Installation and Start-Up
150kW InfraStruXure
Large Data Centers
480 V/ 600V Input
TM
System
208/480/600V
About this Manual
This manual is intended for APC Field Service Engineers or APC-trained installers of an
InfraStruXure system. It covers basic installation and start-up.
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 manuals,
Note
look for the latest letter revision (A, B, etc.) of the part number on the back cover of this
manual.
150kW 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
Receiving/moving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation/Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance performed while the
PDU is receiving input power
Total Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Emergency Power Off (EPO) . . . . . . . . . . . . . . . . . . . . . . . . 3
EMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . 2
Site Planning............................................................5
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
InfraStruXure PDU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
NetShelter VX Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Space Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Weight Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Heat Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical Requirements and Specifications . . . . . . . . . . . . . . . . . 9
Procedures requiring a licensed electrician . . . . . . . . . . . . . . 9
Electrical requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Emergency Power Off (EPO) . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Basic Installation Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
150kW InfraStruXure System—Installation and Start-Up iii
Installation Procedures .......................................... 13
Level the PDU and NetShelter Enclosures. . . . . . . . . . . . . . . . . 13
Connect the Power Source to the PDU . . . . . . . . . . . . . . . . . . . 14
Access the PDU Main Input breaker . . . . . . . . . . . . . . . . . . 14
Attach conduit to the PDU for the input conductors . . . . . . . 14
Install a circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Route the input conductors to the
Main Input circuit breaker
Torque specs and tools required . . . . . . . . . . . . . . . . . . . . 16
Connect an Emergency Power Off Switch . . . . . . . . . . . . . . . . 17
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Connect an EPO switch to the
user connection plate and test the switch
Safety warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Connect User Input Contacts and Relay Outputs to the
User Connection Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
To connect and monitor your contacts: . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . 18
Install Shielding Troughs,
Shielding Partitions, and Cable Ladders . . . . . . . . . . . . . . . . . . 23
Shielding Troughs and Shielding Partitions for
overhead wiring along rows
Cable Ladders for overhead wiring across rows . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . 23
Install InfraStruXure Rack-Mount Devices . . . . . . . . . . . . . . . . . 25
Install the Rack Automatic Transfer Switches (ATS) . . . . . . . . 25
Install the Rack Power Distribution Units (PDUs) . . . . . . . . . 25
Install the InfraStruXure Manager and Hub (or Switch) . . . . . 25
Install the Environmental Monitoring Unit or
Environmental Management System
. . . . . . . . . . . . . . . . . 25
Route and Attach Overhead Wiring . . . . . . . . . . . . . . . . . . . . . 26
Wiring Under the Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Route Data Cables to the
InfraStruXure Manager Hub (or Switch) . . . . . . . . . . . . . . . . . . 30
iv 150kW InfraStruXure System—Installation and Start-Up
Start-Up Procedure .................................................31
Safety warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Ensure that all power is off . . . . . . . . . . . . . . . . . . . . . . . . 31
Apply power to the system . . . . . . . . . . . . . . . . . . . . . . . . 33
Configure the InfraStruXure Manager . . . . . . . . . . . . . . . . . . . 35
Appendix A: Operation ..........................................37
How to Apply Power to the System . . . . . . . . . . . . . . . . . . . . . 37
How to Ensure Total Power Off . . . . . . . . . . . . . . . . . . . . . . . . 39
150kW InfraStruXure System—Installation and Start-Up v
Safety
Overview
Save these instructions
This manual contains important instructions that must be followed during installation, operation, and
configuration of the InfraStruXure system.
Safety symbols used in this manual
Indicates an electrical hazard, which, if not avoided, could result in injury or
Electrical
Hazard
Warning
death.
Indicates a hazard, which, if not avoided, could result in personal injury or
damage to the 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 section of
this manual.
See also
Indicates that more information is available on the same subject in a different manual.
150kW InfraStruXure System—Installation and Start-Up 1
Warnings
Receiving/moving
Do not tilt the PDU greater than 45° from its vertical axis. Never lay the PDU on its side.
Installation/Maintenance
Only a certified electrician can:
• Connect the PDU to its power source
• Connect a switch to the EPO interface on the PDU
• Install a customer-specified, hard-wired power cable
Only a certified electrician or an APC Field Service Engineer can perform maintenance of the PDU.
When you connect the PDU to its power source, 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 Size
480V 225A
600V 200A
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 150kW InfraStruXure System—Installation and Start-Up
Safety: Warnings
Total Po w e r Off
1. Set the PDU Main Input to OFF.
2. Set the upstream power source feeding the PDU to OFF.
Emergency Power Off (EPO)
Hazardous voltage from the branch circuit must be isolated from the 24VAC, 24VDC, and contact
closure terminals. 24VAC and 24VDC 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 60VDC, 250VA, and the current is limited to 1000/Vmax. 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.
150kW InfraStruXure System—Installation and Start-Up 3
Safety: Warnings
EMI
This equipment has been tested and found to comply with the limits for 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 numérique de la classe A est conforme à la norme NMB-003 du Canada.
4 150kW InfraStruXure System—Installation and Start-Up
Site Planning
Dimensions
InfraStruXure PDU
Without PDU Shielding Trough
81in (2060mm)
Including PDU Shielding Trough
88.2in (2240 mm)
PDU Shielding Trough
7.2in
(183mm)
23in (584 mm)
29in (710 mm)
NetShelter VX Enclosure
23.5in
(597mm)
42.2in
(1072mm)
36in (910mm)
81.5in
(2070mm)
Shielding Partitions
23.5in
(597mm)
23.5in
(597mm)
4.8in
(122mm)
7.2in
(183mm)
150kW InfraStruXure System—Installation and Start-Up 5
Space Considerations
Study the figure below to determine your space requirements for installing the InfraStruXure PDU.
Consult your local codes and NEC for additional requirements.
Ceiling Clearance
>12in (304mm)
Minimum Rear Clearance
Minimum Front Clearance
42in (1067 mm)
42in (1067 mm)
6 150kW InfraStruXure System—Installation and Start-Up
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 2000lb (907kg)
NetShelter VX Base Enclosure (empty) 351lb (160kg)
150kW InfraStruXure System—Installation and Start-Up 7
Heat Output
Consider the heat dissipation ratings of equipment to determine cooling requirements. Additional
cooling equipment may be required. Heat output of the 150 kW InfraStruXure PDU is 9980 BTU/hr
(2.92kW).
8 150kW InfraStruXure System—Installation and Start-Up
Electrical Requirements and Specifications
Procedures requiring a licensed electrician
Only a certified electrician can:
Electrical
Hazard
• Connect a switch to the EPO interface on the PDU
• Install a customer-specified, hard-wired power cable
• Perform maintenance of the PDU
Electrical requirements
Service distribution breaker
Conductors to Main Input switch
Recommended wire sizing
L1, L2, L3 2/0AWG 2/0AWG
G6AWG 6AWG
GEC 4AWG 4 AWG
† Provided by customer.
‡The specifications are recommendations. Consult the NEC and local code for requirements specific to your
installation.
• Connect the PDU to its power source
480V 600V
†‡
225A 200A
†
‡
3W + G + GEC 3W + G + GEC
150kW InfraStruXure System—Installation and Start-Up 9
Emergency Power Off (EPO)
Overview
To provide a mechanism for emergency power off, attach a remote switch to the EPO interface on the
PDU monitoring unit through the user connection plate. The EPO interface () is connected to the
PDU monitoring unit () (by way of the user connection plate), which connects to the internal EPO
switch of an APC UPS or other APC connected device ().
When the EPO is activated, the UPS DC Disconnect breaker is opened, and the UPS System Enable
switch is turned off. In this sequence, there is no power from the UPS inverters and batteries, and no
power to the InfraStruXure PDU.
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
See “Connect an Emergency Power Off Switch” on page 18 for instructions on how to
connect an EPO switch to the PDU.
10 150kW InfraStruXure System—Installation and Start-Up
Basic Installation Procedure
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 component’s manual.
Search all boxes and packaging to make sure that they are empty before
discarding.
Note
Configure-To-Order (CTO) report. Move the InfraStruXure PDU and NetShelter VX
Enclosures to their final location.
If installing InfraStruXure on a raised floor, make sure that the
raised-floor structure has a lb/in² rating that will support the full
Warning
weight of the InfraStruXure installation. See “Weight Considerations”
on page 7.
3. Level the PDU and NetShelter enclosures, using the 13/14-mm wrench included with each unit.
See page 13 for detailed instructions.
4. Join adjacent NetShelter enclosures.
For instructions on joining adjacent NetShelter VX Enclosures, see the
installation manual included with your enclosures.
See also
5. Ensure total power off.
See page 33 for detailed instructions.
6. Connect the power source to the PDU.
A licensed electrician must connect the power source.
See page 14 for detailed instructions.
7. Connect an EPO switch to the PDU monitoring unit.
See page 18 for detailed instructions.
150kW InfraStruXure System—Installation and Start-Up 11
Site Planning: Basic Installation Procedure
8. Install Shielding Troughs, Shielding Partitions, and Cable Ladders.
For instructions, see the manuals included with your Shielding Partitions,
and Cable Ladders.
See also
9. 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 Automatic
Switches (ATS), Rack Power Distribution Units, and other InfraStruXure
See also
rack-mount devices.
10. Route and attach power cables to each Rack ATS and/or Rack PDU.
See page 26 for detailed instructions.
11. Route and attach communication cables to the InfraStruXure Manager hub (or switch).
See page 32 for detailed instructions.
12. Start the system.
Only qualified, APC-trained personnel may perform a system start-up.
See page 33 for detailed instructions.
13. Configure the InfraStruXure Manager.
For instructions, see the manual included with your InfraStruXure
Manager.
See also
12 150kW InfraStruXure System—Installation and Start-Up
Installation Procedures
Level the PDU and NetShelter Enclosures
Leveling feet are attached under the enclosure at each corner and can help provide a stable base if the
selected top floor space is uneven. However, 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.
150kW InfraStruXure System—Installation and Start-Up 13
Connect the Power Source to the PDU
Access the PDU Main Input breaker
Open the back doors of the PDU by unlocking the top, smaller door, using the provided key and then
loosening the two screws holding the bottom half of the door in place.
Attach conduit to the PDU for the input conductors
1. Remove the rectangular gland plate by loosening the captive screws, using a Phillips or standard
screwdriver:
– In the bottom of the PDU for wiring under a raised floor: remove the plate in the floor of the
PDU.
14 150kW InfraStruXure System—Installation and Start-Up
Installation Procedures: Connect the Power Source to the PDU
– In the top of the PDU for overhead wiring: detach the user connection plate, route it through
the opening in the gland plate, carefully set it aside (do not disturb the connected wires), and
remove the gland plate in the roof of the PDU.
2. Use a knock-out punch to create an
appropriately-sized hole in the gland plate for
the conduit.
3. Re-attach the gland plate.
4. Install a lock-nut and bushing to the conduit.
5. Thread the conduit through the hole.
Install a circuit breaker
Make sure the cables used for power input are protected by a 225-amp (for 480V)
or 200-amp (for 600V) circuit breaker.
Warning
150kW InfraStruXure System—Installation and Start-Up 15
Installation Procedures: Connect the Power Source to the PDU
Route the input conductors to the Main Input circuit breaker
Route the input conductors to the Main Input circuit breaker of the PDU and connect the input wiring
according to the lables on the circuit breaker and the following illustration. Refer to the following
table “Torque specs and tools required” for specific information about connecting to each terminal.
Connect the conductors to the terminals according to the labels on the terminals.
Use copper conductors only.
Warning
*
3-phase, 3-wire + ground + GEC to building steel
G
L3
L2
L1
GEC
Torque specs and tools required
Before connecting to the terminals, verify the torque specs below by checking the specifications on
the Main Input circuit breaker.
Terminal Torque Tools
L1, L2, L3 150in-lb (17Nm) 6-mm Allen wrench
G 4–6 AWG: 45in-lb (5.0Nm) Slotted screwdriver
GEC 8AWG: 40in-lb (4.5 Nm) Slotted screwdriver
C
*
Other types of electrodes may be used if building steel is not available, consult NEC codes for
requirements.
16 150kW InfraStruXure System—Installation and Start-Up
Connect an Emergency Power Off Switch
APC offers an optional InfraStruXure EPO System (EPW9). Contact your APC
sales representative, or visit the APC Web site (www.apc.com) for more
Note
Caution
Note
Overview
information.
If you are not connecting an Emergency Power Off switch to the PDU, leave the
Arm/Test rocker switch on the PDU monitoring unit in the Te st position.
The PDU monitoring unit provides the EPO function. The purpose of this function
is to activate any shunt trips that are controlled by the PDU monitoring unit. These
shunt trips are on breakers that are part of the power source feeding the PDU. The
PDU breakers do not have any shunt trips.
Connecting the switch. The
Emergency Power Off (EPO) switch
connects to the PDU user connection plate.
The figure on the right shows the location
of the user connection plate on the roof of
the PDU. Connect a switch using one of
three following connections:
• Contact closure
•24VAC
•24VDC
Contact closure is recommended.
Note
Configuring and testing. Configuring and
testing of the switch is done through the EPO
interface on the PDU monitoring unit. The
figure to the right shows the PDU monitoring
unit and the location of the EPO LEDs and
switches.
USER INTERFACE
© 2001 APC
MADE IN USA
1 234
Contact Inputs
Contact Outputs
– +
EPO 24V
EPO
ATS 1
ATS 0
ATS 2
AC/DC
ATS EN
Contact
150kW InfraStruXure System—Installation and Start-Up 17
Installation Procedures: Connect an Emergency Power Off Switch
Connect an EPO switch to the user connection plate and test the switch
1. Connect the switch to the EPO connection point terminals located on the bottom side of the
PDU user connection plate. Read the label next to the terminal block to determine which
terminals to connect to for the signal type you are using:
– Contact Closure—Normally Open
USER INTERFACE
© 2001 APC
MADE IN USA
External set of
Normally Open Dry Contacts
– +
1 234
Contact Inputs
Contact Outputs
EPO 24V
ATS EN
AC/DC
EPO
Contact
ATS 1
ATS 0
ATS 2
– Contact Closure—Normally Closed
USER INTERFACE
© 2001 APC
MADE IN USA
External set of
Normally Closed Dry Contacts
– +
1 234
Contact Inputs
Contact Outputs
EPO 24V
ATS EN
AC/DC
EPO
Contact
ATS 1
ATS 0
ATS 2
– 24 VAC/VDC—Normally Open
External Set of Normally Open Dry Contacts
USER INTERFACE
© 2001 APC
MADE IN USA
1 234
Contact Inputs
Contact Outputs
– +
EPO 24V
ATS EN
AC/DC
EPO
Contact
ATS 1
ATS 0
ATS 2
24V AC or DC Power Supply
2. Verify that the EPO DIP switches on the PDU monitoring unit are configured properly for the
signal type that you are using. The labels above the switches and the figure below show the
correct settings for both the Normally Open (NO) and Normally Closed (NC) position.
TRIPPED
Normally ClosedNormally Open
ARMED
EPO
TEST
NC
NO
or 24V AC/DC
The default setting on the EPO interface on the PDU monitoring unit is for a Normally
Open (NO) switch.
Note
18 150kW InfraStruXure System—Installation and Start-Up
Installation Procedures: Connect an Emergency Power Off Switch
3. Test the EPO switch to ensure that it is wired and working correctly:
a. Place the Arm/Test rocker switch in the Test position. The EPO state LEDs will be off and
the PDU display interface will show the following alarm (in addition to any other active
alarms):
Active Alarm xxofxx
EPO Ready To Test
b. Engage the EPO switch. (If your switch is momentary, engage it with one person watching
the EPO state LEDs, and another at the EPO switch.)
c. Observe the EPO LEDs. If the switch is wired and working properly, when the switch is
engaged, both of the EPO state LEDs are red.
d. If the test was successful, place the Arm/Test rocker switch back to the Arm position. The
PDU display interface will clear the EPO test mode alarm. If the test was not successful, see
the following troubleshooting chart.
Problem Action
Neither State LED was red when EPO
switch was engaged.
Only one of the state LEDs was red
when the EPO switch was engaged.
• Check the wiring to your EPO switch.
• Check to make sure the EPO DIP switch
configuration is correct for your switch (NO or
NC). See step 2 on the previous page for proper
configuration instructions.
• Check to make sure that the EPO DIP switch
configuration is correct for your switch (NO or NC)
and test again. See step 2 on the previous page for
proper configuration instructions.
• If the switch is configured correctly and both LEDs
are not red after testing again, contact customer
support at a number on the back cover of this
manual.
e. Repeat this test for each EPO switch installed.
4. Ensure that the Arm/Test rocker switch is in the Arm position on the monitoring unit.
150kW InfraStruXure System—Installation and Start-Up 19
Installation Procedures: Connect an Emergency Power Off Switch
Safety warnings
Hazardous voltage from the branch circuit must be isolated from the 24VAC, 24VDC, and contact
closure terminals. 24VAC and 24VDC 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 60VDC, 250VA, and the current is limited to 1000/Vmax. The fuse is
limited to 5A if less than 20VAC or 20VDC, or 100/Vmaximum if less than 30 VAC 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.
20 150kW InfraStruXure System—Installation and Start-Up
Connect User Input Contacts and Relay Outputs to the User Connection Plate
Overview
Make contact closure connections
(NO or NC) at the user connection
USER INTERFACE
© 2001 APC
plate to monitor dry contacts. You
can make eight connections—four
input contacts and four relay
outputs.
The figure at the right shows the
location of the user connection
plate on the roof of the PDU
enclosure.
You can make connections from
inside the enclosure, or you can
remove the user connection plate
and make your connections.
MADE IN USA
1 234
Contact Inputs
Contact Outputs
– +
EPO 24V
EPO
ATS 1
ATS 0
ATS 2
AC/DC
ATS EN
Contact
Remove the plate using a Phillips
or standard screw driver to loosen
the two captive screws. Use the
knockout in the plate to route
cables to and from the user
connections on the plate. If you
remove the plate, make sure that
you do not disturb the existing
connections.
150kW InfraStruXure System—Installation and Start-Up 21
Installation Procedures: Connect User Input Contacts and Relay Outputs to the User Connection Plate
To connect and monitor your contacts:
1. Choose one or more contact number(s) on the User/EPO contacts port on the user connection
plate to which you will connect the contacts. The user connection plate connects to the PDU
monitoring unit.
2. From the PDU display interface:
a. Press the
b. Select Contacts on the top-level menu screen, and press the
c. Select Contact Inputs and press
d. Select Contact In and press the
ESC or ENTER key to go to the top-level menu screen.
Load-Meter
Volt-Meter
Contacts
Breakers
ENTER to display the contact inputs screen.
>Contact Inputs
>Relay Outputs
>Alarm Relay Map
ENTER key to select the number of the contact you are
Alarms
Panel
Config
Help
ENTER key.
connecting. The continue arrow will appear next to the contact number.
Contact In:01of04
Name: User Contact1
Normal:Open
Status: Closed
e. Press the Up or Down arrow key to select the appropriate contact number, and press the
ENTER key.
f. Press the Down arrow key to enter a unique Name for the contact and to configure the
Normal state of the contact (Open or Closed). The default Normal state is Open. Press the
ENTER key to select the item to configure.
You will be prompted for your password to configure these items.
Note
3. Connect contact wires (300V-rated cabling required) to the terminal block on the user
connection plate. You will need a 2.5-mm standard screwdriver.
4. Run the wires from the terminal block out the roof or under the floor of the PDU to your
contact’s location.
Ensure that the wires are properly retained and away from high
voltage lines and breakers.
Warning
For relay output specifications, see the “Specifications” section in the
InfraStruXure PDU Operation and Configuration manual (990-1984).
See also
22 150kW InfraStruXure System—Installation and Start-Up
Install Shielding Troughs, Shielding Partitions, and Cable Ladders
Shielding Troughs and Shielding Partitions for overhead wiring along rows
If you ordered APC Shielding Troughs, Shielding Partitions, and Cable Ladders to route overhead
wiring for your system, assemble the Shielding Troughs and the Shielding Partitions along the rows
of enclosures and assemble the Cable Ladders between rows.
For information on grounding the Shielding Troughs and Shielding Partitions, see the
instruction sheet (990-1393B) included with the Shielding Troughs and Shielding
See also
Shielding Troughs. There are two types of Shielding Troughs:
• The PDU Shielding Trough, 24 inches (610 millimeters) in length, is not adjustable. The
Partitions.
trough sits on top of the InfraStruXure PDU and accommodates power cables as they exit the
roof of the PDU.
• The NetShelter Shielding Trough is 24 inches (610millimeters) in length and is not adjustable.
The Shielding Troughs have an opening in each side through which you route data cables to
the Shielding Partitions.
Shielding Trough accessories. APC offers the following accessories for Shielding Troughs:
• Shielding Trough Covers for both 24- inch (600-millimeter) wide (AR8174BLK) and 30-inch
(750-millimeter) wide (AR8175BLK) enclosures. Contact APC for more information.
• Shielding Trough End Caps (AR8167BLK) to place on the side of a Shielding Trough at the
end of a row. Contact APC for more information.
150kW InfraStruXure System—Installation and Start-Up 23
Installation Procedures: Install Shielding Troughs, Shielding Partitions, and Cable Ladders
Shielding Partitions. There are two types of Shielding Partitions, each of which forms a side wall
of a trough for data cables. You can customize the width of the trough for each row of your
system — wider for rows carrying many data cables, narrower for rows carrying fewer.
• As the back wall, use a Shielding Partition that
contains an opening for routing data cables.
• As the front wall, use a solid Shielding Partition to
hide data cables for a clean appearance.
Cable Ladders for overhead wiring across rows
After installing the Shielding Troughs and Shielding Partitions, install the Cable Ladders between
rows of enclosures. You can also run Cable Ladders across Shielding Troughs in the same row, using
the hardware provided in the ladder kit.
For more information on installing the Cable Ladders see the instruction sheet included
with the cable ladders (990-1576).
See also
Use wide Cable Ladders 12 inches (305 millimeters) where many power cables or data cables will
run between rows; use narrow Cable Ladders 6 inches (152 millimeters) where few power cables or
data cables will run between rows.
The Cable Ladders are 116 inches (2946 millimeters) long. You can adjust the length of the Cable
Ladders in the following ways:
• Cut the ends with a hacksaw to shorten them.
• Insert the connectors only partially into the side rails to extend them.
Do not change the spacing between rows or the length and position of the Cable
Ladders from the layout you planned with your APC representative when you placed
Note
your order. For overhead wiring, each PDU power cable is provided at a pre-determined
length. Changes to the physical configuration of your system could cause some PDU
power cables to be too short or too long.
24 150kW InfraStruXure System—Installation and Start-Up
Install InfraStruXure Rack-Mount Devices
Install the Rack Automatic Transfer Switches (ATS)
Install a Rack ATS in the top of each enclosure for overhead wiring, and in the bottom of each
enclosure for wiring under the floor.
See the installation instructions in the manual included with your Rack ATS.
See also
The Rack ATS is an optional component and not all InfraStruXure systems will include them.
Install the Rack Power Distribution Units (PDUs)
Install Rack PDUs in the rear of the NetShelterVX enclosure, in the channel directly behind the rear
vertical mounting rails. For overhead wiring, make sure that the power cord is pointing toward the
roof of the enclosure. For under the floor wiring, make sure that the power cord is pointing toward the
floor.
See the installation instructions in the manual included with your Rack PDU.
See also
Install the InfraStruXure Manager and Hub (or Switch)
Install the InfraStruXure Manager in the enclosure closest to the PDU. The Cat-5 data cables
included with your configuration are of varying lengths, based on the distance components will be
installed from the PDU.
See the installation instructions in the manual included with your InfraStruXure
Manager.
See also
Install the Environmental Monitoring Unit or Environmental Management System
The Environmental Monitoring Unit and the Environmental Management System are optional
components and not all InfraStruXure systems will include them.
See also
See the installation instructions in the manual included with the Environmental
Monitoring Unit or Environmental Management System.
150kW InfraStruXure System—Installation and Start-Up 25
Route and Attach Overhead Wiring
Route and attach power cables to equipment racks
If you ordered overhead wiring, connect the prewired power cables of the PDU as follows:
1. Install the Shielding Troughs, Shielding Partitions, and Cable Ladders so that you can route
power cables from the PDU to the NetShelter VX Enclosures.
For installation instructions, see the manual included with your Shielding Troughs,
Shielding Partitions, and Cable Ladders.
See also
2. Find the numbers that indicate the enclosure to which each power cable will supply power.
These numbers appear on the roof of the PDU where the power cables exit, and on the ends of
each power cable.
The enclosures are not numbered. Consult your InfraStruXure Configure-To- Order
(CTO) report to determine the enclosure associated with each power cable.
Note
3. Beginning with the power cables for the enclosures farthest from the PDU, run each power
cable within the Shielding Trough along the row and, if necessary, across one or more Cable
Ladders to the enclosure to which it will provide power.
Ensure that the L21-20 twist-lock connector at the end of each power cable always lies
on top of any longer power cables in the Shielding Trough.
Note
4. Connect the appropriate power cable to APC power management equipment in the enclosure in
one of the four following ways:
– For single-feed devices without redundancy: attach a power cable directly to a Rack PDU
installed in a NetShelter VX Enclosure.
26 150kW InfraStruXure System—Installation and Start-Up
Installation Procedures: Route and Attach Overhead Wiring
– For dual feed devices within a redundant system: attach a power cable from each PDU to two
different Rack PDUs in the NetShelter VX Enclosure.
– For single-feed devices within a redundant system with an Automatic Transfer Switch:
connect a power cable to the Automatic Transfer Switch (A and B feeds) and connect the
Automatic Transfer Switch power cord to a Rack PDU in the NetShelter VX Enclosure.
– For dual-feed devices in a redundant system with an Automatic Transfer Switch: connect a
power cable from each PDU to the Automatic Transfer Switch’s A and B feeds, and another
power cable from one PDU to a Rack PDU, and the Automatic Transfer Switch’s power cord
to a second Rack PDU in the NetShelter VX Enclosure.
Lay the cables neatly in the Shielding Trough to minimize cable build-up.
Note
150kW InfraStruXure System—Installation and Start-Up 27
Installation Procedures: Route and Attach Overhead Wiring
5. From each NetShelter VX Enclosure, run the power cable of the appropriate APC power
management device out the roof of the enclosure, through the notch in the rear side of the
Shielding Trough, to the connector of the appropriate power cable from the PDU. Plug the two
connectors together, and twist them clockwise to lock.
Note
The APC InfraStruXure Build-Out Tool allows you to attach three 20 A, single-pole
breakers to one three-phase power cable if you are powering 120V (L-N) loads.
However, if you are powering 208V (L-L) loads, you must attach a three-phase power
cable to one three-pole 20A breaker.
28 150kW InfraStruXure System—Installation and Start-Up
Wiring Under the Floor
A licensed electrician must route and connect the power cables for under-floor
Electrical
Hazard
Warning
If you are routing power cables to the enclosures under a raised floor, you must provide the
appropriate power cables and equipment for installation, and a licensed electrician must route and
connect the power cables to the PDU circuit breakers. To wire each power cable to an enclosure:
1. Push out a knock-out filler in the floor of the PDU to create an opening for the cable.
2. Install Liquidite waterproof conduit under the floor from each enclosure to the PDU.
3. From the Rack PDU or Rack ATS in each enclosure, thread the appropriate power cable (for
wiring.
Make sure all wire connections and circuit breaker connections are properly
torqued.
your application) from the enclosure through the Liquidite conduit to the PDU.
4. At the PDU, route the cable through the opening you created in step 1and then through the
wireway to connect it to the upper circuit breaker panel.
150kW InfraStruXure System—Installation and Start-Up 29
Installation Procedures: Wiring Under the Floor
5. At the circuit breaker panel, cut the wires to the proper length, and connect the power cable’s
individual wires:
a. If you have branch current monitoring installed, route each phase conductor through a
current sensor. If it is a three-phase cable, route the L1, L2, and L3 wires through a separate
current sensor.
b. Connect the L1, L2, and L3 wires to the circuit breaker(s). The following illustration shows a
three-phase cable connecting to three single-pole breakers; however, you can also connect a
three-phase cable to a three-pole breaker, or a single-phase cable to a single-pole breaker.
c. Connect the neutral wire to the closest open termination point on the Neutral Bar (N).
d. Connect the ground wire to the closest open termination point on the Ground Bar (G).
N
G
The following table provides specific information about connecting to each terminal.
Termina l To rque Tools
L1, L2, L3 150in-lb (17Nm) 6-mm Allen wrench
G 4–6 AWG: 45in-lb (5.0Nm) Slotted screwdriver
GEC 8AWG: 40in-lb(4.5Nm) Slotted screwdriver
Any customer-specified, hard-wired, multi-circuit power cable that is
installed by an electrical contractor must be installed with a circuit breaker
Note
which provides both automatic and manual disconnection of all non-grounded
circuit conductors.
30 150kW InfraStruXure System—Installation and Start-Up
Route Data Cables to the InfraStruXure Manager Hub (or Switch)
1. Connect a Cat-5 network cable (provided) to the network or 10 Base-T ports on your APC
InfraStruXure devices. The following devices need to be connected:
Automatic Transfer Switch
Rack PDU Environmental Monitoring Unit
InfraStruXure PDU
2. Route the connected Cat-5 network cables through the data cable troughs to the InfraStruXure
Manager Hub (or Switch).
3. Connect each device’s network cable to any available station port in the InfraStruXure Manager
Hub (or Switch). Station ports are those with an x after the number (e.g., 2x).
150kW InfraStruXure System—Installation and Start-Up 31
Start-Up Procedure
Safety warnings
This section provides instructions on how to perform a system start-up. Do not skip any steps in this
procedure.
Only APC Field Service Engineers or qualified, APC-trained personnel may
Electrical
Hazard
Electrical
Hazard
Ensure that all power is off
1. Set the PDU Main Input to OFF.
perform a system start-up
Before you proceed, ensure that power is off by following the procedure in this
section.
2. Set the upstream input circuit breaker (utility
or UPS) to the OFF or Locked Out position.
150kW InfraStruXure System—Installation and Start-Up 33
Start-Up Procedure
3. Set the Main Output circuit breaker on the front of the PDU to OFF.
34 150kW InfraStruXure System—Installation and Start-Up
Apply power to the system
1. Set the upstream input circuit breaker (utility or UPS) to ON.
2. Set the Main Input on the PDU to ON.
Start-Up Procedure
3. Verify that the proper voltage is present on the secondary winding of the transformer (208V,
metered phase-to-phase), using a true RMS voltmeter.
150kW InfraStruXure System—Installation and Start-Up 35
Start-Up Procedure
4. Set the Main Output circuit breaker on the PDU to ON.
Note
When the Main Output circuit breaker is closed, the power distribution circuit
breaker panels are energized.
5. Close (turn ON) the PDU distribution panel circuit breakers.
When the distribution panel circuit breakers are closed, the PDU power cables and
connected equipment are energized.
Note
36 150kW InfraStruXure System—Installation and Start-Up
Configure the InfraStruXure Manager
Once all equipment is installed, the network cables are connected to the InfraStruXure Manager Hub
(or Switch), and start-up of the system is complete, configure the InfraStruXure Manager.
For instructions, see the InfraStruXure Manager Installation and Quick-Start
manual included with your InfraStruXure Manager.
See also
If you use PowerChute Network Shutdown (PCNS) software with your
InfraStruXure UPS, your UPS must have a connection to the “User LAN” (public
Note
network) for PCNS to function correctly. If the Network Management Card
installed in your UPS is connected to the InfraStruXure Manager’s “APC LAN,”
you must install a second Network Management Card in your UPS and connect it to
the “User LAN” (public network) to use PCNS.
150kW InfraStruXure System—Installation and Start-Up 37
Appendix A: Operation
How to Apply Power to the System
This procedure instructs on how to apply power to a system that has already been installed. For initial
start-up instructions, see “Start-Up Procedure” on page 33 of this manual.
1. Close (turn ON) the main circuit breaker of
the power source supplying power to the
PDU.
2. Set the Main Input on the PDU to ON.
3. Power the PDU distribution circuit breakers.:
a. Set theMain Output circuit breaker on the
PDU to ON.
After the Main Output breaker has been closed, both PDU distribution panels will be
energized.
Note
150kW InfraStruXure System—Installation and Start-Up 39
Appendix A: Operation
b. Close (turn ON) the PDU distribution
panel circuit breakers.
Note
When the distribution panel circuit breakers are closed, the PDU power cables and
connected equipment are energized.
40 150kW InfraStruXure System—Installation and Start-Up
How to Ensure Total Power Off
1. Open (turn OFF) the main circuit breaker on
the power source feeding the PDU.
2. Set the Main Input on the PDU to OFF.
3. Set the Main Output circuit breaker on the
front of the PDU to OFF.
150kW InfraStruXure System—Installation and Start-Up 41
Index
A
Applying power to the system 33–
34, 37–38
Automatic transfer switches,
installing 25
C
Cable ladders, installing 24
Ceiling clearance 6
Circuit breaker size 2
D
Dimensions
InfraStruXure PDU 5
NetShelter VX enclosure 5
E
Electrical requirements 9
Emergency power off (EPO)
connecting the switch 17–20
overview 10
problems with 19
safety warnings 20
EMI warnings 4
Environmental management
system, installing 25
Environmental monitoring unit,
installing 25
F
Front clearance, minimum value 6
I
InfraStruXure Manager
configuring the 35
installing 25
routing data cables to the 30
InfraStruXure PDU
dimensions 5
electrical requirements 9
heat output 8
level the 13
maximum weight 7
Input conductors
attaching conduit for the 14–15
routing to the main input circuit
breaker 16
Input contacts
connect to the user connection
plate 21–22
Installation 13–30
connect the power source 14–16
connect user input contacts and
relay outputs 21–22
connecting an EPO switch 17–
20
install shielding troughs,
shielding partitions, and cable
ladders 23–24
level the PDU and NetShelter
enclosures 13
overview of basic procedure 11–
12
rack-mount devices 25
route and attach overhead wiring
26–28
warnings for 2
wiring under the floor 29
M
Main input breaker, accessing the 14
Maintenance, warnings 2
Moving the PDU, warnings 2
N
NetShelter VX enclosure
dimensions 5
level the 13
maximum weight 7
O
Operation 37–39
P
Power cables, routing to equipment
racks 26–28
Power source, connecting to the
PDU 14–16
R
Rack PDUs, installing 25
Rear clearance, minimum value 6
Receiving the PDU, warnings 2
Relay outputs
connecting to the user
connection plate 21–22
S
Safety 1–4
during start-up 31
symbols used in this manual 1
Shielding partitions
dimensions 5
installing 24
Shielding troughs
dimensions 5
installing 23
Site planning 5–12
basic installation procedure 11–
12
dimensions 5
electrical requirements 9
Emergency power off (EPO) 10
heat output 8
space considerations 6
weight considerations 7
Start-up procedure 31–34
T
Torque specifications, for wiring 16
Total power off procedure 3, 31–32,
39
150kW InfraStruXure System—Installation and Start-Up 43
U
Updates, to this manual i
W
Warnings 2–4
Wiring, under the floor 29
44 150kW InfraStruXure System—Installation and Start-Up
APC Worldwide Customer Support
Customer support for this or any other APC product is available at no charge in any of the following ways:
• Visit the APC Web site to access documents in the APC Knowledge Base and to submit customer
support requests.
– www.apc.com (Corporate Headquarters)
Connect to localized APC Web sites for specific countries, each of which provides customer
support information.
– www.apc.com/support/
Global support searching APC Knowledge Base and using e-support.
• Contact an APC Customer Support center by telephone or e-mail.
– Regional centers:
Direct InfraStruXure Customer Support Line (1)(877)537-0607 (toll free)
APC headquarters U.S., Canada (1)(800)800-4272 (toll free)
Latin America (1)(401)789-5735 (USA)
Europe, Middle East, Africa
Japan (0) 35434-2021
Australia, New Zealand, South Pacific area (61) (2) 9955 9366 (Australia)
– Local, country-specific centers: go to www.apc.com/support/contact for contact information.
Contact the
information on how to obtain local customer support.
APC representative or other distributor from whom you purchased your APC product for
Entire contents copyright © 2004 American Power Conversion. All rights reserved.
Reproduction in whole or in part without permission is prohibited. APC, the APC logo,
NetShelter, InfraStruXure, and Symmetra are trademarks of American Power Conversion
Corporation and may be registered in some jurisdictions. All other trademarks, product
names, and corporate names are the property of their respective owners and are used for
informational purposes only.
(353)(91)702000 (Ireland)
990-1983 10/2004
*990-1983*
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