American Power Conversion InfraStruXureTM System User Manual
Installation and Start-Up
80kW InfraStruXureTM System
Medium Data Centers
208/480/600V Input
About this Manual
This manual is intended for APC Field Service Engineers or APC-trained installers of a 80kW
InfraStruXure system. It covers basic installation and start-up.
For additional information about installing the InfraStruXure system, see Certified Electrician’s
Instructions (990-1469A), which provides specific instructions for the electrician connecting utility
to the InfraStruXure PDU.
For information about installing specific components in your InfraStruXure system, see the
documentation included with each component. Before installing or operating any component, refer to
the safety instructions in the component’s manual.
The illustrations of products in this manual may vary slightly from the products in your InfraStruXure
system.
You can check for updates to this manual by clicking on the User Manuals link on the
Support page of the APC Web site (www.apc.com). In the list of InfraStruXure
Note
manuals, look for the latest letter revision (A, B, etc.) of the part number on this manual.
InfraStruXure System—Installation and Start-Up i
Contents
Safety ......................................................................1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Save these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety symbols used in this manual . . . . . . . . . . . . . . . . . . . 1
Cross-reference symbols used in this manual . . . . . . . . . . . . . 1
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation/Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance performed while the
PDU is receiving input power
Total Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DANGER—Risk of Electric Shock! . . . . . . . . . . . . . . . . . . . . . 3
Emergency Power Off (EPO) . . . . . . . . . . . . . . . . . . . . . . . . 3
EMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . 2
Site Planning............................................................5
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
InfraStruXure PDU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Symmetra PX UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
NetShelter VX Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rack Distribution Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Space Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Weight Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Heat Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical Requirements and Specifications . . . . . . . . . . . . . . . . 11
Cross Tie Output Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . 12
Emergency Power Off (EPO) . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Basic Installation Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
InfraStruXure System—Installation and Start-Up iii
Installation Procedures .......................................... 18
Installation Procedures .......................................... 19
Level the PDU, UPS, RDP, NetShelter and Battery Enclosures . . 19
Exchange Side Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Attach the PDU, UPS, and Battery Enclosure . . . . . . . . . . . . . . 22
Ensure that All Power is Off . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Connect Utility Conductors to the PDU . . . . . . . . . . . . . . . . . . 25
Connect AC Power and Control Wiring . . . . . . . . . . . . . . . . . . 26
Connect DC Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cascade Battery Enclosures . . . . . . . . . . . . . . . . . . . . . . . 31
Connect power cables from the
Battery Enclosure to the Symmetra PX UPS
. . . . . . . . . . . . . 32
Connect an Emergency Power Off Switch . . . . . . . . . . . . . . . . 33
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Connect an EPO switch to the
user connection plate and test the switch
Safety warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
. . . . . . . . . . . . . . 34
Connect User Input Contacts and
Relay Outputs to the User Connection Plate. . . . . . . . . . . . . . . 37
Install Shielding Troughs,
Shielding Partitions, and Cable Ladders . . . . . . . . . . . . . . . . . . 39
Shielding Troughs and Shielding Partitions
for overhead wiring along rows
Cable Ladders for overhead wiring across rows . . . . . . . . . . 40
. . . . . . . . . . . . . . . . . . . . 39
Install InfraStruXure Rack-Mount Devices . . . . . . . . . . . . . . . . . 41
Install the Rack Automatic Transfer Switches (ATS) . . . . . . . . 41
Install the Rack Power Distribution Units (PDU) . . . . . . . . . . 41
Install the InfraStruXure Manager and Hub (or Switch) . . . . . 41
Install the Environmental Monitoring Unit or
Environmental Management System
. . . . . . . . . . . . . . . . . 41
Route and Attach Overhead Wiring . . . . . . . . . . . . . . . . . . . . . 42
Connect the sub-feed power cable conductors to a
three-pole breaker on the PDU
Route and attach power cables to equipment racks . . . . . . . 43
iv InfraStruXure System—Installation and Start-Up
. . . . . . . . . . . . . . . . . . . . . 42
Route Data Cables to the
InfraStruXure Manager Hub (or Switch) . . . . . . . . . . . . . . . . . . 46
Connect network cables to components . . . . . . . . . . . . . . . 46
Route network cables to the
InfraStruXure Manager Hub (or Switch)
. . . . . . . . . . . . . . . . 47
Start-Up Procedure .................................................49
Safety warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Ensure that all power is off . . . . . . . . . . . . . . . . . . . . . . . . 49
Apply power to the system . . . . . . . . . . . . . . . . . . . . . . . . 51
Verify UPS battery operation . . . . . . . . . . . . . . . . . . . . . . . 54
Verify proper voltage and phase rotation on the PDU . . . . . . 56
Start the UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Verify proper phasing:
place the UPS into bypass operation
Return from maintenance bypass operation . . . . . . . . . . . . . 62
Power the PDU Distribution Circuit Breakers . . . . . . . . . . . . 63
Close Cross-Tie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
. . . . . . . . . . . . . . . . . . 60
Configure the InfraStruXure Manager . . . . . . . . . . . . . . . . . . . 65
Appendix A : System Operation ..............................67
How to Transfer the UPS into
Maintenance Bypass Operation . . . . . . . . . . . . . . . . . . . . . . . . 67
How to Return from
Maintenance Bypass Operation . . . . . . . . . . . . . . . . . . . . . . . . 70
How to Ensure Total Power Off . . . . . . . . . . . . . . . . . . . . . . . . 73
How to Apply Power to the System . . . . . . . . . . . . . . . . . . . . . 75
Appendix B : Single-Line Diagrams .........................79
Appendix C: Changes in This Manual......................83
InfraStruXure System—Installation and Start-Up v
Safety
d
o
Overview
Save these instructions
This manual contains important instructions that must be followed during installation, operation, and
maintenance of the InfraStruXure System.
Safety symbols used in this manual
Indicates an electrical hazard, which, if not avoided, could result in injury or
Electrical
Hazar
Warning
death.
Indicates a hazard, which, if not avoided, could result in personal injury or
damage to product or other property.
Indicates a potential hazard which could result in damage to product or other property.
Caution
Indicates important information.
Note
Indicates a heavy load that should not be lifted without assistance.
Heavy
Indicates a standby state. When in standby, the unit is not operating, but it may still
contain hazardous voltage. It is not safe to service until the equipment is
disconnected from all sources of electrical power.
Cross-reference symbols used in this manual
Indicates that more information is available on the same subject in a different manual.
See als
Indicates that more information is available on the same subject in a different section
of this manual.
InfraStruXure System—Installation and Start-Up 1
Warnings
Installation/Maintenance
Only a certified electrician can perform these tasks:
• Connect the PDU to utility
• Connect the cross tie output breaker to another PDU
• Connect a switch to the EPO interface on the PDU
Only a certified electrician or an APC Field Service Engineer can perform these tasks:
• Connect the PDU to the Symmetra PX UPS
• Perform maintenance of the PDU
When you connect the PDU to utility, you must install a circuit breaker to protect the PDU against
over- current. Determine the type of circuit breaker that you need to install:
Input Voltage Circuit Breaker Sizing
208V 350A
480V 150A
600V 125A
Maintenance performed while the PDU is receiving input power
APC does not recommend that you perform maintenance of the PDU while it is receiving input
power. However, due to the critical nature of data center loads, this may occur. If you must perform
maintenance while the PDU is receiving input power, observe the following precautions to reduce the
risk of electric shock:
1. Never work alone.
2. Perform the maintenance only if you are a certified electrician who is trained in the hazards of
live electrical installation.
3. Know the procedure for disconnecting electricity to the PDU and the data center in case of an
emergency.
4. Wear appropriate personal protective equipment.
5. Use double-insulated tools.
6. Always follow local and site regulations when working on the PDU.
2 InfraStruXure System—Installation and Start-Up
Total Power Off
d
1. Set the Symmetra PX UPS System Enable switch to Off.
2. Set the DC Disconnect breaker of each Battery Enclosure to Off.
3. Set the PDU Main Input (A) switch to Off.
4. If applicable, set the PDU Bypass Input (B) switch to Off.
5. If applicable, set the PDU Cross Tie Output (X) circuit breaker to Off.
6. Set all upstream utility circuit breakers feeding the PDU to Off.
7. Disconnect the batteries in the Battery Enclosure and any XR Battery Enclosures by pulling
them out to the red disconnect line.
DANGER—Risk of Electric Shock!
Hazardous, live parts may exist inside the PDU because of the Symmetra PX UPS
inverter even when the AC power is disconnected. Test any electrical parts before
Electrical
Hazar
touching them.
Safety: Warnings
Emergency Power Off (EPO)
Hazardous voltage from the branch circuit must be isolated from the 24VAC, 24VDC, and contact
closure. 24VAC and 24 VDC are considered Class 2 circuits as defined in Article 725 of the National
Electrical Code (NFPA 70) and Section 16 of the Canadian Electrical Code (C22.1).
A Class 2 circuit is a source having limited voltage and energy capacity as follows:
a. If an Inherently Limited Power Source, voltage and energy are limited to less than 30VAC,
less than 30VDC, and 8A.
b. If not an Inherently Limited Power Source, voltage and energy are limited to less than
30VAC, less than 60 VDC, 250VA, and the current is limited to 1000/ V max. The fuse is
limited to 5A if less than 20VAC or 20VDC, or 100/Vmaximum if less than 30VAC or
60VDC.
If you choose to use a 24VAC, 24 VDC, or contact closure connection to the EPO, use one of the
following UL-listed wire types:
• CL2 Class 2 cable for general purpose use
• CL2P Plenum cable for use in ducts, plenums, and other space used for environmental air
• CL2R Riser cable for use in a vertical run shaft from floor to floor
• CL2X Limited Use cable for use in dwellings and for use in a raceway
• For installation in Canada, the cable should be CSA Certified, type ELC (extra-low-voltage
control cable).
If you do not use a CL2 cable, route the EPO wiring in conduit that does not contain any branch
circuit wiring.
InfraStruXure System—Installation and Start-Up 3
Safety: Warnings
EMI
This equipment has been tested and found to comply with the limits for a Class A digital device,
pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference when the equipment is operated in a commercial environment. This
equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in
accordance with this user manual, may cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely to cause harmful interference.The user will
bear sole responsibility for correcting such interference.
This Class A digital apparatus complies with Canadian ICES-003.
Cet appareil numerique de le class A est conforme a la norme NMB-003 du Canada.
4 InfraStruXure System—Installation and Start-Up
Site Planning
Dimensions
InfraStruXure PDU
Without Shielding Trough
81.5in (2070mm)
Shielding Partitions
29.5in
(749.3mm)
4.74
4.72in
(120mm)
With Shielding Trough
88.78in (2255mm)
Symmetra PX UPS
29.5in
(749.3mm)
23.5in
(597mm)
81.5in
(2070mm)
Wide PDU Shielding Trough
7.28in
(185mm)
29.5in
(749.3mm)
34.5in
(876.3mm)
Power Module
5.2in
(130mm)
34.5in
(876.3mm)
InfraStruXure System—Installation and Start-Up 5
19in
(480mm)
28in
(720mm)
Site Planning: Dimensions
Battery Enclosure
23.5in
(597mm)
Battery Module
34.5in
(876.3mm)
NetShelter VX Enclosure
81.5in
(2070mm)
23.5in
(597mm)
(2070mm)
81.5in
Shielding Partitions
23.5in
(597mm)
Shielding Trough
19.0in
(480mm)
4.8in
(122mm)
5.2in
(130mm)
28in
(720mm)
23.5in
(597mm)
42.2in
(1071.9)
6 InfraStruXure System—Installation and Start-Up
7.2in
(183mm)
Rack Distribution Panel
(2060mm)
Site Planning: Dimensions
81in
24in
(610mm)
35in
(890mm)
InfraStruXure System—Installation and Start-Up 7
Space Considerations
Study the figures below to determine your space requirements for installing the InfraStruXure PDU,
Symmetra PX UPS, and Battery Enclosure. Consult your local codes and the NEC for additional
requirements.
Ceiling Clearance
18in (457.2 mm)
Minimum Rear Clearance
Minimum Front Clearance
208V:36in (914.4mm)
480V: 42 in (1066.8mm)
8 InfraStruXure System—Installation and Start-Up
208V:36in (914.4 mm)
480V: 42 in (1066.8mm)
Weight Considerations
Ensure that the floor and sub-floor can support the total weight of the configuration when
concentrated on the leveling feet. If you are placing equipment on a raised floor, consult the flooring
manufacturer for loading requirements before installing equipment.
Component Maximum Weight
InfraStruXure PDU 2100lb (953kg)
Symmetra PX UPS 1700lb (775kg)
Battery Enclosure 2152lb (976kg)
NetShelter VX Enclosure (empty) 363lb (165kg)
InfraStruXure System—Installation and Start-Up 9
Heat Output
Consider the heat dissipation ratings of equipment to determine cooling requirements. Additional
cooling equipment may be required. The following table shows the heat output of the InfraStruXure
PDU and the Symmetra PX UPS.
InfraStruXure PDU
208V 6,165BTU/hr. (1.81kW)
480V 5,079BTU/hr. (1.49kW)
600V 5,527BTU/hr. (1.62kW)
Symmetra PX UPS 23,757BTU/hr. (6.96kW)
The heat output is higher while batteries are charging. Under normal operating
conditions, battery recharging periods are infrequent.
Note
10 InfraStruXure System—Installation and Start-Up
Electrical Requirements and Specifications
d
o
Procedures requiring a licensed electrician
Procedures requiring a licensed electrician include:
• Connection of utility conductors
Electrical
Hazar
See als
Electrical requirements
• Installation of a 350-, 150-, or 125-amp circuit breaker
• Connection to the Main Input switch
• Connection to a branch circuit
• Connection to the cross tie output breaker
To connect utility conductors, see Certified Electrician’s Instructions (990-1469A)
included with your InfraStruXure PDU documentation.
208VAC 480VAC 600VAC
Upstream circuit breaker
Conductors to Main Input switch
† ‡
† ‡*
Conductors to the Bypass Input switch
Conductors to the Cross Tie Output
† ‡
breaker
Recommended wire sizing
‡
350A 150A 125A
3W + G, 4 W + G
† ‡
4W + G
*
3W + G + GEC to building steel
4W + G
L1, L2, L3 400kcmil (350A) 1/0AWG (150A) 2AWG (125A)
*
N
400 k cm il 1/0 AW G 2 AWG
G 3 AWG 6 AWG 6 AWG
GEC 1/0 AW G 6 AWG 8 AWG
Torque according to wire size
L1, L2, L3 Underfloor Wiring: 500in-lbs, Overhead Wiring: 160in-lb
(18Nm) of lugs onto the circuit breaker
N 125in-lb
G, GEC 45in-lb if single terminal (ground), 50in-lb if double terminal
(G + GEC)
* Transformerless PDUs only.
† Provided by customer.
‡ Consult local and national codes for sizing requirements.
InfraStruXure System—Installation and Start-Up 11
Cross Tie Output Circuit Breaker
Overview
The optional cross tie output circuit breaker allows two separate UPSs that are fed from two different
power sources (dual-fed) to be tied together to create a 2N system. The illustration below shows an
example configuration.
POWER SOURCE B
Inpu t
Step-down
Tra nsf or mer
POWER SOURCE A
AABBXX
Inpu t
Step-down
Tra nsf or mer
PDU A PDU B
To UPS To UPS
With a dual-fed 2N system, the secondary of UPS A’s input transformer, located within PDU A, is
connected to the bypass feed of UPS B; and the secondary of UPS B’s input transformer, located
within PDU B, is connected to the bypass feed of UPS A.
The purpose of a 2N system is to use two UPSs such that if something were to happen to one of the
UPSs, the other UPS is available to supply power to the load equipment. 2N systems provide an
added benefit for 480V and 600V power distribution systems in that isolation transformers are not
required to step down the 480V or 600V input to 208V because transformers in the PDUs perform
this task.
It is important to note that the cross tie feature is to be used on 2N dual-fed systems only. The cross
tie circuit breaker is not to be used to supply power to any other load device. Cross tie connections are
made through the load-side terminals of a molded-case circuit breaker, located in the front, upper,
right-hand side of the PDU. PDUs with the bottom feed option are supplied with terminals on the
front, lower, right-hand side of the PDU.
12 InfraStruXure System—Installation and Start-Up
Emergency Power Off (EPO)
Overview
To provide a mechanism for emergency power off, attach a remote switch (not included) to the EPO
interface on the PDU monitoring unit. The EPO interface () is connected to the PDU Main Input
switch () and to the UPS internal EPO switch (). (Control wires from the PDU to the UPS are
connected during installation of the InfraStruXure system.)
Switch
When the EPO is activated, the main input circuit breaker to the PDU transformer is opened, the UPS
DC Disconnect breaker is opened, and the UPS System Enable switch is turned off. In this sequence,
there is not power from the PDU transformer and there is no power from the UPS inverters and
batteries.
APC offers an optional InfraStruXure EPO System (EPW9). Contact your APC sales
representative, or visit the APC Web site (www.apc.com) for more information.
Note
PDU
UPS
See “Connect an Emergency Power Off Switch” on page 33 for instructions on how to
connect an EPO switch to the PDU.
InfraStruXure System—Installation and Start-Up 13
Basic Installation Procedure
o
This section provides the basic steps that you need to perform when installing InfraStruXure power
and rack components. Follow the references provided with each step for detailed instructions.
Do not begin installing your InfraStruXure system without an APC Field Service
Warning
1. Unpack the components according to the unpacking instructions included on the outside of the
2. Determine the correct placement of your system components by studying your InfraStruXure
Engineer present.
packaging or in the installation manual included with the component.
Search all boxes and packaging to make sure that they are empty before
discarding.
Note
Configure-To-Order (CTO) Report. Move the Symmetra PX UPS, InfraStruXure PDU, RDP,
Battery Enclosure, and NetShelter VX Enclosures to their final location.
If installing InfraStruXure on a raised floor, make sure that the raised-
2
rating that will support the full weight of the
Warning
floor structure has a lb/in
InfraStruXure installation. See “Weight Considerations” on page 9.
3. Level the PDU, UPS, RDP, NetShelter, and Battery Enclosures, using the 13/14-mm wrench
included with each unit.
See page 18 for detailed instructions.
4. Exchange side panels and run battery communication cables.
See page 20 for detailed instructions.
5. Join adjacent enclosures.
For instructions on joining the PDU, UPS, and Battery Enclosure see page 22.
For instructions on joining to RDP to a NetShelter VX Enclosure, or joining
adjacent NetShelter VX Enclosures, see the installation manual included with
See als
your enclosures.
6. Ensure total power off.
See page 23 for detailed instructions.
14 InfraStruXure System—Installation and Start-Up
Site Planning: Basic Installation Procedure
o
o
o
o
7. Connect utility conductors to the PDU.
A licensed electrician must connect utility power.
For instructions, see Certified Electrician’s Instructions (990-1469A) included
with your InfraStruXure PDU documentation.
See als
8. Connect AC power and control wiring.
See page 26 for detailed instructions.
9. Connect DC power wiring.
See page 30 for detailed instructions.
10. Connect an EPO switch to the PDU user connection plate.
See page 33 for detailed instructions.
11. Connect user input contacts and relay outputs to the PDU user connection plate, if applicable.
See page 37 for detailed instructions.
12. Install Shielding Troughs, Shielding Partitions, and Cable Ladders.
See page 39 for general information.
For detailed information and grounding instructions, see the instruction sheet
included with the Shielding Troughs and Shielding Partitions
See als
(990-1393B).
For more information on installing and grounding the Cable Ladders see the
instruction sheet included with the cable ladders (990-1576).
See als
13. Install the Rack Automatic Transfer Switches (ATS), Rack Power Distribution Units, and other
InfraStruXure rack-mount devices.
For instructions, see the manuals included with your Rack ATS, Rack PDU, or
other InfraStruXure rack-mount device.
See als
14. Route and attach power cables to RDPs and to each Rack ATS and/or Rack PDUs.
See page 41 for detailed instructions.
15. Route and attach communication cables to the InfraStruXure Manager hub (or switch).
See page 46 for detailed instructions.
InfraStruXure System—Installation and Start-Up 15
Site Planning: Basic Installation Procedure
o
16. Start the system.
Only qualified, APC-trained personnel may perform a system start-up.
See page 45 for detailed instructions.
17. Configure the InfraStruXure Manager.
For instructions, see the manual included with your InfraStruXure Manager.
See als
16 InfraStruXure System—Installation and Start-Up
Tools Required
The following tools are required to perform the procedures in this manual. Additional tools may be
required for components not covered in this manual.
Tool Supplied?
13-mm socket wrench No
17-mm socket wrench No
T-20 screwdriver No
Standard screwdriver No
Level No
Open-ended wrench (14 mm) for adjusting the leveling feet Yes
Step ladder No
Crimper No
Volt-meter No
Phase-rotation meter No
InfraStruXure System—Installation and Start-Up 17
Installation Procedures
18 InfraStruXure System—Installation and Start-Up
Installation Procedures
Level the PDU, UPS, RDP, NetShelter and Battery Enclosures
Leveling feet are attached under the enclosure at each corner. The leveling feet can help provide a
stable base if the selected floor space is uneven, but they are not intended to compensate for a badly
sloped surface. To level the enclosure:
1. Fit the 14-millimeter end of the open-ended wrench (provided) to the hex head just above the
round pad on the bottom of the leveling foot. Turn the wrench clockwise to extend the leveling
foot until it makes firm contact with the floor.
2. Repeat step 1 for each of the remaining leveling feet.
3. Use a level to determine which feet need further adjustment to level the enclosure. Adjust as
necessary.
InfraStruXure System—Installation and Start-Up 19
Exchange Side Panels
Before installing the InfraStruXure PDU, Symmetra PX UPS, and Battery Enclosure, you will need
to exchange side panels so that the adjacent panels will have matching holes for joining the
enclosures together and for routing input and output wiring between them. The following side panels
will need to be exchanged:
• Adjacent side panels of a PDU and UPS
• Adjacent side panels of a Battery Enclosure and a UPS
• Adjacent side panels of two Battery Enclosures
To exchange side panels:
1. Detach the ground wires from the side panels that you will be exchanging.
20 InfraStruXure System—Installation and Start-Up
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