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
External connection board . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installing Conduit Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Access to Input/Output section . . . . . . . . . . . . . . . . . . . . . . . . 15
Connecting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Emergency Power Off (EPO) . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Communication interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Communication interface ports . . . . . . . . . . . . . . . . . . . . . . . . 22
Overview of Communication interface . . . . . . . . . . . . . . . . . . . 23
990-2440 AIS 5000 400V Installation Manual i
10kVA 400V UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
IS10KH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
20kVA 400V UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
IS20KH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
30kVA 400V UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
IS30KH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
40kVA 400V UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
IS40KH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
60kVA 400V UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
IS60KH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
80kVA 400V UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
IS80KH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
100kVA 400V UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
IS100KH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Options ................................................................ 52
IP32 Drip Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Mounting the drip shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Drip shield sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Relay Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Communication Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Cards and slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Programming and Set-Up ...................................... 59
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Display introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Display functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Display messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Programming the UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
User stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Settings for redundant systems . . . . . . . . . . . . . . . . . . . . . . . . 67
Setting stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
ii AIS 5000 400V Installation Manual 990-2440
Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Operation mode descriptions: . . . . . . . . . . . . . . . . . . . . . . . . . 71
Normal to Bypass Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Bypass to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Normal to Manual Bypass Operation . . . . . . . . . . . . . . . . . . . . 73
Manual Bypass to Normal Operation
(including start up procedure) . . . . . . . . . . . . . . . . . . . . . . . . . 74
990-2440 AIS 5000 400V Installation Manual iii
Safety
o
IMPORTANT SAFETY INSTRUCTIONS
- SAVE THESE INSTRUCTIONS
IMPORTANT SAFETY INSTRUCTIONS — SAVE THESE INSTRUCTIONS
This manual contains important safety instructions for the AIS series that should be followed during
installation, operation, and maintenance. See the battery installation manual for battery-specific
instructions.
Symbols used in this manual
WARNING!
Risk of electric shock.
Caution
Note
See als
CAUTION!
Read this information to avoid equipment damage.
Indicates important information.
Indicates that more information is available on this subject in a different section of this
manual.
Indicates that more information is available on the same subject in a different manual.
Use a pallet jack or a forklift for components over 54 kg.
Two people to lift a component weighing between 18 – 32 kg.
990-2440 AIS 5000 400V Installation Manual 1
User Safety
WARNING!
This UPS 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!
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 deactivation.
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”
Caution
WARNING!
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.
WARNING!
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.
990-2440 AIS 5000 400V Installation Manual 2
General Information
About this manual
This Installation Manual gives a detailed overview of the various functions of the APC UPS system
and contains information on how to install, connect, program and maintain the AIS 5000 UPS
system.
Further information on the AIS 5000 series is available on www.apc.com.
990-2440 AIS 5000 400V Installation Manual 3
Site Requirements
Receiving and inspecting the UPS
Your AIS 5000 UPS system has been tested and inspected for quality assurance prior to shipment
from APC. To ensure that the UPS has not been damaged during transportation, carefully inspect both
the exterior and interior of the equipment immediately upon receipt as described in the Receiving and
Unpacking folder.
Type label. Copy type label data (serial number) to label copy below for easy identification of the
system. The type label is placed on the inside of the UPS front door.
Place label according to SKU no.
Hotline Support US /Canada/LAM
Hotline Support EMEA
World Wide Support numbers
SKU no.
IS10KH
IS20KH
IS30KH
IS40KH
IS60KH
IS80KH
IS100KH
400V for external bat teries
400V for external bat teries
400V for external bat teries
400V for external bat teries
400V for external bat teries
400V for external bat teries
400V for external bat teries
TEST PERSONNEL DATE AND SIGNATURE
+353 91 70 2000
Model
AIS 5000 10kVA
10kVA / 8kW
AIS 5000 20kVA
20kVA / 16kW
AIS 5000 30kVA
30kVA / 24kW
AIS 5000 40kVA
40kVA / 32kW
AIS 5000 60kVA
60kVA / 48kW
AIS 5000 80kVA
80kVA / 64kW
AIS 5000 100kVA
100kVA / 80kW
800 800 4APC
Www.apc.com/suppor t/service/geo map_world.cfm
Voltage Current in/out
Mains: 3Ø+PE, Bypass & Output: 3Ø+N+PE
400V/400V
(50Hz)
400V/400V
(50Hz)
400V/400V
(50Hz)
400V/400V
(50Hz)
400V/400V
(50Hz)
400V/400V
(50Hz )
400V/400V
(50Hz)
20A / 14A
39A / 29A
58A / 43A
77A / 58A
115A / 87A
151A / 115A
192A / 144A
KVA input
14kVA
27kVA
40kVA
53.2kVA
79.5kVA
104.5kVA
133kVA
1213 lbs
1433 lbs
1653 lbs
1984 lbs
2425 lbs
1100 kg
2866 lbs
1300 kg
3307 lbs
1500 kg
Weight
550 kg
650 kg
750 kg
900 kg
Battery
Nom. Vdc Current
240V
240V
240V
240V
240V
240V
240V
38A
75A
112A
148A
220A
291A
364A
990-2440 AIS 5000 400V Installation Manual 4
General Information - Site Requirements
Moving the equipment to site:
Before moving the equipment to the installation site, the following should be checked:
• Can the transport equipment handle the weight of the system?
• Is there enough space to transport the system to its final destination?
• Can the raised floor (double floor) handle the weight of the system?
The equipment is delivered on a pallet and can be transported on a fork-lift or a pallet truck.
The UPS is contained in a cubicle with a stable frame. This frame can carry heavy components such
as transformers, chokes etc. The frame can be placed directly on a levelled concrete floor.
Clearance at installation site. The system can be installed with the back to the wall or back-to-
back - however, a distance of minimum 4 inches (approx. 100 mm) between the wall and the UPS is
necessary. 20 inches (approx. 500 mm) is the preferred distance (see below illustration).
A clearance of 20 inches (approx. 500 mm) above the system is necessary to ensure sufficient space
for air circulation.
UPS
Clearance; minimum 100 mm – preferably 500 mm.
UPS
990-2440 AIS 5000 400V Installation Manual 5
Air Filter
The air filter must be fitted at the air inlet of the UPS, and is designed for extra protection of UPS
systems installed in environments with conductive dust.
Fitting the air filter
Insert the air filter in the brackets and slide it completely into the UPS enclosure.
The air filter can be mounted/replaced during normal operation of the UPS.
Note
990-2440 AIS 5000 400V Installation Manual 6
Air filter sizes
A
A
A
F
t si
d
A
15 mm
700 mm
For 40-100 kVA
General Information - Air Filter
700 mm
Front side
e
ron
15 mm
Bottom Side
700 mm
Bottom Side
For 10-30 kVA
ir filter
Upper Side
700 mm
ir filter
Upper Side
630 mm
450 mm
15 mm
700 mm
For 80-100 kVA
700 mm
ir filter
300 mm
Front side
Bottom Side Upper Side
(cut view)
990-2440 AIS 5000 400V Installation Manual 7
General Information - Air Filter
A
Enclosure dimensions and footprint
Enclosure dimensions.
UPS Height (mm) Width (mm) Depth (mm) Weight (kg)
10 kVA 1,803 826 813 550
20 kVA 1,803 826 813 650
30 kVA 1,803 826 813 750
40 kVA 1,803 1,219 813 900
60 kVA 1,803 1,219 813 1,100
80 kVA 1,803 1,626 813 1,300
100 kVA 1,803 1,626 813 1,500
71
(1,803)
1.00
(25)
10-30kV
32.50
(826)
24.99
(635)
30.52
(775)
Conduit Box
2.76
(70)
71
(1,803)
1.00
(25)
40-60kVA
48
(1,219)
24.99
(635)
39.90
(1,013)
45.43
(1,154)
12.14
(308)
Conduit Box
2.76
(70)
8 AIS 5000 400V Installation Manual 990-2440
71
(1,803)
80-100kVA
64
(1,626)
General Information - Air Filter
Conduit Box
24.99
(635)
1.00
(25)
Footprint.
Top and bottom view of 10–30kVA UPS:
Perforated area
for air circulation
61.00
(1,549)
16.26
(413)
COG-X
(1,414)
61.19
(1,554)
12.80
(325)
COG-Z
36.00 (914)
Minimum
service
clearance
55.66
27.91
(709)
2.76
(70)
3.96
(100)
3.76
(95)
Conduit Box
990-2440 AIS 5000 400V Installation Manual 9
General Information - Air Filter
Top and bottom view of 40–60kVA UPS:
3.96
(100)
61.00
(1,549)
Perforated area
for air circula tion
Perforated area
for air circulation
20.67
(525)
COG-X
12.80
(325)
COG-Z
36.00 (914)
Minimum
service
clerance
3.76
(95)
Conduit Box
10 AIS 5000 400V Installation Manual 990-2440
Top and bottom view of 80–100kVA UPS:
Perforated ar ea
for air circulation
61.00
(1,549)
31.50
(800)
COG-X
Perforated ar ea
for air circulation
General Information - Air Filter
11.81
(300)
COG-Z
36.00 (914)
Minimum
service
clearance
3.96
(100)
3.76
(95)
Conduit Box
990-2440 AIS 5000 400V Installation Manual 11
External Connection
Connecting the UPS
External connection board
Common
Fau lt
Status:
Alarm
Common
Fa ul t
Status:
Alarm
Battery
Operation
External
Contac torbypass
011
012
014
X00 1
021
022
024
X00 2
031
032
034
X00 3
041
042
044
X00 4
Battery temp.
compensation
H001
H003
H004
Output Switch
Coupling Switch
1 2 3 4 1 2 3 4
X009
Output Switc h
X011
Battery
MCCB
pos.
indication
Coupling Switch
X007 X008
SW01
Serivce
Switch pos.
indication
Analog
1 2 3 4
1 2 3 4
AUX4 inp ut
Remote
Control
1 2 3
X00 5
Emergency
Shut Down
Internal Supply
Emergency
Shut Down
1 2 3 4
External
X00 6
Supply 12Vdc
or 24Vdc
X001–X004 are relay change-over contacts 2A, 250Vac (0, 5A, 60Vdc). X006 is
Emergency Power Off (EPO) on the input. X007 pin 3–4 for Battery Temperature Sensor.
Note
Use 1.5 mm CU conductors only.
Note
12 AIS 5000 400V Installation Manual 990-2440
Installing Conduit Boxes
Top view:
External Connection - Connecting the UPS
UPS Feet
Conduit Box
Front of Conduit Box
In p u t
Comm.
DC
Output
Bypass
990-2440 AIS 5000 400V Installation Manual 13
External Connection - Connecting the UPS
Mounting the Conduit Box:
1. Open UPS front door.
2. Remove cover from the input/output section.
S001
S002
0
S002
0
0
0
1
1
S001
1
1
In order to remove the cover from the inand output section, please remove all 8
M6×12 torx screws.
3. Place Conduit Box under UPS and align it with hole in UPS bottom plate.
4. Take out Conduit Box and make holes in Conduit Box according to below table.
Conduit sizes (mm):
Input Conduit
Output/Bypass
Conduit
Battery
Conduit
Alarm Conduit
10 kVA 12.7 12.7 12.7 12.7
20 kVA 19.05 12.7 25.4 12.7
30 kVA 25.4 19.05 31.75 12.7
40 kVA 25.4 25.4 38.1 12.7
60 kVA 31.75 25.4 63.5 12.7
80 kVA 38.1 31.75 2 × 38.1 12.7
100 kVA 38.1 31.75 2 × 50 12.7
14 AIS 5000 400V Installation Manual 990-2440
External Connection - Connecting the UPS
5. Install Conduit Box under UPS. Push projecting edge of Conduit Box into slot on UPS bottom
plate. From inside the UPS, mount front of Conduit Box onto UPS bottom plate using 2 M4×12
cross head screws for 10–30 kVA and 3 M4×12 cross head screws for 40–100 kVA.
6. Mount conduits.
7. Feed cables.
8. Install cables according to the procedures described in the following sections.
Access to Input/Output section
To access cable terminals, open front door, remove screws and lift off front cover (remember earth
wire on rear side).
Remember to remount front cover (and earth wire) before system start-up.
Caution
CAUTION!
Ensure correct phase rotation of utility input voltage! Max. power cable size: see section
with technical specifications starting on page 24.
990-2440 AIS 5000 400V Installation Manual 15
External Connection - Connecting the UPS
Low-voltage section behind
cover (Communication
Interface, EPO).
1
1
1
1
S001
S002
0
0
S001
S002
0
0
Input and Output section (high-voltage
section) behind cover.
16 AIS 5000 400V Installation Manual 990-2440
Connecting cables
Input/Output section 10–30 kVA
External Connection - Connecting the UPS
Q090
1
0onoff
Q001
1
0onoff
Q050
1
0
Q100
Q004
1
0
on
1
0
off
on
Battery
off
B-
on
B+
Grounding Busbar
• X001 Mains Input (L1, L2, L3)
• X090 Bypass Input L1, L2, L3, N)
• X004 Output (L1, L2, L3, N)
• Q004 Battery (+, –)
X001
X090
L1
L3
N
L2
X004
990-2440 AIS 5000 400V Installation Manual 17
External Connection - Connecting the UPS
Input/Output section 40–60 kVA
X001
Q090
1
0onoff
1
0onoff
Q001
Q050
1
0
Q100
on
B+
Q004
1
0
on
1
0
off
on
Battery
off
B-
Grounding Busbar
• X001 Mains Input (L1, L2, L3)
• X090 Bypass Input (L1, L2, L3, N)
• X004 Output (L1, L2, L3, N)
• Q004 Battery (+, –)
X090
L2 L3
L1
X004
N
18 AIS 5000 400V Installation Manual 990-2440
Input/Output section 80–100 kVA
External Connection - Connecting the UPS
X001
Q090
1
0onoff
Q001
1
0onoff
Q050
1
0
1
0
B+ B-
Q100
on
Q004
on
1
0
off
on
Batter y
off
Grounding Busbar
• X001 Mains Input (L1, L2, L3)
• X090 Bypass Input (L1, L2, L3, N)
• X004 Output (L1, L2, L3, N)
• Q004 Battery (+, –)
X090
N
L1 L2 L3
X004
990-2440 AIS 5000 400V Installation Manual 19
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