American Power Conversion AP9604S User Manual

APC Silcon

240-320kW 400V UPS Installation Guide

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.

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2 Installation Guide APC Silcon 240-320kW 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

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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.

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4 Installation Guide APC Silcon 240-320kW 400V UPS

240-320kW

1600 mm wide

1800 mm

APC Isolation

Transformer Module

320kW

1600 mm wide

1800 mm

APC isolation

Transformer Module

240kW

800 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]

240kW 1800 1600 800

320kW 1800 1600 800

Cabinet

Installation Guide APC Silcon 240-320kW 400V UPS 5

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Installation

Power cable entry

com. cable entry

Rear

Front

Rear

Power cable entry

3.2 Footprint

3.2.1 1600mm Cabinet for 240-320kW UPS

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3.2.2 825mm Cabinet for Isolation Transformer or Switch Gear

6 Installation Guide APC Silcon 240-320kW 400V UPS

Rear

Power cable entry

Front

3.2.3 1600mm Cabinet for 320kW Isolation Transformer

Installation

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External Connection

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

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.

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CAUTION!

At a switch mode load of 100% the neutral must be rated for 200% output phase current.

External Connection

UPS External

Input

Fuses* FM

[A]

380-415V

240kW 500 2//125 100 400 2//100

320kW 630 2//200 150 500 2//150

* DIN gL types

NOTICE!

All cable dimensions are recommended sizes only. Refer to local legal regulations.

UPS External Alarm

Cable max.

[mm2]

240kW 2 30 400 2//100

320kW 2 30 500 2//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

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]

NOTICE!

Install gland plate in bottom of unit.

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External Connection

4.2 System Integration Interface

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.

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4.2.1 Connections

Blue Brown

External Connection

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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.

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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.

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External Connection

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 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.

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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.

14 Installation Guide APC Silcon 240-320kW 400V UPS

4.4 Relay Board

Maximum load: 8.0A – 250VAC

Minimum load: 0.05A – 6VAC

0.3A – 60VDC

0.05A – 6VDC

External Connection

Relays

All relays are “fail safe”: In alarm modes, relay coil will be de-energized.

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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

13 ## (X014) Boost charge

14 (X015) Battery voltage

outside limits

15 (X016) Battery condition

16 ## (X017) Common fault All alarms as mentioned above

operation

fault

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

Main inverter failure (temperature too high or fuse blown)

Static switch temperature too high

Delta inverter temperature too high

Magnetic temperature too high

Isolation transformer (option) temperature too high

Battery temperature too high

(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.

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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

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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

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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.

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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

Monitoring port

To UPS port

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

Optional Power port

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.

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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.

has not been configured. See the APC Silcon Management Quick flashing quickly (5 times per second)

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.

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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.

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