Emerson 115-50-60HZ, 15-90KVA, 115-600V, 115-208, 115-480 User Manual
...
AC Power
For Business-Critical Continuity™
Liebert® APM
User Manual–15-90kVA, 120, 208, 480 and 600V, 50/60Hz
™
TABLE OF CONTENTS
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GLOSSARY OF SYMBOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.1 Limited Life Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.1 Battery Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.0 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.1 Initial Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1.1 Storing for Delayed Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.1 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 UPS Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3.1 Positioning the UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3.2 Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 Considerations in Moving the Liebert APM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 Mechanical Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5.1 Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5.2 Floor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5.3 Cable Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5.4 Special Considerations for Paral lel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5.5 Special Considerations for 1+N Parallel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 45kVA and 90kVA UPS Frames—Auxiliary Cabinets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6.1 Optional Cabinets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.7 Optional Seismic Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.8 Liebert FlexPower
2.9 Static Bypass Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
™
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.0 ELECTRICAL CONNECTIONS—UPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.1 Power Cabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1.1 Cable Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 External Protective Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2.1 Rectifier and Bypass Input Supply of the UPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.2 External Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.3 UPS Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.4 UPS Input Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.5 Cabling Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2.6 Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.7 Accessory Fuses and Backfeed Breaker Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.8 Safety Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2.9 Protective Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2.10 Cabling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3 Control Cables Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3.1 Static Bypass Assembly Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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3.4 Dry Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.4.1 Input Dry Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.4.2 Output Dry Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.4.3 Liebert BDC Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.4.4 Battery Cabinet Interface Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.4.5 EPO Input—Optional. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.0 BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.3 UPS Batteries—Liebert
4.4 External Battery Cabinet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.4.1 Matching Battery Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.4.2 Connecting the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.4.3 Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.4.4 Connecting the Battery Cabinet to the UPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.5 Battery Ground Fault Detection Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.6 Non-Standard Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.0 LIEBERT® BDC
™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
5.1 Normal (UPS) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.1.1 Bypass Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2 Maintenance Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.3 Locating the Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.4 Cable Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.4.1 Wiring Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.4.2 Power Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.4.3 Input/Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.5 Bolting Cabinets Together. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
®
APM 45kVA Frame Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.0 INSTALLATION DRAWINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
7.0 OPTION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
7.1 Liebert IntelliSlot Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.2 Liebert IntelliSlot Web Card—SNMP/HTTP Network Interface Card. . . . . . . . . . . . . . . . . 66
7.3 Web Card—Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.4 Relay Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.5 Liebert
®
IntelliSlot™ MultiPort 4 Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.6 Alber BDSi Battery Monitoring System—Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.7 Battery Temperature Compensation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.0 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
8.1 Static Bypass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.2 Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.0 OPERATOR CONTROL AND DISPLAY PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
9.1 Operator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.2 Mimic Display Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9.3 Control Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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9.4 Alarm Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
9.5 LCD Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
9.6 Navigation Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9.7 LCD Menus and Data Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9.8 Language Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9.9 Current Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9.10 UPS History Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
9.11 Types of LCD Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.11.1 Opening Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.11.2 Default Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.11.3 UPS Help Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
9.11.4 Screen Saver Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
9.12 Pop-Up Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
9.12.1 From Bypass to Inverter Mode With Power Interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
9.12.2 From Inverter to Bypass Mode With Interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
9.12.3 System Self-Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
9.12.4 Battery Capacity Test Confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
9.12.5 Battery Self-Test Aborted, Condition Not Met . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
9.12.6 Battery Refresh Charge Aborted, Condition Not Met . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
9.12.7 Enter Control Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
10.0 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
10.1 Liebert® APM™ Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.2 UPS Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.2.1 Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.2.2 Switching Between UPS Operation Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10.3 UPS Battery Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
10.4 Switching the UPS from Normal Operation to Maintenance Bypass. . . . . . . . . . . . . . . . . . 94
10.5 Switching the UPS from Maintenance Bypass to Normal Operation . . . . . . . . . . . . . . . . . . 95
10.6 De-Energize Liebert APM with Maintenance Bypass Cabinet.. . . . . . . . . . . . . . . . . . . . . . . 96
10.7 De-Energize Liebert
10.8 Switching the Liebert
10.8.1 Procedure to Take UPS1 Offline While Leaving UPS2 Online . . . . . . . . . . . . . . . . . . . . . . . . 97
10.8.2 Procedure to Put UPS1 Back Online. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10.8.3 Procedure to Take UPS2 Offline While Leaving UPS1 Online . . . . . . . . . . . . . . . . . . . . . . . . 98
10.8.4 Procedure to Put UPS2 Back Online. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10.9 APM Procedure from Parallel Inverter Operation to Wrap-Around Bypass . . . . . . . . . . . 100
10.10 APM Procedure from Wrap-Around Bypass to Parallel Inverter Operation . . . . . . . . . . . 100
10.11 Emergency Shutdown With EPO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
10.12 Auto Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
10.13 Reset After Shutdown for Emergency Stop (EPO Action) or Other Conditions . . . . . . . . . 101
10.14 Battery Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
10.14.1 Battery Undervoltage Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
10.14.2 Battery End-of-Discharge (EOD) Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
10.15 Replacing Dust Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
®
APM™ Without Maintenance Bypass Cabinet. . . . . . . . . . . . . . . . . . 97
®
APM™ from Parallel to Single UPS Operation . . . . . . . . . . . . . . . . 97
iii
11.0 SPECIFICATIONS AND TECHNICAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
11.1 Conformity and Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
11.2 UPS Environmental. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
11.3 Batteries Approved for Use in Liebert
®
APM™ Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . 105
11.4 UPS Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
12.0 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
12.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
12.2 Routine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
12.2.1 Record Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
12.2.2 Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
12.2.3 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
12.2.4 Battery Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
12.2.5 Torque Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
12.3 Detecting Trouble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
12.4 Reporting a Problem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
12.5 Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
12.6 Recommended Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
APPENDIX A-HAZARDOUS SUBSTANCES OR ELEMENTS ANNOUNCEMENT . . . . . . . . . . . . . . . A116
APPENDIX B-UPS STATUS MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A117
iv
FIGURES
Figure 1 Cabinet arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 2 Liebert FlexPower assembly indicators and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 3 Static bypass assembly connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 4 Single UPS block diagram—dual input single source configuration . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 5 Input busbars—Liebert APM 45kVA frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 6 Input busbars—Liebert APM 90kVA frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 7 Liebert BDC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 8 Busbars—Liebert BDC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 9 Busbars—External 600mm battery cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 10 Busbars—External 900mm battery cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 11 Accessory fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 12 Dual input backfeed breaker wiring when bypass distribution cabinet not used. . . . . . . . . . . . . 26
Figure 13 Ground and neutral busbar connections—45kVA frame busbars . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 14 Ground and neutral busbar connections—90kVA frame busbars . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 15 Static bypass assembly connections to display cabinet and options . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 16 Auxiliary terminal block detail (static switch assembly front panel) . . . . . . . . . . . . . . . . . . . . . . 32
Figure 17 Input dry contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 18 Output dry contacts and EPO wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 19 EPO wiring and signal names for J6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 20 Battery cabinet, 600mm wide—details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 21 Battery trays for 600mm battery cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 22 Battery cabinet with trays for 900mm battery cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 23 Battery cabinet connection to Liebert APM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 24 Wiring of battery ground fault detection set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 25 Single input UPS with external Liebert BDCwith optional internal transformer—typical
configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 26 Liebert BDC—access plate removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 27 BDC connection to Liebert
Figure 28 Bolting Liebert
®
APM™ to a Liebert BDC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 29 UPS dimensions- front view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 30 Lineup arrangement, Liebert APM with battery and Liebert BDCs. . . . . . . . . . . . . . . . . . . . . . . 50
Figure 31 UPS dimensions continued, center of gravity—side, top and bottom views . . . . . . . . . . . . . . . . . 51
Figure 32 Liebert APM with top fan kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 33 UPS main components—typical unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 34 UPS cable connections—45kVA and 90kVA frames. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 35 Battery cabinet connection to UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 36 Battery cabinet connection to UPS (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 37 Battery cabinet outline drawing, weights and center of gravity, 600mm cabinet . . . . . . . . . . . . 60
Figure 38 Battery cabinet outline drawing, weights and center of gravity 900mm cabinet . . . . . . . . . . . . . 61
Figure 39 Outline drawing, Liebert BDC for Liebert
Figure 40 Outline drawing, Liebert BDC for Liebert APM, 15-90kVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 41 Liebert BDC connection to UPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 42 Acceptable hardware configuration for torque application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 43 Seismic mounting bracket details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 44 Liebert IntelliSlot Web card display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 45 Liebert IntelliSlot MultiPort 4 card pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 46 Alber BDSi controller and input connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 47 Multi-temperature sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 48 Single module block diagram—Single input configuration with three-breaker Liebert BDC . . . 72
®
APM™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
®
APM™, 15-45kVA . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
v
Figure 49 Single module block diagram—Dual input configuration with three-breaker Liebert BDC . . . . 73
Figure 50 Block diagram—Single input configuration with four-breaker internal bypass. . . . . . . . . . . . . . 74
Figure 51 Overview of control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 52 Mimic display indicators location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 53 Control button layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 54 Alarm buzzer location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 55 Sections of the LCD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 56 Menu tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Figure 57 Language selection screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 58 Date and time screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 59 History log records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 60 Opening display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 61 Default screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 62 Screen saver window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 63 Battery start button location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 64 Typical configuration for single UPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 65 Liebert APM six-breaker buyout paralleling configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Figure 66 Dust filter replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 67 Battery, circuit breaker and UPS wiring with external batteries with four connecting
wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 68 Battery, circuit breaker and UPS wiring with external batteries with three connecting
wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
vi
TABLES
Table 1 Component service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 2 Battery voltage, nominal and float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table 3 Battery retorque values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table 4 LED indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Table 5 Description of dry contact input port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Table 6 Output dry contact relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table 7 Liebert BDC interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table 8 Battery cabinet interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Table 9 EPO input contact relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table 10 Control wiring for Liebert
Table 11 Control wiring for Liebert APM UPS to Liebert BDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Table 12 Center of gravity and weights for Liebert
Table 13 Center of gravity and weights for Liebert
Table 14 Center of gravity and weights for Liebert APM 45 kVA frame . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Table 15 Center of gravity and weights for Liebert APM 45 kVA frame with top fan option . . . . . . . . . . . 55
Table 16 Interconnect wiring for Liebert
Table 17 Interconnect wiring for Liebert APM to Liebert BDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Table 18 Spring washer torque application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Table 19 Liebert APM communication options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Table 20 Relay Card pin configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Table 21 Relay card jumper configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Table 22 UPS operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Table 23 Descriptions of UPS operator control and display panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Table 24 Mimic display status indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Table 25 Control buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Table 26 Icons for navigation keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Table 27 UPS menus and data window items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Table 28 UPS operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Table 29 Dip switch matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Table 30 Mimic indicators after initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Table 31 Mimic indicators for normal mode operation with battery breaker closed . . . . . . . . . . . . . . . . . . 92
Table 32 Mimic indicators for normal mode operation with battery breaker open . . . . . . . . . . . . . . . . . . . 92
Table 33 Environmental requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Table 34 UPS mechanical characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Table 35 45kVA Liebert BDC mechanical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Table 36 90kVA Liebert BDC mechanical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Table 37 600mm battery cabinet mechanical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Table 38 900mm battery cabinet mechanical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Table 39 Batteries approved for use in External Battery Cabinet, 600mm . . . . . . . . . . . . . . . . . . . . . . . . 105
Table 40 Internal batteries approved for use with 45kVA frame Liebert APM . . . . . . . . . . . . . . . . . . . . . 105
Table 41 UPS currents and terminals—Input (for single-input unit, 208V operation) . . . . . . . . . . . . . . . 106
Table 42 UPS currents and terminals—Input (for dual-input unit only, 208V operation) . . . . . . . . . . . . 106
Table 43 UPS currents and terminals—Bypass input (for dual-input units, 208V operation) . . . . . . . . . 106
Table 44 UPS currents and terminals—Output 208V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Table 45 UPS currents and terminals—Battery (288V string) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Table 46 AC/AC efficiency, loss and air exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Table 47 Rectifier input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Table 48 Battery DC intermediate circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Table 49 Inverter output to critical load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
®
APM™ to battery cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
®
APM™ 90 kVA frame. . . . . . . . . . . . . . . . . . . . . . . . . 53
®
APM 90 kVA frame with top fan option. . . . . . . . . . 54
®
APM™ to battery cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
vii
Table 50 Bypass input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Table 51 Battery voltage record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Table 52 Circuit breakers with compression lugs (for power wiring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Table 53 Terminal block with compression lugs (for control wiring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Table 54 Battery retorque values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Table 55 Recommended test equipment and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Table 56 Hazardous substances or elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Table 57 UPS status messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
viii
IMPORTANT SAFETY INSTRUCTIONS
!
!
SAVE THESE INSTRUCTIONS
This manual contains important instructions that should be followed during installation of the
Liebert
Read this manual thoroughly, paying special attention to the sections that apply to your installation,
before working with the UPS. Retain this manual for use by installing personnel.
A properly trained and qualified electrical contractor should oversee the installation of the
equipment.
The Liebert APM cannot be put into operation until it is commissioned by the manufacturer or
authorized engineer. Otherwise, human safety may be endangered and damage to the UPS will not be
covered by the warranty.
The Liebert APM is designed for commercial and industrial uses and cannot be used as life support
equipment.
®
APM™, Liebert Bypass Distribution Cabinet™ and batteries (where applicable).
WARNING
Risk of moving heavy equipment and electric shock. Can cause equipment damage, injury and
death.
Exercise extreme care when handling UPS cabinets to avoid equipment damage or injury to
personnel. The Liebert APM’s weight ranges from 1100 to 2750 lb. (500 to 1250kg).
Determine unit weight and locate center of gravity symbols before handling the UPS.
Test lift and balance the cabinet before transporting it. Never tilt equipment more
than 15 degrees from vertical.
Battery manufacturers supply details of the necessary precautions to be observed when
working on, or in the vicinity of, a large bank of battery cells. These precautions should be
followed at all times.
Follow all battery safety precautions when installing, charging or servicing batteries. In
addition to the hazard of electric shock, gas produced by batteries can be explosive and
sulfuric acid can cause severe burns. When connected, the nominal battery voltage is 288VDC
and is potentially lethal.
In case of fire involving electrical equipment, use only carbon dioxide fire extinguishers or
those approved for use in fighting electrical fires.
Extreme caution is required when performing maintenance.
Be constantly aware that the UPS system contains high DC as well as AC voltages.
Check for voltage with both AC and DC voltmeters prior to making contact.
WARNING
Risk of moving electric shock. Can cause equipment damage, injury and death.
As with other types of high power equipment, dangerous voltages are present within the UPS
and battery enclosure even after input power has been disconnected. The risk of contact with
these voltages is minimized as the live component parts are housed behind a metal panel.
Further internal safety screens make the equipment protected to IP20 standards. Never
remove panels or covers or open doors that will expose internal components to contact.
Read and follow all warnings, cautions and safety and operating instructions to avoid serious
injury or death from electric shock. No risk exists to any personnel when operating the
equipment in the normal manner, following the recommended operating procedures.
All equipment maintenance and servicing procedures involve internal access and should be
carried out only by trained personnel.
1
Ground Leakage Currents
!
!
CAUTION
Risk of electric shock from high leakage current. Can cause injury, property damage and
death.
EARTH CONNECTION IS ESSENTIAL BEFORE CONNECTING THE INPUT SUPPLY.
Earth leakage current exceeds 3.5 mA and is less than 1000 mA.
Transient and steady-state earth leakage currents, which may occur when starting the
equipment, should be taken into account when selecting instantaneous RCCB or RCD devices.
Residual Current Circuit Breakers (RCCBs) must be selected sensitive to DC unidirectional
pulses (Class A) and insensitive to transient current pulses.
Note also that the earth leakage currents of the load will be carried by this RCCB or RCD.
This equipment must be earthed in accordance with the local electrical code of practice.
WARNING
Risk of electric shock. Can cause injury, property damage and death.
Under typical operation and with all UPS doors closed, only normal safety precautions are
necessary. The area around the UPS system should be kept free of puddles of water, excess
moisture and debris.
Special safety precautions are required for procedures involving handling, installation and
maintenance of the UPS system and the internal batteries (internal batteries accommodated
by 45kVA frame only). Observe all safety precautions in this manual before handling or
installing the UPS system as well as during all maintenance procedures. Observe all battery
safety precautions before working on or near the battery.
This equipment contains several circuits that are energized with high voltage. Only
test equipment designed for troubleshooting should be used. This is particularly true for
oscilloscopes. Always check with AC and DC voltmeters to ensure safety before making
contact or using tools. Even when the power is turned Off, dangerously high electric charges
may exist within the UPS.
All power and control wiring should be installed by a qualified electrician. All power
and control wiring must comply with the NEC and applicable local codes.
ONLY qualified service personnel should perform maintenance on the UPS system.
When performing maintenance with any part of the equipment under power, service
personnel and test equipment should be standing on rubber mats. The service personnel
should wear insulating shoes for isolation from direct contact with the floor (earth ground).
Never work alone, even if all power is removed from the equipment. A second person should
be standing by to assist and summon help in case an accident should occur.
NOTICE
Risk of improper ground connection. Can cause equipment damage.
Ground connection is essential before connecting the input supply. This equipment must be
grounded in accordance with local electrical codes. Maximum load must not exceed that
shown on the UPS rating label.
NOTICE
Risk of improper improper electromagnetic shielding. Can cause radio communication
interference.
This unit complies with the limits for a Class A digital device, pursuant to Part 15 Subpart J
of the FCC rules. These limits provide reasonable protection against harmful interference in a
commercial environment. This unit generates, uses and radiates radio frequency energy and,
if not installed and used in accordance with this instruction manual, may cause harmful
interference to radio communications. This unit is not designed for use in a residential area.
Operation of this unit in a residential area may cause harmful interference that the user is
solely responsible for correcting.
2
Battery Cabinet Precautions
!
!
The following warning applies to all battery cabinets supplied with UPS systems. Additional
warnings and cautions applicable to battery cabinets may be found in 4.0 - Battery Installation.
WARNING
Risk of improper handling. Can cause injury, property damage and death.
Internal battery strapping must be verified by manufacturer prior to moving a battery cabinet
(after initial installation).
• Battery cabinets contain non-spillable batteries.
• Keep units upright.
• Do not stack.
• Do not tilt.
Failure to heed this warning could result in smoke, fire or electric hazard.
Call 1-800-LIEBERT before moving battery cabinets (after initial installation).
Battery Hazards
WARNING
Risk of electric shock. Can cause injury, property damage and death.
Special care should be taken when working with the batteries associated with this equipment.
Batteries are always live. Battery terminal voltage will exceed 300VDC and is potentially
lethal.
In addition to the hazard of electric shock, gas produced by batteries can be explosive and
sulfuric acid can cause severe burns.
Batteries should be installed, serviced and replaced only by properly trained and qualified
service personnel trained in safe battery handling methods and who have the correct PPE
(Personal Protection Equipment) and tools.
The following precautions should be observed when working with the batteries:
• Eye protection should be worn to prevent injury from electrical arcs.
• Remove rings, watches and all other metal objects.
• Use only tools with insulated handles.
• Wear rubber gloves and boots.
• When replacing batteries, replace them with the same type and number of batteries or battery packs.
• Do not dispose of batteries in a fire. The batteries may explode.
• Do not open or mutilate batteries. Releas ed electr olyte i s harmful to the ski n and eyes. It is
toxic.
• Never lay metal objects of any type on top of the batteries.
• Disconnect the charging source before connecting or disconnecting battery terminals.
• Determine whether the battery is grounded. If the battery is grounded, remove source of
the ground. Contact with any part of a grounded battery can result in electrical shock. The
likelihood of such shock can be reduced if such grounds are removed during installation and
maintenance.
If a battery leaks electrolyte, or is otherwise physically damaged, it must be replaced, stored in a
container resistant to sulfuric acid and disposed of in accordance with local regulations.
If electrolyte comes into contact with skin, the affected area should be washed immediately with large
amounts of water.
3
GLOSSARY OF SYMBOLS
!
PbH2SO4
-
+
R
Risk of electrical shock
Indicates caution followed by important instructions
AC input
AC output
i
Requests the user to consult the manual
Indicates the unit contains a valve-regulated lead acid battery
Recycle
DC voltage
AC voltage
Equipment grounding conductor
Bonded to ground
4
1.0 INTRODUCTION
The Liebert® APM™ UPS is a transformer-free, hardware-scalable, online uninterruptible power
system with 208/120V input and 208/120V output capability. The Liebert APM can operate with
either a 50 or 60Hz input and provide a matching output. The rack mounted 15kVA/kW modules
allow scaling the UPS’s capacity in 15kVA increments from 15kVA to a maximum of 90kVA in a
single frame.
Optional transformers are available to add 480V or 600V input capab il it y to the Liebert APM in bo th
the UPS, 90kVA/kW frame only, or the Bypass Distribution Cabinet (BDC) in either the 45kVA/kW or
the 90kVA/kW frame.
The Liebert APM UPS is a SmartAisle™ technology, appropriate for use with the SmartAisle design
approach.
The Liebert APM provides continuous, high-quality AC power to business-critical equipment, such as
telecommunications and data processing equipment. The Liebert APM supplies power free of the
disturbances and variations in voltage and frequ ency common to utility power, which is subject to
brownouts, blackouts, surges and sags.
The Liebert APM utilizes the latest in high-frequency, double-conversion pulse width modulation
(PWM) technology and fully digital controls to enhance its reliability and increase the ease of use.
Two frame sizes are available: 45kVA/kW and 90kVA/kW. The 45kVA/kW frame is designed to accept
internal batteries; the 90kVA/kW frame does not. The 90kVA frame is, however, designed to accept
Internal Transformers and a four-breaker bypass.
Introduction
1.1 Limited Life Components
The Liebert APM UPS has a design life well in excess of 10 years. Well-mai ntained units can continu e
to provide economic benefits for 20 years or more. Long-life components are used in the UPS wherever
practical and cost-effective. However, due to the currently available component material,
manufacturing technology limitations and the general function and use of the component, a few
components in your Liebert UPS will have a shorter life cycle and require replacement in less than 10
years.
The following components utilized in your UPS system have a limited life cycle and are specifically
exempt from warranty. To prevent a wear-out failure of one of these components affecting your
critical load operations, Liebert recommends these components be periodically inspected and replaced
before the expected expiration of their life cycle. The expected life of each component listed below is
simply an estimate and is not a guarantee. Individual users may have site-specific requirements,
maintenance and other environmental conditions that affect the length of the component's useful life
cycle.
Table 1 Component service life
Component Expected Life Replace in:
Air filters 1 to 3 years Check four times per year
Valve-regulated, lead-acid (VRLA) 10 years 6 to 8 years
In most cases, replacement components must exactly match the original component specifications.
These replacement components are not readily available from third-party component distributors.
For assistance with your specific component specifications, replacement component selection and
sourcing, call 1-800-LIEBERT. For customers using Emerson Network Power Liebert Services’
preventive maintenance services, periodic inspection of these components is part of this service, as
well as recommending component replacement intervals to customers to avoid unanticipated
interruptions in critical load operations.
5
1.2 Battery Maintenance
!
!
!
WARNING
Risk of electrical shock and high short circuit current. Can cause equipment damage, personal
injury and death.
These maintenance procedures will expose hazardous live parts. Refer servicing to properly
trained and qualified personnel working in accordance with applicable regulations as well as
with manufacturers’ specifications.
1.2.1 Battery Safety Precautions
Servicing of batteries should be performed or supervised by personnel knowledgeable of batteries and
the required precautions. Keep unauthorized personnel away from batteries.
When replacing batteries, use the same number and type of batteries.
WARNING
Risk of electric shock, explosive reaction, hazardous chemicals and fire. Can cause equipment
damage, personal injury and death.
Lead-acid batteries contain hazardous materials. Batteries must be handled, transported and
recycled or discarded in accordance with federal, state and local regulations. Because lead is a
toxic substance, lead-acid batteries must be recycled rather than discarded.
Do not dispose of battery or batteries in a fire. The battery may explode.
Do not open or mutilate the battery or batteries. Released electrolyte is harmful to the skin
and eyes. It is toxic.
Introduction
WARNING
Risk of electrical shock and high short circuit current. Can cause equipment damage, personal
injury and death.
The following precautions must be observed when working on batteries:
• Remove watches, rings and other metal objects.
• Use tools with insulated handles.
• Wear rubber gloves and boots.
• Do not lay tools or metal parts on top of batteries.
• Disconnect charging source prior to connecting or disconnecting battery terminals.
• Determine whether the battery is grounded. If it is grounded, remove source of ground.
Contact with any part of a grounded battery can result in electrical shock . The likelihood of
such shock will be reduced if such grounds are removed during installation and
maintenance.
Lead-acid batteries can present a risk of fire because they generate hydrogen gas. In addition, the
electrical connections must be protected against accidental short circuits which can cause sparks. The
following procedures should be followed:
• DO NOT SMOKE when near batteries.
• DO NOT cause flame or spark in battery area.
• Discharge static electricity from body before touching batteries by first touching a grounded metal
surface.
• After replacing battery jars in a battery cabinet, replace the retaining straps that hold the jars in
place on the shelves. This will limit accidental movement of the jars and connectors should the
cabinet ever need to be repositioned or relocated.
Regular maintenance of the battery module is an absolute necessity. Periodic inspections of battery
and terminal voltages, specific gravity and connection resistance should be made. Strictly follow the
procedures outlined in the battery manufacturer’s manual, available on the manufacturer’s Web site.
Valve-regulated lead-acid (sealed-cell) batteries do require periodic maintenance. Although
maintenance of electrolyte levels is not required, visual inspections and checks of battery voltage and
connection resistance should be made.
6
Introduction
!
NOTICE
Risk of equipment damage. Batteries should be cleaned with a dry cloth or a cloth lightly
moistened with water. Do not use cleaners on the batteries. Solvents can make the battery
cases brittle.
Because individual battery characteristics are not identical and may change over time, the UPS
module is equipped with circuitry to equalize battery cell voltages. This circuit increases charging
voltage to maintain flooded type battery cells at full capacity.
WARNING
Risk of electric shock, explosive reaction, hazardous chemicals and fire. Can cause equipment
damage, personal injury and death.
Do not use equalize charging with valve-regulated, lead-acid batt eries, such as those in
Liebert Battery Cabinets. Refer to the battery manufacturer’s manual, available on the
manufacturer’s Web site, for specific information about equalize charging.
Matching Battery Cabinets—Optional
Although the individual battery cells are sealed (valve-regulated) and require only minimal
maintenance, the Battery Cabinets should be given a periodic inspection and electrical check. Checks
should be performed at least annually to ensure years of trouble-free service.
Voltage Records: With the Battery Cabinet DC circuit breaker closed and the connected UPS
operating, measure and record battery float voltage. With the DC circuit breaker open, measure and
record the nominal (open circuit) voltage. Both these measurements should be made across the final
positive and negative terminal lugs. Compare these values with those shown below. The recorded
nominal voltage should be no less than the value shown; while the recorded float voltage should be
within the range shown. If a discrepancy is found, contact Liebert
Table 2 Battery voltage, nominal and float
Battery Voltage, VDC
Number of Cells
144 324 316 - 331
Nominal Float
®
Services.
Power Connections: Check for corrosion and connection integrity. Inspect wiring for discolored or
cracked insulation. Clean and/or retighten as required. Refer to torque specifications in Table 3.
Battery Cell Terminals: Check for discoloration, corrosion and connection integrity. Clean and
tighten if necessary. Note that when installing a new battery, the initial torque value is 5 lb.-in. more
than the retorque value. Table 3 shows battery retorque values.
Table 3 Battery retorque values
Battery Mfr. Battery Model # Retorque Value
HX205-FR 65 in-lb
HX300-FR 65 in-lb
HX330-FR 65 in-lb
Enersys
If the system uses a different model battery, contact Liebert
To access battery cell terminals, disconnect the inter-tier cable and two shelf retaining screws. Once
disconnected, insulate (with protective boot or electrical tape) the cables to prevent accidental shorts.
The battery shelf can now be pulled out. Tighten each terminal connection to the retorque value.
When replacing a battery, the terminal connections must be cleaned and tightened. Disconnect and
insulate the cables connected to the battery. Secure each battery shelf with retaining screws when
maintenance is complete.
HX400-FR 65 in-lb
HX500-FR 65 in-lb
HX540-FR 65 in-lb
16HX800F 100 in-lb
16HX925F 100 in-lb
®
Services for the required torque value.
7
Introduction
Other DC Sources
If the UPS system uses a DC source other than a factory-supplied Matching Battery Cabinet, perform
maintenance on the DC source as recommended in the DC source manufacturer’s maintenance
manual, available on the manufacturer’s Web site.
8
2.0 INSTALLATION
!
This section describes the Liebert® APM™’s environmental requirements and mechanical
considerations that must be taken into account when planning the positioning and cabling of the UPS
equipment.
Because each site is unique, this section presents a guide to general procedures and practices that
should be observed by the installing engineer, rather than step-by-step installation instructions.
WARNING
Risk of electric shock. Can cause injury, property damage and death.
Special care should be taken when working with the batteries associated with this equipment.
When connected together, the nominal battery voltage is 288VDC and is potentially lethal.
• Eye protection should be worn to prevent injury from accidental electrical arcs.
• Remove rings, watches and all metal objects.
• Only use tools with insulated handles.
• Wear rubber gloves.
If a battery leaks electrolyte or is otherwise physically damaged, it must be replaced, stored in
a container resistant to sulfuric acid and disposed of in accordance with local regulations.
If electrolyte comes into contact with skin, the affected area should be washed immediately
with large amounts of water.
Installation
NOTICE
Risk of improper installation. Can cause equipment damage.
Do not apply electrical power to the UPS equipment before the commissioning engineer
arrives at the installation site.
The UPS must be installed by a properly trained and qualified engineer in accordance with
the information contained in this chapter. All the equipment not referred to in this manual is
shipped with details of its own mechanical and electrical installation information.
NOTE
Three-phase, four-wire input power is required.
NOTE
Input power must be supplied to the Liebert APM from a properly grounded Wye or Delta
source. The Liebert APM is not for use with impedance grounded systems, corner-grounded
systems or high-leg Delta systems. For these applications, an isolation transformer must be
installed between the input power and the Liebert APM.
9
2.1 Initial Inspections
!
!
1. While the Liebert® APM™ and ancillary cabinets are stil l on the tr uck, inspect the equipment and
shipping container for any signs of damage or mishandling. Do not attempt to install the system if
damage is apparent. If any damage is noted, file a damage claim with the shipping agency
immediately and contact Liebert Services at 1-800-LIEBERT to inform them of the damage claim
and the condition of the equipment.
2. Compare the contents of the shipment with the bill of lading. Report any missing items to the
carrier and your local Emerson representative immediately.
3. Check the product label on the back of front door and confirm the contents match the UPS model,
capacity and main parameters that were ordered.
2.1.1 Storing for Delayed Installat ion
If the equipment will not be installed immediately, it must be stored indoors where the humidity is no
higher than 90% and the temperature is no higher than 104°F (40°C). The storage area must protect
the Liebert APM from excessive moisture (see 11.2 - UPS Environmental).
CAUTION
If the UPS must remain disconnected from power for more than six (6) months, the batteries
(if so equipped) must be recharged before use. To charge the batteries, the unit must be
connected to utility power and started up—the charger operates only while the Liebert APM
is operating.
Installation
CAUTION
When batteries are installed in the UPS or are cabinet-mounted adjacent to the UPS, the
battery—not the UPS—dictates the designed maximum ambient temperature.
2.2 Preliminary Checks
2.2.1 Identification
The equipment supplied has an identification tag on the back of the main door listing the type and
size of the UPS.
2.3 UPS Location
2.3.1 Positioning the UPS
Choose a location for the UPS that offers:
• Easy connection to inputs, outputs and auxiliary equipment
• Enough space to service the UPS
• Air circulation sufficient to expel heat produ ced by UP S
• Protection against moisture and excessive humidity
• Protection against dust and other particulate matter
• Compliance with fire prevention regulations and practices
• Operating environment temperature of 74-80°F (23-27°C) for maximum battery efficiency
10
2.3.2 Environmental Considerations
!
!
Before installing the Liebert® APM™, verify that the UPS room satisfies the environmental conditions
stipulated in 11.2 - UPS Environmental, paying particular attention to the ambient temperature
and air exchange system.
The UPS unit should be installed in a cool, dry, clean-air environment with adequate ventilation to
keep the ambient temperature within the specified operating range 32°F to 104°F (0°C to 40°C).
For optimal UPS and battery system performance and service life, maintain the operating
temperature within the range of 74-80°F, (23-27°C).
The Liebert APM is cooled by internal fans. Cooling air enters the unit through the front of the unit
and is exhausted out the back. To permit proper air flow and prevent overheating, do NOT block or
cover the ventilation openings or blow air down onto the unit. The UPS requires 24 in. (610mm)
ventilation clearance above the unit and 12" (305mm) behind the UPS.
See Table 46 for details on heat dissipation.
Battery Location
Temperature is a major factor in determining battery life and capacity. Battery manufacturers
recommend an operating temperature of 77°F (25°C). Ambient temperatures warmer than this reduce
battery life; temperatures below this reduces battery capacityv. In a typical installation, battery
temperature should be maintained between 74°F and 80°F (23-27°C). Batteries should be placed
where there are no main heat sources or air inlets to prevent portions of batteries from being either
much warmer or much cooler than other parts of the batteries.
Installation
2.4 Considerations in Moving the Liebert APM
Ensure that the UPS weight is within the designated surface weight loading (lb./ft2 or kg/cm2) of any
handling equipment. See Table 34 for weights of various units.
The Liebert APM may be rolled on its casters for short distances only. For longer distances, move the
UPS with a forklift or similar equipment to ease the relocation and to reduce vibration.
The optional battery cabinets should be moved with a forklift or similar equipment.
WARNING
Risk of moving heavy unit. Can cause property damage, injury and death.
Ensure that any equipment that will be used to move the Liebert APM has sufficient lifting
capacity. The Liebert APM’s weight ranges from 1100 to 2750 lb. (500 to 1250kg). See
Table 34 for details.
The UPS presents a tipping hazard. Do not tilt the Liebert APM more than 15 degrees from
vertical.
The UPS is fitted with casters—Take care to prevent movement when unbolting the
equipment from its shipping pallet. Ensure adequate personnel and lifting equipment are
available when taking the Liebert APM off its shipping pallet.
WARNING
Risk of heavy unit tipping over while being moved. Can cause property damage, injury and
death.
The casters are strong enough for movement across even surfaces only. Casters may fail if
they are subjected to shock loading, such as being dropped or rolled over holes in the floor or
obstructions. Such failure may cause the unit to tip over, injuring personnel and damaging
the equipment.
Care must be taken when maneuvering units fitted with batteries. Keep such moves to a
minimum. For further information, see Battery Cabinet Precautions on page 3.
Final Positioning
When the equipment has been finally positioned, ensure that the adjustable stops are set so that the
UPS will remain stationary and stable (see 6.0 - Installation Drawings).
The Liebert APM and its auxiliary cabinets must be installed on a concrete or equivalent, nonresilient floor.
11
2.5 Mechanical Considerations
!
The Liebert® APM™ is constructed with a steel frame and removable panels. Top and side panels are
secured to the chassis by screws. The doors may be opened for access to power connections bars,
auxiliary terminals blocks and power switches.
The UPS comes with an Operator Control Panel that provides basic operational status and alarm
information. The cabinet houses both the power components and the internal batteries. Cooling is
provided by internal fans. The unit sits on four casters. Adjustable stops are provided to prevent the
UPS from moving once it has been moved to its final position.
WARNING
Risk of heavy units tipping over while being moved. Can cause property damage, injury and
death.
The Liebert BDC
Improper lifting may cause the cabinets to fall, causing personal injury or death and
equipment damage.
Emerson recommends lifting the units with one of the following methods:
• Installing four eyebolts in the factory-fabricated holes, one at each corner of the unit,
attaching cables or similar strapping to the eyebolts and lifting with a suitable mechanism.
• Placing suitable straps on the Liebert BDC
the unit to be lifted.
™
and battery cabinets must be properly prepared and secured for lifting.
Installation
™
or battery cabinet. The straps must go under
2.5.1 Clearances
There are no ventilation grilles on the sides of the UPS. The sides must be accessible during
installation. After installation, the unit must have a clearance of 12 in. (305mm) in the rear to permit
adequate circulation of air exhausted from the UPS. The Top Fan option eliminates the 12" (305mm)
rear clearance requirement, but it increases the Liebert APM’s height by 7.63" (194mm).
To enable routine tightening of power terminations within the UPS, make sure there is sufficient
clearance in front of the Liebert APM to permit free passage of personnel with the door fully opened.
Leave a minimum of 24 in. (610mm) between the top of the UPS and the ceiling to permit adequate
air circulation above the unit. Emerson recommends against using air conditioning or other systems
that blow air onto the top of the unit.
2.5.2 Floor Installation
If the Liebert APM, Liebert BDC or battery cabinet is to be placed on a raised floor, the UPS should be
mounted on a pedestal that will support the equipment point loading. Refer to the bottom view in
Figures 31, 37 or 40 to design this pedestal.
2.5.3 Cable Entry
Cables can enter the Liebert APM, Liebert BDC and battery cabinets from the top or bottom through
removable metal plates.
Some plates have factory-punched holes and others are designed to allow the personnel to punch
holes for fitting and securing the conduit. Once the conduit holes are punched, these plates should be
reattached to the UPS. The conduit size and wiring method must be in accordance with all local,
regional and national codes and regulations, including NEC ANSI/NFPA 70.
The UPS must be accessible from the right side to allow personnel to complete the cable connections
and make necessary adjustments. After installation is complete, the Liebert APM may be serviced
from the front.
NOTE
When installing the UPS, the customer must provide a disconnect with overcurrent protection
at the output of the UPS.
12
2.5.4 Special Considerations for Parallel Systems
1. Consider the grounding configuration of the UPS system before finalizing module placement. For
optimal ground performance, the Liebert
Cabling Guidelines.
2. For optimal load-sharing performance, the UPS bypass input cables and output cables should be
approximately the same length, plus or minus 20 percent.
3. Position modules in such a way as to minimize the length of power cables and control wiring
between UPS modules and the paralleling cabinet.
®
APM™ modules should be close together. See 3.2.5 -
2.5.5 Special Considerations for 1+N Parallel Systems
Consider the grounding configuration of the UPS system before finalizing module placement. See
3.2.5 - Cabling Guidelines.
Emerson recommends matching the impedance in the bypass path of paralleled systems as closely as
possible.
The impedance mismatch can be minimized by controlling the wiring length of each unit. The design
and the layout of the UPS system and associated panels and cabling should be examined closely to
ensure that cable lengths and impedances are closely matched. The Liebert 1+N UPS module is
supplied with a sharing reactor to minimize the impact of cable impedance mismatch. The cabling
impedance must be carefully controlled to ensure good bypass current sharing.
For Liebert APM
If the cabling impedances must be greater than 10%, contact your Emerson representative to
calculate whether the system will result in an overload condition when operating on bypass.
™
systems, the cabling impedances must be within 10% from maximum to minimum.
Installation
When bringing the 1+N system online for the first time or after removing one unit, Emerson
recommends checking the bypass current mismatch. To check the bypass current mismatch:
1. Place a load on the bypass of each UPS module.
2. View the output current of each unit.
The accuracy of the currents displayed on the UPS module is sufficient for this check. If the mismatch
is greater than 10%, the bypass impedances must be balanced or the load must be limited to less than
the maximum rating.
2.6 45kVA and 90kVA UPS Frames—Auxiliary Cabinets
The 45kVA frame consists of a single cabinet housing the UPS components and the internal battery
string. The 90kVA frame, also a single cabinet, does not accommodate internal batteries, but does
provide for an internal 4-breaker bypass, or an internal transformer. The internal transformers are
available with either 480V:208V or 600V:208V input primaries.
Optional battery cabinets are available for each Lieber t
Each battery cabinet houses a single string of batteries per cabinet that operate in parallel with the
Liebert APM’s internal batteries (45kVA frame only). The battery cabinets are designed to be bolted
to the left side of the UPS (see Figure 1). Refer to 4.4 - External Battery Cabinet Installation for
details.
Optional Liebert BDC
™
units are available. These cabinets house the components necessary to
provide an external wraparound maintenance bypass switch for servicing the UPS.
Liebert BDCs are designed to be bolted to the right side of the UPS (see Figure 1). Refer to 5.3 -
Locating the Cabinet for further details.
®
APM™ model to provide extended run time.
System Composition
A UPS system can comprise a number of equipment cabinets, depending on the system design
requirements—e.g., UPS cabinet, External Battery Cabi net and External Bypass Cabinet. In general,
all cabinets used will be the same height and are designed to be positioned side-by-side to form an
aesthetically appealing equipment suite.
13
2.6.1 Optional Cabinets
Liebert
APM
Bypass
Distribution
Cabinet
Bypass
Distribution
Cabinet
Liebert
APM
Battery
Cabinet
Battery
Cabinet
Liebert
APM
Battery
Cabinet
Liebert APM connected only to Liebert BDC
(BDC must be on right side of the Liebert APM)
Liebert APM connected to Liebert BDC and Battery Cabinets
(BDC must be on right side of the Liebert APM)
(Battery Cabinets must be on the left side of the Liebert APM)
ALL UNITS VIEWED FROM ABOVE
Liebert APM connected to Battery Cabinet (Battery Cabinets
must be on the left side of the Liebert APM)
Run LED
Battery Start
Button
Ready Switch
Fault LED
DIP Switches
If the Liebert APM installation includes a Liebert BDC, the UPS must be positioned to allow the
Liebert BDC to be bolted to right side of the Liebert APM (see Figure 1).
The Liebert BDC must be cabled and bolted to the Liebert APM before the UPS and bypass cabinet
are moved into their final position. Connect the input wiring to the Liebert BDC ONLY after the units
are connected and positioned.
Battery cabinets may be bolted only to the left side of the Liebert APM; see Figure 1.
Figure 1 Cabinet arrangement
Installation
2.7 Optional Seismic Brackets
Optional seismic mounting brackets to anchor the Liebert® APM™, Liebert BDC™ and battery cabinet
to the floor are available. Refer to Figure 43 for mounting details.
2.8 Liebert FlexPower™ Assembly
Figure 2 Liebert FlexPower assembly indicators and controls
The Battery start button allows starting of UPS on battery; refer to 10.3 - UPS Battery Start.
The Run LED is illuminated Green when the Liebert FlexPower assembly is operating normally.
14
The Fault LED will illuminate red when the Liebert FlexPower assembly has a problem.
J10
J7J5
J6J8J9
RS-232
Liebert IntelliSlot
Bays 1, 2, 3
RS-485
J4
J11
J12
Monitor
Table 4 LED indications
LED Status Indication
Run LED (Green)
Flashing Green The inverter is starting, but has no output yet.
Constant Green The inverter has started to supply power.
OFF The inverter has not started up.
Fault LED (Red)
Auxiliary power failure (15V or 24V), rectifier overtemperature, rectifier failure (including battery
SCR short circuit), battery converter failure, soft start failure, main circuit back feed, abnormal
Constant Red
Flashing Red
OFF No above failures or alarms.
input current, inverter failure, output short circuit, bypass SCR short circuit fault, inverter relay
short circuit fault, abnormal bus voltage under non-sleep mode, module not ready, module ID
out of range and duplicated module ID.
Charger failure, abnormal main circuit voltage, abnormal main circuit frequency, main circuit
undervoltage, main circuit reverse phase, battery unavailable, reverse battery, input zero-loss,
current sharing failure, module overload, inverter relay disconnection fault, bypass SCR
disconnection fault and input fuse blown.
2.9 Static Bypass Assembly
Figure 3 Static bypass assembly connections
Installation
The Static bypass assembly has three Liebert IntelliSlot interface card bays and connections for
ancillary cabinets (Liebert BDC and battery) and for options.
15
3.0 ELECTRICAL CONNECTIONS—UPS
!
The UPS requires both power and control cabling once it has been mechanically installed. All control
cables must run separate from power cables in metal conduits or metal ducts that are electrically
bonded to the metalwork of the cabinets to which they are connected.
WARNING
Risk of electric shock. Can cause property damage, injury and death.
Before connecting input power to the Liebert
location and operation of the overcurrent protection devices that connect the UPS
input/bypass supply to the power distribution panel.
De-energize and lockout or tagout all incoming high- and low-voltage power circuits before
installing cables or making any electrical connections.
3.1 Power Cabling
3.1.1 Cable Rating
The main factors affecting the choice and size of cable are voltage, current (also taking into account
overcurrent), room temperature and conditions of installation of the cable. Refer to ANSI/NFPA 70.
The power cables of the system must be sized with respect to the following description:
Electrical Connections—UPS
®
APM™, ensure that you are aware of the
• UPS input cables - The UPS input cables must be sized for the maximum input current, including the maximum battery recharge current, given in Table 41, with respect to the unit rating and
the input AC voltage.
• UPS bypass and output cables - The bypass and output cables must be sized for the nominal
output current, given in Table 41, with respect to the unit rating and the output AC voltage.
• Battery cables - Each UPS unit has its own internal batteries factory-wired. If connecting an
external battery cabinet, the battery cables must be sized for the battery discharge current at the
end-of-discharge voltage, as given in Table 41, with respect to the unit rating.
NOTE
Table 41 gives nominal currents for determining the size of UPS power cables. Other
important factors to consider include cable route length and coordination with protective
devices.
The power cables can be sized to suit the UPS unit rating according to Table 41.
Lug Size and Torque Requirements
Refer to Table 41 for lug size and torque requirements and to Table 18 and Figure 42.
3.2 External Protective Devices
For safety concerns, it is necessary to install external circuit breakers or other protective devices for
the input AC supply of the UPS system. This section provides generic practical information for
qualified installation engineers. The installation engineers should be knowledgeable about regulatory
wiring standards and the equipment to be installed.
To reduce the risk of fire, connect only to a circuit provided with branch circuit overcurrent protection
in accordance with NEC ANSI/NFPA 70.
16
3.2.1 Rectifier and Bypass Input Supply of the UPS Overcurrents
Install suitable protective devices in the distribution unit of the incoming mains supply, considering
the power cable current-carrying capacity and overload capacity of the system. Generally, the
magnetic circuit breaker with IEC60947-2 tripping curve C (normal) at the 125% of the nominal
current listed in Table 41 is recommended.
Split bypass: In case a split bypass is used, separate protective devices should be installed for the
rectifier input and bypass input in the incoming mains distribution panel.
NOTE
The rectifier input and bypass input must use the same neutral line.
For an IT power network system, a 4-pole protective device must be installed on the external
input distribution and external output distribution of the UPS.
Earth Leakage, RCD Devices
Any residual current detector (RCD) installed upstream of the UPS input supply:
• Must be sensitive to DC unidirectional pulses (Class A)
• Must be insensitive to transient current pulses, and
• Must have an average sensitivity, adjustable between 0.3 and 1A.
To avoid false alarms, earth leakage moni toring devices when used in systems with split bypass input
or when used in paralleled UPS configurations, must be located upstream of the common neutral
sinking point. Alternatively, the device must monitor the combined four-wire rectifier and split
bypass input currents.
Electrical Connections—UPS
The residual earth current introduced by the RFI suppression filter inside the UPS is greater than
3.5mA and less than 300mA. Liebert recommends verifying the selectivity with all other differential
devices both upstream of the input distribution board and downstream (toward the load).
3.2.2 External Battery
The DC-compatible circuit breaker provides overcurrent protection for UPS system and battery,
which is provided by the external battery cabinet.
3.2.3 UPS Output
If an external distribution panel is used for load distribution, the selection of protective devices must
provide discrimination with those that are used at the input to the UPS (see Table 47).
17
3.2.4 UPS Input Configuration
NOTES
1. Install in accordance with national and local electrical codes.
2. Input and bypass must share the same single source.
3. A neutral is required from the systemAC input source. A full
capacity neutral conductor is recommended. Grounding
conductors are recommended.
4. Bypass and rectifier inputs and output cables must be run
in separate conduits.
5. Control wiring must be run in separate conduits.
6. Optional 54-pole, 225A for 45kVA frame only or optional 54-pole,
400A for 90kVA frame only.
7. Customer must supply shunt trip breaker with 120V coil.
BIB - Bypass Isolation Breaker
MBB - Maintenance Bypass Breaker
MIB - Maintenance Isolation Breaker
* External Overcurrent Protection
by others
Field-Supplied Wiring
UAM01023
Rev. 3
Bypass Distribution Cabinet
* Bypass
AC Input
4-Wire + GND
* Rectifier
AC Input
4-Wire + GND
See Note 7
BIB
MBB
MIB
Static Bypass
UPS Cabinet
Battery
Optional
54-Pole
See Note 6
AC Output
208V
4-Wire + GND
By default, the Liebert® APM™ ships with internal links installed between the bypass i nput and main
(rectifier) input (single input configuration see Figure 48).
Figure 4 shows the Liebert APM in a split bypass (single source dual-input) configuration. In this
configuration, the static bypass and the maintenance bypass l ines are supplied by the same source
using separate feeds. Both feeds must be protected externally with properly sized protective devices.
To wire the Liebert APM as a single source dual-input UPS, remove the links and wire the bypass
feed to the bypass busbars, then wire the main feed to the main busbars (see Figure 6).
Figure 4 Single UPS block diagram—dual input single source configuration
Electrical Connections—UPS
18
3.2.5 Cabling Guidelines
The following are guidelines only and are superseded by local regulations and codes of practice where
applicable. Use wiring rated at 75°C or greater.
1. Take special care when determining the size of the neutral cable, as current circulating on the
neutral cable may be greater than nominal current in the case of non-linear loads. Refer to the
values in 11.4 - UPS Electrical Characteristics.
2. The ground conductor should be sized according to such factors as the fault rating, cable lengths
and type of protection. The ground cable connecting the UPS to the main ground system must
follow the most direct route possible. Control wiring and power wiring must be run in separate
conduit. Output and input cables must be run in separate conduit.
3. Consider using paralleled smaller cables for heavy currents—this can ease installation.
4. When sizing battery cables, a maximum voltage drop of 4VDC is permissible at the current
ratings in Table 43. For terminal connection sizing, see Tables 41 through 43.
5. In most installations, the load equipment is connected to a distribution network of individually
protected busbars fed by the UPS output, rather than connected directly to the UPS itself. When
this is the case, the UPS output cables can be rated to suit the individual distribution network
demands rather than being fully load-rated.
NOTE
If more load is added to the distribution panel, the unit’s cabling must be resized.
6. When laying power cables, do not form coils; this will help avoid increasing formatio n of
electromagnetic interference.
Electrical Connections—UPS
NOTE
Right-side access may be required when making power connections. Cable connections should
®
be made before a cabinet is attached to the right side of the Liebert
APM™ or before the UPS is
placed where another obstruction, such as a wall, is against the Liebert APM’s the right side.
19
3.2.6 Cable Connections
The rectifier input, bypass output and battery are easily accessible from the right side of the unit for
installation. All require lug type terminations. They are connected to busbars on the right side of the
Liebert
is removed.
®
APM™, as shown in Figures 5 and 6. These busbars are accessible when the right side panel
NOTICE
Risk of improper installation. Can cause equipment damage.
When wiring a single-input only system, connect only the power wiring to the input busbars.
Figure 5 Input busbars—Liebert APM 45kVA frame
Electrical Connections—UPS
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