APC BC300 User Manual

APC BC300 Series 60kW 208/480V

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 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 60kW 208/480V 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) 11

3.3.2 Wire Terminals 12

3.3.3 Wiring Diagram for BC300 13

3.3.4 Single Line Diagram for BC300 14

3.3.5 External Connection Board 17

3.3.6 Communication Interface Board (Option) 18

3.4 Smart Slot and Connection of Triple Chassis 19

3.5 APC BC300 Triple Chassis 20

3.5.1 Safety Warnings 20

3.5.2 Product Description 20

3.5.3 Installing Management Products 21

3.5.4 Powering the APC BC300 Triple Chassis 22

3.5.5 Troubleshooting 23

3.5.6 Product Specifications 24

3.6 Installation of External Batteries and Battery Breaker 26

3.6.1 Battery Installation 26

3.6.2 Battery Replacement 29

4.0 Initial Start-up and Phase Check 30

4.1 Initial Start-up and Phase Check (External Batteries) 30

5.0 Clearing the Events Log 31

6.0 Start-up and Shutdown Procedure 32

6.1 Start-up from Maintenance Bypass 32

6.2 Shutdown Procedure 32

7.0 Technical Specifications 34

7.1 APC BC300 Series 60 kW Technical Data 34

7.2 Battery Specifications 35

7.3 Dimensions/Weight 35

8.0 How to Contact APC 36

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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. 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 is not provided by APC.

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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

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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Installation

3.1.1 UPS Footprint (measurements in inches & mm)

39.4

(1000)

31.7

(804)

36.00 (914)

Minimum Service

Clearance

39.4

(1000)

17.9

(455)

(Rear)

(Front)

17.9

(455)

Conduit

Connection

Box

Cable Entry

Section A-A

View From Inside Cabinet, Looking Down

19.8

(504)

27.9

(708)

31.7

(804)

59.1

(1500)

Front View Side View

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 = 2214lbs (1005kg)

5. Installation must comply with all applicable national and local codes

36.00 (914)

Recommended

Cooling

Clearance

31.7

(804)

Figure 1 - Footprint

3.2 Installing the Conduit Connection Kit

Insulated and other tools required

• 13 mm ratchet or wrench

• T20 torx screwdriver

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• Greenly punch

• Equipment suitable for lifting heavy UPS off the ground

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

6) Tighten the bolts

3.2.3 Installing Conduit Box and Base Covers

1) Punch conduit holes in the back of the conduit box

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Installation

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

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

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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Notes:

1. 208V F1, F2, F3 = 175A

2. 480V F1, F2, F3 = 75A

3. 208V F4, F5, F6 = 250A

4. 480V F4, F5, F6 = 110A

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.

Maintenance

Bypass Switch

Contacts marked "U"

closed in "UPS".

Contacts marked "BP"

closed in Bypass.

Contacts are Make

before Break.

AC Output from UPS

TO CRITICAL

LOAD CENTER

AC Output

to Critical Load

GRD

1718

Uninterruptible Power Supply

L3 L3

AC Input

to UPS

UPS Input

Disc. Switch

Shown in Open

Position

AC Line

Input

GRD

Installation

Figure 2 - SBP Electrical Schematic 208V & 480V

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Installation

3.3.1 Component Overview (door open)

ON/OFF buttons

Controller Board

Display unit

Battery connection

Communication Interface

Figure 3 Component Overview

Input

Output

Grounding

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