Instruction/ maintenance manual of the product 240-320kW 400V American Power Conversion
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APC Silcon 240-320kW 400V UPS Installation Guide Copyright 2000 APC Denmark ApS This manual is subject to change without notice and does not represent a commitment on the part of the vendor.
2 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Thank You! Thank you for chosing the APC Silcon Series UPS. Please read this Installation Guide thoroughly prior to installing the system. It provides important information on safe and efficient installation.
990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 3 Contents 1.0 Introduction 5 1.1 Tools and Equipment 5 2.0 Unpacking 6 3.0 Installation 7 3.1 Requirements on Site 7 3.1.1 Cabinet Dimensions 7 3.2 Footprint 8 3.2.1 1600mm Cabinet for 240-320kW UPS 8 3.
4 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a 6.3 Intersystem Synchronization Unit 56 6.4 Remote Display 57 6.4.1 Extension of Remote Display Communication Distance 57 6.4.2 Remote Display Installation 59 6.4.3 Remote Display Use 60 6.5 Isolation Transformer 61 6.
Introduction 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 5 1.0 Introduction Power regulation varies from country to country, and information given in this installation guide can therefore only be of a general nature. Electricians should therefore always refer to national and local electrical codes prior to installing the UPS system.
6 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Unpacking 2.0 Unpacking 1. To unpack UPS unit, remove top and bottom screws from side plates of packaging and lift up side plates 2. Verify compliance between type label on reverse side of front door and system ordered.
Installation 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 7 3.0 Installation 3.1 Requirements on Site All system parts are accessible from front or top of UPS. Cable entries are accessible from bottom. A 1-metre free space on all sides should be allowed during installation.
8 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Installation 3.2 Footprint 3.2.1 1600mm Cabinet for 240-320kW UPS 3.2.2 825mm Cabinet for Isolation Transformer or Switch Gear 3.2.3 1600mm Cabinet for Isolation Transformer Power cable entry com.
External Connection 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 9 4.0 External Connection 4.1 Connecting the UPS NOTICE! Check correct phase rotation of mains input voltage!! Max. input/output cables: 3//300 mm 2 . If there is no neutral input Dzn0 or Dyn11 input isolation transformer is required.
10 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a External Connection * DIN gL types PVC cables insulated to withstand ambient temperature of max. 30oC ** Must be rated as external PE cable if mains system is not supplying PE CAUTION! At a switch mode load of 100% the neutral must be rated for 200% output phase current.
External Connection 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 11 4.2 System Integration Interface System Integration Interface (SII) is the control link between UPS and system main switches as shown in above diagram. The purpose of the SII is to ensure correct operation of switches without losing system output power.
12 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a External Connection 4.2.1 Connections Blue Brown.
External Connection 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 13 Terminal Blocks: X003/X004 (Anxiliary Contacts) When switching Q001, Q002, Q010, Battery Breaker 1 or Battery Breaker 2 from “ON or 1” to “OFF or 0”, the anxiliary contact has to be open BEFORE the corresponding main contacts are opened.
14 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a External Connection The built-in parallel board connects two or more UPS systems in parallel, either to obtain increased system reliability or to obtain higher output power. The parallel board also ensures correct load-sharing between paralled systems.
External Connection 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 15 External Control Cables External multicore cable is equipped with 15-pin SUB-D plug at either end. Connect pin 1 to pin 1, and pin 2 to pin 2 etc. up to pin 15 - with the exception of pin 8, which is not to be connected.
16 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a External Connection 4.4 Relay Board Relays All relays are “fail safe”: In alarm modes, relay coil will be de-energized. Maximum load: 8.0A – 250VAC Minimum load: 0.05A – 6VAC 1 2 3 0.
External Connection 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 17 4.4.1 Relay Board/Relay Functions NOTICE If alarm mode “ Communication to controller lost ” is active, ALL relays .
18 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a External Connection ## Delay programmable in configuration stack : “ Common fault delay ” .
External Connection 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 19 4.5 Communication Interface Board The 3-port ComInterface is used to establish an interaction between UPS and e.g. a computer system. Main purpose: To ensure a controlled computer shut-down in case of a mains supply failure.
20 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a External Connection 4.6 Connecting of APC Silcon Tripel Chassis The enclosed Triple Chassis must be connected to the serial port on the Communication Interface Board, and to the 24V supply (cables included).
External Connection 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 21 4.7 APC Silcon Triple Chassis The APC Silcon Triple Chassis is an American Power Conversion (APC) external management peripheral that allows you to use monitoring and control management peripherals with your APC Silcon series UPS.
22 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a External Connection 4.7.2.3 LEDs The APC Silcon Triple Chassis status LED provides important information concerning operation of the chassis. Refer to the table below for a description of the conditions indicated by the LED.
External Connection 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 23 4.7.3.1 Order of Management Peripheral Cards Because UPS signals are passed between management peripherals, you must install management peripheral cards in the correct order for them to work together properly.
24 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a External Connection To add card slots, you can daisy-chain the APC Silcon Triple Chassis with the standard Triple Chassis (AP9604) management peripheral, installing the APC Silcon Triple Chassis closer to the UPS.
External Connection 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 25 4.7.5 Troubleshooting The following table shows the solution to common problems with the operation of the Triple Chassis 4.
26 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a External Connection 4) Pack the APC Silcon Triple Chassis carefully in its original packaging, if possible. Do not use polystyrene beads for packing. Damage sustained in transit is not covered under the warranty.
External Connection 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 27 UPS Shut Down RS-232 Input or Advanced Mode RS-232 Data RX In Line Fail RS-232 Output or Advanced Mode RS-232 Data TX .
28 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a External Connection 4.7.6.2 Power, Physical, and Environmental Specifications. Item Specification Power Turn on voltage: > 22 VDC Turn off voltage: < 16 VDC Current draw (normal operation): 90 mADC Current draw (voltage < 16 VDC ): < 1 mADC Physical Size (H xW x D): 1.
External Connection 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 29 4.8 APC Silcon Battery Cabinets Installation and use of this product must comply with all national, federal, state, municipal or local codes.
30 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a External Connection 4.8.0.6 Installation of Batteries See Installation Guide for Battery Cabinet for: • Preparing Batteries and UPS • .
External Connection 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 31 4.9 Battery Breaker Box/Fuse-box Battery Breaker Box/Fuse-box provides overcurrent and short-circuit protection for UPS installations with external batteries. CAUTION! Batteries connected to a UPS out of service for a period exceeding 8 days may be damaged.
32 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a External Connection 4.9.1 Battery Breaker Box UPS Ampere Rating [A] Connection Cable [mm2] Max.
External Connection 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 33 4.9.2 APC Battery Breaker Box Connection Diagram X009 LED signal from UPS “ OK to operate corresponding MCCB ” X01.
34 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a External Connection 4.9.3 UPS with External Battery in Battery Breaker Box/Fuse-box Configuration.
Programming Parameters 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 35 5.0 Programming Parameters Below table shows operating parameters programmable from keyboard.
36 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Programming Parameters 5.1.1 Programming Keys NOTICE! Display accuracy is + 1%, + digit. Scrolls up through list Scrolls down through list.
Programming Parameters 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 37 5.1.2 Programming Example - Switch to Bypass Operation Return to normal operation Follow same procedure to program other parameters. 5.2 System Configuration System configuration parameters are vital for correct system operation and are password- protected.
38 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Programming Parameters System Configuration Parameters (password protected) * Bold text refers to factory standard setting **Advanced Batt.
Programming Parameters 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 39 5.2.1 Programming Example - Change Charge Voltage to 446 NOTICE! Change charge voltages, battery warning limit, shut down voltage and high battery temperature limit by entering the actual value.
40 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Programming Parameters 5.2.2 Programming Example - Change to Output Isolation Transformer available NOTICE! Change parameters by pressing the key once or several times.
Programming Parameters 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 41 5.3 Programming Parameters for Advanced Parallel Operation To use the advanced parallel functions, the following parameters must be programmed: 1. “Station number” 2.
42 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Programming Parameters 5.3.2 Programming example Example with four systems in parallel with separate batteries. • Programme the station addresses 1-4: 1 for UPS 1, 2 for UPS 2, 3 for UPS 3, and 4 for UPS 4.
Options/Accessories 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 43 6.0 Options/Accessories Please contact your local APC representative for information on options/accessories available in your region. See “How to Contact APC” in this guide.
44 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Options/Accessories 6.1.1 Wiring up UPS with SBP in TN-C-S Network 6.1.2 Wiring up UPS with SBP in TN-S Network.
Options/Accessories 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 45 6.1.3 Operating The External Service Bypass Switch Action 1. Press on the ke yboard 2. Press or on the ke yboard until 3. Press on the ke yboard 4. Press on the ke yboard 5.
46 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Options/Accessories 6.1.3.1 Switching from External Bypass to Normal UPS Operation Action 1. T urn the input s witch (Q002) to position ” 0 “ 2. Open the UPS front door and press the green "ON ” key 3.
Options/Accessories 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 47 6.2 Service Bypass Panel for Parallel Redundant Operation Service Bypass Panel (SBP) Mains Supply System Output Contro.
48 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Options/Accessories 6.2.1 Two Parallel Systems with Service Bypass Panel.
Options/Accessories 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 49 6.2.2 Parallel/Redundant Operation with Service Bypass Panel and External Battery via MCCB.
50 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Options/Accessories 6.2.3 Operating External Service Bypass Switch for Parallel Systems 6.2.3.1 Bypassing Parallel UPS Systems CAUTION! Batteries connected to a UPS out of service for a period exceeding 8 days may be damaged.
Options/Accessories 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 51 Step 1-4 can be carried out with any of the parallel systems, ho we ver this will switch all systems into bypass operation. 1. Press on the keyboard 2. Press or on the keyboard until 3.
52 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Options/Accessories 6.2.3.2 Switching Parallel System from External Bypass into Normal UPS Operation H002a.
Options/Accessories 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 53 Action 1. Check that output s witch (Q004) is in position “ 0 ” 2. Check that all output s witches (Q002) are in position “ 0 ” 3. T ur n input switches (Q001) to position “ 1 ” 4.
54 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Options/Accessories 6.2.4 Isolating One UPS for Service/Maintenance In a redundant system, one UPS may be isolated for service/maintenance without affecting other UPSs. 1. Check that remaining UPS(s) is capable of carrying the load in the event that one UPS is isolated 2.
Options/Accessories 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 55 6.2.5 Switching Back to Normal Parallel/Redundant Operation 1. Turn input switch (Q001) and output switch (Q002) to position “ 1 ” 2.
56 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Options/Accessories 6.3 Intersystem Synchronization Unit Intersystem Synchronization Unit System (ISU System) The ISU system consists of inter-connected ISUs. One ISU system may consist of up to 5 ISUs, regardles of ISU configuration.
Options/Accessories 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 57 6.4 Remote Display With the remote display unit data may be displayed at distances of up to 25 m from UPS.
58 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Options/Accessories 6.4.1.1 Connections Without Converter Connect a 25-pin female Sub-D and a 9-pin male Sub-D connector with a 3-wire shielded cable, as shown in the table below. Connect shield at one end only.
Options/Accessories 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 59 6.4.2 Remote Display Installation 6.4.2.1 Connecting RS232C and Mains Adapter 6.4.2.2 Remote Display Power Supply The remote display is supplied by normal AC power with no battery back-up.
60 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Options/Accessories 6.4.3 Remote Display Use The remote display is an inactive unit unable to influence the operation of the UPS: Some of the alarms visible on the internal display are also available on the remote display (See the Alarm section in the APC Silcon User Guide).
Options/Accessories 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 61 6.5 Isolation Transformer UPS Height [mm] Width [mm] Depth [mm] Weight [kg] 240kW 320kW 1800 1800 800 1600 800 800 1240 1470 NOTICE! APC isolation transformers are available in various configuration.
62 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Options/Accessories 6.5.1 Connecting Isolation Transformer *DIN gL types PVC cables insulated to withstand a maximum ambient temperature o.
Options/Accessories 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 63 NOTICE! If an MCCB is used in stead of external input fuses, the MCCB load capacity must be 8xIn (nominal current) for minimum 10 ms. NOTICE! Check correct phase rotation of mains input voltage! Maximum input/output cables: 3//300 mm 2 .
64 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Options/Accessories *DIN gL types PVC cables insulated to withstand a maximum ambient temperature of 30 o C Isolation Transformer External Input Fuses* FM [A] 380-415V External Input Cable [mm2] 380-415V External PE Cable [mm2] External Output Cable [mm2] External Temp.
Options/Accessories 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 65 6.5.2 Wiring up UPS with External Yyn0 Isolation Transformer at Output WARNING! Isolation transformer provides galvanic isolation between mains supply and load.
66 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Options/Accessories 6.5.3 Wiring up UPS with External Yyn0 Isolation Transformer at Input WARNING! Isolation transformer provides galvanic isolation between mains supply and load. Load will loose galvanic isolation if isolation transformer is bypassed.
Options/Accessories 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 67 6.5.4 Wiring up UPS with External Optional Dzn0 Isolation Transformer at Input WARNING! Isolation transformer provides galvanic isolation between mains supply and load. Load will loose galvanic isolation if isolation transformer is bypassed.
68 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Options/Accessories 6.5.5 Wiring up UPS with External Optional Dzn0 Isolation Transformer at Output WARNING! Isolation transformer provides galvanic isolation between mains supply and load.
Options/Accessories 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 69 6.5.6 Wiring up UPS with External Optional Dyn11 Isolation Transformer at Input WARNING! Isolation transformer provides galvanic isolation between mains supply and load.
70 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a System Specifications 7.0 System Specifications 7.1 Technical Data 7.2 Dimensions / Weight Voltage 3x380/400/415V Input Voltage tolerance Normal operation Bypass operation + 15% + 10% (standard) + 4, 6, 8% (programmable) Frequency 50Hz/60Hz + 6 standard + 0.
Warranty 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 71 8.0 Warranty 8.1 APC Silcon Series Limited Factory Warranty APC warrants that the unit, when properly installed and commissioned .
72 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a Appendix 9.0 Appendix 9.1 Table 1. Installation Planning Data Main Input Breaker Field Wiring* Battery Bank** UPS Module Service Bypass Pa.
Appendix 990-4045a Installation Guide APC Silcon 240-320kW 400V UPS 73 Notes: 1. Nominal input current based on rated load. 2. Maximum input current based on rated load + full battery recharge. Full battery recharge assumed to increase input current with 10%.
74 Installation Guide APC Silcon 240-320kW 400V UPS 990-4045a How to Contact APC 10.0 How to Contact APC APC Corporate 132 Fairgrounds Road West Kingston, RI 02892 USA Telephone: +1 401 789-5735 Fax: .
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