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American Power Conversion 480kW 400V manuel d'utilisation

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  • Page 1

    APC Silcon 480kW 400V UPS Installation Guide Copyright 2001 APC Japan Inc This manual is subject to change without notice and does not represent a commitment on the part of the vendor[...]

  • Page 2

    2 Installation Guide APC Silcon 480kW 400V UPS 990-4059 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. The installation and use of this product must comply with national, federal, state, m[...]

  • Page 3

    Introduction 990-4059 Installation Guide APC Silcon 480kW 400V UPS 3 1.0 Introduction Power regulation varies from area to area, 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. 1.1 Tools a[...]

  • Page 4

    4 Installation Guide APC Silcon 480kW 400V UPS 990-4059 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. Check input and output voltage 3. Copy type label data to label copy below[...]

  • Page 5

    Installation 990-4059 Installation Guide APC Silcon 480kW 400V UPS 5 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. After installation of the UPS, leave a free space of 600 mm to the[...]

  • Page 6

    6 Installation Guide APC Silcon 480kW 400V UPS 990-4059 Installation 3.2 Footprint 3.2.1 1900mm Cabinet for 480kW UPS 3.2.2 1600mm Cabinet for 480kW Isolation Transformer Rear Front Com. cable entry Power cable entry Rear Power cable entry Front ?[...]

  • Page 7

    External Connection 990-4059 Installation Guide APC Silcon 480kW 400V UPS 7 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. CAUTION! This UPS unit is an EN 50091-2 p[...]

  • Page 8

    8 Installation Guide APC Silcon 480kW 400V UPS 990-4059 External Connection PVC cables insulated to withstand ambient temperature of max. 30°C ** Must be rated as external PE cable if mains system is not supplying PE 4.2 System Integration Interface UPS External Input Fuses* FM [A] 380-415V External Input Cable [mm2] 380-415V External PE Cable [mm[...]

  • Page 9

    External Connection 990-4059 Installation Guide APC Silcon 480kW 400V UPS 9 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. Auxiliary contacts on the main switches transmit the [...]

  • Page 10

    10 Installation Guide APC Silcon 480kW 400V UPS 990-4059 External Connection 4.2.1 Connections Blue Brown[...]

  • Page 11

    External Connection 990-4059 Installation Guide APC Silcon 480kW 400V UPS 11 Terminal Blocks: X003/X004 (Anxiliary Contacts) When switching Q001, Q002, 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. When switching Q001, Q002, Batter[...]

  • Page 12

    12 Installation Guide APC Silcon 480kW 400V UPS 990-4059 External Connection 4.3 Parallel Board 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. To prepare the UPS fo[...]

  • Page 13

    External Connection 990-4059 Installation Guide APC Silcon 480kW 400V UPS 13 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. Shield is connected to plug cover at both ends. Term[...]

  • Page 14

    14 Installation Guide APC Silcon 480kW 400V UPS 990-4059 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 0.3A – 60VDC 0.05A – 6VDC[...]

  • Page 15

    External Connection 990-4059 Installation Guide APC Silcon 480kW 400V UPS 15 4.4.1 Relay Board/Relay Functions ## Delay programmable in configuration stack : “ Common fault delay ” . Settings 0,10,20,30 seconds. NOTICE If alarm mode “ Communication to controller lost ” is active, ALL relays will indicate failure Relay Number Message Alarm-t[...]

  • Page 16

    16 Installation Guide APC Silcon 480kW 400V UPS 990-4059 External Connection See section 5.2: System configuration NOTICE! Alarm Trigging Events 1-2-3-9-10-11-13 activates the corresponding alarm relay after the delay. Alarm Trigging Events 4-5-6-7-8-12-14-15 activates the corresponding alarm relay momentarily. Common fault relay 16 is activated at[...]

  • Page 17

    External Connection 990-4059 Installation Guide APC Silcon 480kW 400V UPS 17 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. 4.5.1 Connections . .[...]

  • Page 18

    18 Installation Guide APC Silcon 480kW 400V UPS 990-4059 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). Terminal locations shown below. For more information please refer to the following se[...]

  • Page 19

    External Connection 990-4059 Installation Guide APC Silcon 480kW 400V UPS 19 4.7 APC Silcon Triple Chassis The APC Silcon Triple Chassis (AP9604S) 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. The retrofit model (AP9604SR) is[...]

  • Page 20

    20 Installation Guide APC Silcon 480kW 400V UPS 990-4059 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. 4.7.2.4 Optional Power Input With the Optional Power input, you can [...]

  • Page 21

    External Connection 990-4059 Installation Guide APC Silcon 480kW 400V UPS 21 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. The card slots are numbered 1 to 3, from left to right, as view[...]

  • Page 22

    22 Installation Guide APC Silcon 480kW 400V UPS 990-4059 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. 4.7.4 Powering the APC Silcon Triple Chassis The APC Silcon Triple Chassis supp[...]

  • Page 23

    External Connection 990-4059 Installation Guide APC Silcon 480kW 400V UPS 23 4.7.5 Troubleshooting The following table shows the solution to common problems with the operation of the Triple Chassis 4.7.5.1 If Problems Persist For problems not covered in the troubleshooting chart or for persistent problems, follow this procedure: 1) Note the serial [...]

  • Page 24

    24 Installation Guide APC Silcon 480kW 400V UPS 990-4059 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. Enclose a letter in the package with your name, address, RMA number, a copy of t[...]

  • Page 25

    External Connection 990-4059 Installation Guide APC Silcon 480kW 400V UPS 25 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 Out Unregulated +24 VDC Output Normally Open Line Fail Signal Normally Open Low Battery Signal Normally Closed Line Fail Signal Common Chassis[...]

  • Page 26

    26 Installation Guide APC Silcon 480kW 400V UPS 990-4059 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): 44 x 432 x 127[...]

  • Page 27

    External Connection 990-4059 Installation Guide APC Silcon 480kW 400V UPS 27 4.8 APC Silcon Battery Cabinets Installation and use of this product must comply with all national, federal, state, municipal or local codes. If you need assistance, please have your UPS model and serial number ready and call APC, see “How to Contact APC” in this guide[...]

  • Page 28

    28 Installation Guide APC Silcon 480kW 400V UPS 990-4059 External Connection 4.8.0.6 Installation of Batteries See Installation Guide for Battery Cabinet for: • Preparing Batteries and UPS • Dimensions and Weight • Connecting Batteries 4.9 Battery Breaker Box/Fuse-box Battery Breaker Box/Fuse-box provides overcurrent and short-circuit protect[...]

  • Page 29

    External Connection 990-4059 Installation Guide APC Silcon 480kW 400V UPS 29 4.9.1 Battery Breaker Box Battery Breaker Box/ Fuse-box Battery APC Silcon UPS ?[...]

  • Page 30

    30 Installation Guide APC Silcon 480kW 400V UPS 990-4059 External Connection 4.9.2 APC Battery Breaker Box Connection Diagram (120-480kW) X009 LED signal from UPS “ OK to operate corresponding MCCB ” X010 MCCB position signals for UPS X011 Trip for emergency stop (220-240V AC) 4.9.3 UPS with External Battery in Battery Breaker Box/Fuse-box Conf[...]

  • Page 31

    External Connection 990-4059 Installation Guide APC Silcon 480kW 400V UPS 31 ?[...]

  • Page 32

    32 Installation Guide APC Silcon 480kW 400V UPS 990-4059 Programming Parameters 5.0 Programming Parameters Below table shows operating parameters programmable from keyboard. Only qualified users should re-set programming parameters. 5.1 Parameters * Factory settings in bold ** Only for systems with Battery Monitor active *** Do not leave system run[...]

  • Page 33

    Programming Parameters 990-4059 Installation Guide APC Silcon 480kW 400V UPS 33 5.1.1 Programming Keys NOTICE! Display accuracy is + 1%, + digit. Scrolls up through list Scrolls down through list Stores parameters/ enter parameter stack Silences the audible alarm Chooses parameters Displays time Exits a mode Accesses alarm stack[...]

  • Page 34

    34 Installation Guide APC Silcon 480kW 400V UPS 990-4059 Programming Parameters 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. NOTICE! Do n[...]

  • Page 35

    Programming Parameters 990-4059 Installation Guide APC Silcon 480kW 400V UPS 35 System Configuration Parameters (password protected) * Bold text refers to factory standard setting **Advanced Battery Monitor Parameter Setting* Comments Enter System no. Voltage L-L 380, 400 , 415 Optional selection of voltage System Frequency 50 /60 Optional selectio[...]

  • Page 36

    36 Installation Guide APC Silcon 480kW 400V UPS 990-4059 Programming Parameters *** If voltage or frequency settings is changed, unit needs to be powered down for the new settings to take effect. 5.2.1 Programming Example - Change Charge Voltage to 446 NOTICE! Change charge voltages, battery warning limit, shut down voltage and high battery tempera[...]

  • Page 37

    Programming Parameters 990-4059 Installation Guide APC Silcon 480kW 400V UPS 37 5.2.2 Programming Example - Change to Output Isolation Transformer available NOTICE! Change parameters by pressing the key once or several times. See example above.[...]

  • Page 38

    38 Installation Guide APC Silcon 480kW 400V UPS 990-4059 Programming Parameters 5.3 Programming Parameters for Advanced Parallel Operation To use the advanced parallel functions, the following parameters must be programmed: 1. “Station number” 2. “Highest station address” 3. “Advanced power management” 4. “APM test mode active” 5. ?[...]

  • Page 39

    Programming Parameters 990-4059 Installation Guide APC Silcon 480kW 400V UPS 39 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. • All UPS systems have to be programmed to “Highest station address”:4. • If[...]

  • Page 40

    40 Installation Guide APC Silcon 480kW 400V UPS 990-4059 Programming Parameters 5.4.1 Installation of new batteries To avoid false alarms, the above procedure MUST be followed. NOTICE! Contact your local dealer if you have any questions regarding changing parameters.[...]

  • Page 41

    Options/Accessories 990-4059 Installation Guide APC Silcon 480kW 400V UPS 41 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. 6.1 Service Bypass Panel for Single Operation UPS Exter-nal System Input Fuse [A] Max. Prospec-[...]

  • Page 42

    42 Installation Guide APC Silcon 480kW 400V UPS 990-4059 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 ? ?[...]

  • Page 43

    Options/Accessories 990-4059 Installation Guide APC Silcon 480kW 400V UPS 43 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. Check lamp indication on the Service Bypass Panel 6. T ur n the e xter nal bypass s witch (Q003) to[...]

  • Page 44

    44 Installation Guide APC Silcon 480kW 400V UPS 990-4059 Options/Accessories 6.1.3.1 Switching from External Bypass to Normal UPS Operation ** System OFF ** Normal operation load power % Display sho ws Lamp indication on Servive Bypass Panel The Green lamp (H002) abov e the output switch handle (Q002) lights Now also the green lamp (H003) abov e th[...]

  • Page 45

    Options/Accessories 990-4059 Installation Guide APC Silcon 480kW 400V UPS 45 6.2 Service Bypass Panel for Parallel Redundant Operation Service Bypass Panel (SBP) Mains Supply System Output Control cables Q003 Q004 Q001b Q001a Q002b Q002a APC Silcon 400V UPS X020 X021 X020 X021 APC Silcon 400V UPS Battery Battery Breaker/ Fuse Box[...]

  • Page 46

    46 Installation Guide APC Silcon 480kW 400V UPS 990-4059 Options/Accessories 6.2.1 Two Parallel Systems with Service Bypass Panel ?[...]

  • Page 47

    Options/Accessories 990-4059 Installation Guide APC Silcon 480kW 400V UPS 47 6.2.2 Parallel/Redundant Operation with Service Bypass Panel and External Battery via MCCB ?[...]

  • Page 48

    48 Installation Guide APC Silcon 480kW 400V UPS 990-4059 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. H002a[...]

  • Page 49

    Options/Accessories 990-4059 Installation Guide APC Silcon 480kW 400V UPS 49 Step 1-4 can be carried out with any of the parallel systems, ho wever this will s witch all systems into bypass operation. 1. Press on the keyboard 2. Press or on the keyboard until 3. Press on the keyboard 4. Press on the keyboard All systems will transf er to bypass ope[...]

  • Page 50

    50 Installation Guide APC Silcon 480kW 400V UPS 990-4059 Options/Accessories 6.2.3.2 Switching Parallel System from External Bypass into Normal UPS Operation H002a[...]

  • Page 51

    Options/Accessories 990-4059 Installation Guide APC Silcon 480kW 400V UPS 51 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. Open the UPS front door and press the green “ ON ” push-botton 5. Press on t[...]

  • Page 52

    52 Installation Guide APC Silcon 480kW 400V UPS 990-4059 Options/Accessories The follo wing can be carried out on any UPS 13. Press on the ke yboard 14 Press or on the ke yboard until 15. Press on the ke yboard 16. Press on the ke yboard All the systems will transf er to nor mal operation. Normal operation load power xx% Display sho ws Bypass opera[...]

  • Page 53

    Options/Accessories 990-4059 Installation Guide APC Silcon 480kW 400V UPS 53 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. Switch off system to[...]

  • Page 54

    54 Installation Guide APC Silcon 480kW 400V UPS 990-4059 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. The ISU system synchronizes the voltage of parallel operat[...]

  • Page 55

    Options/Accessories 990-4059 Installation Guide APC Silcon 480kW 400V UPS 55 6.5 Remote Display With the remote display unit data may be displayed at distances of up to 25 m from UPS. For extended communication distance, see section below. Remote display may easily be connected to UPS via one of the two serial communication ports on the communicati[...]

  • Page 56

    56 Installation Guide APC Silcon 480kW 400V UPS 990-4059 Options/Accessories Remote Display. The converter provides optical signal insulation. Both converter boxes must be supplied by an uninterruptible power source. 6.5.1.1 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[...]

  • Page 57

    Options/Accessories 990-4059 Installation Guide APC Silcon 480kW 400V UPS 57 6.5.2 Remote Display Installation 6.5.2.1 Connecting RS232C and Mains Adapter 6.5.2.2 Remote Display Power Supply The remote display is supplied by normal AC power with no battery back-up. For UPS data transmission to remote display to remain unaffected during power failur[...]

  • Page 58

    58 Installation Guide APC Silcon 480kW 400V UPS 990-4059 Options/Accessories 6.5.3 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). 6.5.3.1 Initiatin[...]

  • Page 59

    Options/Accessories 990-4059 Installation Guide APC Silcon 480kW 400V UPS 59 6.6 Isolation Transformer Isolation Transformer UPS Height [mm]* Width [mm]* Depth [mm]* Weight [kg] 540kVA 480kW 1800 1400 800 2550 *Actual dimensions may vary 1600 mm wide 1800mm ? APC Isolation Transformer Module 480kW[...]

  • Page 60

    60 Installation Guide APC Silcon 480kW 400V UPS 990-4059 Options/Accessories Example of Transformer Configuration (Yyno) NOTICE! APC isolation transformers are available in various configuration. Contact your local APC representative for further information. See “ How to Contact APC ” in this guide. Input Output E G G[...]

  • Page 61

    Options/Accessories 990-4059 Installation Guide APC Silcon 480kW 400V UPS 61 6.6.1 Connecting Isolation Transformer *DIN gL types PVC cables insulated to withstand a maximum ambient temperature of 30 ° C Isolation Transformer UPS External Input Fuses* FM [A] 380-415V External Input Cable [mm 2 ] 380-415V External PE Cable [mm 2 ] External Output C[...]

  • Page 62

    62 Installation Guide APC Silcon 480kW 400V UPS 990-4059 Options/Accessories NOTICE! Make sure that gland plate is installed in bottom of cabinet. CAUTION! At 100% switch mode load, neutral must be rated for 200% phase current.[...]

  • Page 63

    Options/Accessories 990-4059 Installation Guide APC Silcon 480kW 400V UPS 63 6.6.2 Wiring up UPS with External Yyn0 Isolation Transformer at Output WARNING! Isolation transformer provides galvanic isolation between mains supply and load. Load will loose galvanic isolation if isolation transformer is bypassed NOTICE! Refer to local legal regulation [...]

  • Page 64

    64 Installation Guide APC Silcon 480kW 400V UPS 990-4059 Options/Accessories 6.6.3 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. NOTICE! Refer to local legal regu[...]

  • Page 65

    Options/Accessories 990-4059 Installation Guide APC Silcon 480kW 400V UPS 65 6.6.4 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. NOTICE! Refer to local legal re[...]

  • Page 66

    66 Installation Guide APC Silcon 480kW 400V UPS 990-4059 Options/Accessories 6.6.5 Wiring up UPS with External Optional Dzn0 Isolation Transformer at Output WARNING! Isolation transformer provides galvanic isolation between mains supply and load. Do not bypass isolation transformer in order to avoid damaging circulation currents and to prevent load[...]

  • Page 67

    Options/Accessories 990-4059 Installation Guide APC Silcon 480kW 400V UPS 67 6.6.6 Wiring up UPS with External Optional Dyn11 Isolation Transformer at Input WARNING! Isolation transformer provides galvanic isolation between mains supply and load. Do not bypass isolation transformer in order to avoid damaging circulation currents and to prevent load[...]

  • Page 68

    68 Installation Guide APC Silcon 480kW 400V UPS 990-4059 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 ±0.5-8% (programmable) Input power fac[...]

  • Page 69

    Warranty 990-4059 Installation Guide APC Silcon 480kW 400V UPS 69 8.0 Warranty 8.1 APC Silcon Series Limited Factory Warranty APC warrants that the unit, when properly installed and commissioned by APC or APC authorized service personnel, shall be free from defects in materials and workmanship for a period of (1) year from the date of installation [...]

  • Page 70

    70 Installation Guide APC Silcon 480kW 400V UPS 990-4059 Appendix 9.0 Appendix 9.1 Table 1. Installation Planning Data 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%. 3. Nominal power consumption (column 1c) b[...]

  • Page 71

    Appendix 990-4059 Installation Guide APC Silcon 480kW 400V UPS 71 7. Suggested load side overcurrent protection (3b) based on nominal output current (3a). 8. Nominal battery voltage assumed to be 2V/cell (Lead technologi). 9. Recommended cable sizes, see "External Connection" section of this guide. CAUTION! Cable sizes must comply with na[...]

  • Page 72

    72 Installation Guide APC Silcon 480kW 400V UPS 990-4059 How to Contact APC 10.0 How to Contact APC APC Corporate 132 Fairgrounds Road West Kingston, RI 02892 USA Telephone: 401 789-5735 Fax: 401 789-3710 PowerFax™: 800 347-FAXX Pre-sales Technical Support 877-474-5266 (1-877-4Silcon) Post-sales Technical Support 877-287-7835 (1-877-2UPS-TEK) E-m[...]