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APC BC300 Series manual

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Table of contents for the manual

  • Page 1

    APC BC300 Series 40kW 208/450/480V Installation Guide Copyright ©2002 APC Denmark ApS 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 BC300 Series 40kW 208/450/480V UPS 990-1401 Thank You Thank you for choosing the APC BC300 Series. Read this Installation Guide before you install and use the system as it provides important information on safe and efficient installation and use. The installation and use of this product must comply with national, federal, s[...]

  • Page 3

    990-1401 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 3 Contents: 1.0 Introduction 4 1.1 Tools and Equipment Needed 4 2.0 Receiving, Unpacking, Moving and Storing the UPS and Batteries 5 2.1 Receiving, Unpacking and Moving to Site 5 2.2 Storing the UPS and Batteries 5 3.0 Installation 6 3.1 Requirements on Site 6 3.1.1 UPS Footprint (m[...]

  • Page 4

    4 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 990-1401 Introduction 1.0 Introduction This Installation Guide provides information on UPS installation, wiring, start-up and shut- down procedures along with Maintenance Bypass Panel phase check and external battery installation. Refer to national and local electrical codes prior to insta[...]

  • Page 5

    Receiving, Unpacking, Moving and Storing the UPS and Batteries 990-1401 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 5 2.0 Receiving, Unpacking, Moving and Storing the UPS and Batteries 2.1 Receiving, Unpacking and Moving to Site 1. While the UPS system is still on the truck, inspect the equipment and shipping container(s) for any sign[...]

  • Page 6

    6 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 990-1401 Installation 3.0 Installation 3.1 Requirements on Site A 3-foot free space on all sides should be allowed during installation. Place the UPS in a clean, dust-free environment, free of contaminants. Allow air circulation around the UPS cabinet and any battery cabinets or racks. •[...]

  • Page 7

    Installation 990-1401 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 7 3.1.1 UPS Footprint (measurements in inches & mm) Figure 1 - Footprint 3.2 Installing the Conduit Connection Kit Insulated and other tools required • 13 mm ratchet or wrench • T20 torx screwdriver • Greenly punch • Equipment suitable for lifting heavy UPS [...]

  • Page 8

    8 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 990-1401 Installation 3.2.1 Conduit Connection Kit Contents For Pedestals: • 23 pedestals • 4 M8 x 100 mm bolts • 4 M8 lock washers • 4 M8 flat washers • 4 M8 nuts For Conduit Box: • 1 Conduit Box • 1 Conduit Box Cover • 11 M5 x 12 mm T20 Torx screws • 11 M5 lock washers [...]

  • Page 9

    Installation 990-1401 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 9 3) Use four T20 torx screws and washers to fasten the conduit box to the front legs of the UPS 4) After all UPS wiring has been completed, attach conduit box cover to the front of the conduit box 5) Use hook and loop fasteners to attach the base covers to the UPS 3.3 [...]

  • Page 10

    10 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 990-1401 Installation Figure 2 - SBP Electrical Schematic 208V & 480V Figure 3 - SBP Electrical Schematic 450V Notes: 1. 208V F1, F2, F3 = 120A 2. 480V F1, F2, F3 = 55A 3. 208V F4, F5, F6 = 170A 4. 480V F4, F5, F6 = 75A 5. All AC power cabling is 3- or 4-wire + Ground at 208VAC / 480V[...]

  • Page 11

    Installation 990-1401 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 11 3.3.1 Component Overview (door open) Figure 4 Component Overview ON/OFF buttons Communication Interface Controller Board Input Output Battery connection Display unit Grounding[...]

  • Page 12

    12 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 990-1401 Installation 3.3.2 Wire Terminals Figure 5 Wire Terminals Input Terminal Blocks Output Terminal Blocks Battery connection Grounding Terminal[...]

  • Page 13

    Installation 990-1401 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 13 3.3.3 Wiring Diagram for BC300 Figure 6 Wiring Diagram Notes: 1. All systems are 3-wire+ground. 2. Cables not provided by APC. 3. All AC power cables must be 3- or 4-wire plus ground 3-phase 4. Power and data cabling must be run in separate conduits. 5. Installation [...]

  • Page 14

    14 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 990-1401 Installation 3.3.4 Single Line Diagram for BC300 Figure 7 Single Line Diagram 208V NOTICE! Always keep AC, DC and communication cables separated. NOTICE! The grounding electrode conductor (Protective Earth - PE) must be the same size (ampacity) as the UPS input circuit conductors[...]

  • Page 15

    Installation 990-1401 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 15 Figure 8 - Single Line Diagram 40kW 450V Utility Source (provided by others) 450V 3 Wire + Ground MIB Service Bypass Panel F4, 5, 6 UIF Q001 UIS UPS F1, 2, 3 UOF Q002 UOS Q003 BS UPS System Output 40kW 450V 3 Wire + Ground Notes: 1. Must be 3 wire + Ground 2. Must be[...]

  • Page 16

    16 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 990-1401 Installation Figure 9 Single Line Diagram 480V NOTICE! Size utility input overcurrent protection device as per applicable codes. See below table for utility input voltage and current ratings. Notes: 1. Must be 3- or 4-wire + Ground 2. Must be 3- or 4-wire + Ground cabling provide[...]

  • Page 17

    Installation 990-1401 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 17 Notes: 1. 3- or 4-wire provided source. 2. Cables not provided by APC. 3. Recommended input over-current protection (MIB) based on an 80% rated device. 4. All AC cables must be AC 3- or 4-wire 3-phase. 5. Keep UPS input, output and control cables in separate conduits[...]

  • Page 18

    18 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 990-1401 Installation 3.3.5 External Connection Board Use Class 1 wiring methods. Figure 10 External Connection Board[...]

  • Page 19

    Installation 990-1401 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 19 3.3.6 Communication Interface Board (Option) Use Class 1 wiring methods. Figure 11 Communication Interface Board 14 15 2 16 17 4 18 19 6 20 21 8 13 + 25 – "UPS on" (shown with UPS off) "Static bypass operation" (shown with static bypass operatio[...]

  • Page 20

    20 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 990-1401 Installation 3.4 Smart Slot and Connection of Triple Chassis Connect the Triple Chassis to the serial ports on the Communication Interface Board, and to the 24V supply (power supply included). Terminal locations shown below. Figure 12 Communication Interface Serial ports[...]

  • Page 21

    Installation 990-1401 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 21 3.5 APC BC300 Triple Chassis Figure 13Triple Chassis The APC BC300 Triple Chassis is an American Power Conversion (APC) external management product that allows you to use monitoring and control management products with your APC BC300 series UPS. 3.5.1 Safety Warnings[...]

  • Page 22

    22 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 990-1401 Installation • Connecting to other APC external management products in a cascade series. 3.5.2.2 To UPS Port The “ To UPS ” port connects the chassis to the UPS, using the BC300 UPS cable. The cable connector plugs into a communications port on an APC BC300 UPS. 3.5.2.3 LED[...]

  • Page 23

    Installation 990-1401 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 23 1) Make sure that the chassis is powered off. 2) Install management cards into the housings on the rear of the chassis. See the instructions supplied with the cards and the table above. 3) If you are cascading other APC external management products to the APC BC300 T[...]

  • Page 24

    24 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 990-1401 Installation 3.5.4.4 Triple Chassis Power Considerations The Triple Chassis receives its power from the UPS through the supplied 24 VDC universal adapter. The total current required by your management products must not exceed the 850 mA limit of the power adapter. See “ Determi[...]

  • Page 25

    Installation 990-1401 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 25 1) Note the serial number and date of purchase of the APC BC300 Triple Chassis. Contact APC Customer Support at the phone number or address listed in How to Contact APC section of this manual. 2) Be prepared to provide a description of the problem. A technician will [...]

  • Page 26

    26 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 990-1401 Installation Figure 14 Monitoring Port Pin Assignment 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 Clos[...]

  • Page 27

    Installation 990-1401 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 27 3.5.6.2 Power, Physical, and Environmental Specifications. 3.6 Installation of External Batteries and Battery Breaker Some units are connected to optional external batteries in a separate cabinet or rack. External batteries must be installed and connected to the UPS [...]

  • Page 28

    28 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 990-1401 Installation Battery Installation Guidelines: • Refer to any instructions provided with the batteries, battery breaker and pre- charge/discharge switch. • External batteries require a fused disconnect or a DC battery breaker. There should be a disconnecting means for each bat[...]

  • Page 29

    Installation 990-1401 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 29 • Clean cables and battery terminals before making the battery connections. Apply a thin coating of conductive grease before making the battery connections, or, after connection, apply petroleum jelly to the entire connection. • Torque battery connections to the [...]

  • Page 30

    30 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 990-1401 Installation 3.6.2 Battery Replacement Only authorized service personnel familiar with battery systems may replace batteries. See the “ Start-up & Shutdown Procedure ” section in this Installation Guide to bypass and shut down the UPS. • Use the Same Battery Number and [...]

  • Page 31

    Initial Start-up and Phase Check 990-1401 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 31 4.0 Initial Start-up and Phase Check After installing the unit, use this section to perform the initial start-up and the phase check for the Maintenance Bypass Panel. 4.1 Initial Start-up and Phase Check (External Batteries) 1. Ensure that the ext[...]

  • Page 32

    32 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 990-1401 Clearing the Events Log 5.0 Clearing the Events Log The events log contains the 250 most recent UPS events, including alarms. To clear the events log, follow the steps below: 1. Press and at the same time. The display should show “ Key in password ” . 2. Using the key pad, en[...]

  • Page 33

    Start-up and Shutdown Procedure 990-1401 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 33 6.0 Start-up and Shutdown Procedure 6.1 Start-up from Maintenance Bypass This section contains instructions on how to start the UPS from maintenance bypass. The steps in this procedure apply to units with an APC-supplied Maintenance Bypass Panel. 1[...]

  • Page 34

    34 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 990-1401 Start-up and Shutdown Procedure This section contains information on how to shut down the UPS from normal operation mode. This procedure applies to units with an APC-supplied Maintenance Bypass Panel. 1. If you have shut the loads down: Move on to step 2. If the loads are to rema[...]

  • Page 35

    Technical Specifications 990-1401 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 35 7.0 Technical Specifications 7.1 APC BC300 Series 40 kW Technical Data Voltage 3 x 208Y/120 or 208V Delta 450V Delta 3 x 480Y/277 Input Rated input current 146Amps 75 Amps 63Amps Voltage tolerance - Utility - Bypass +10 / -15 +/- 10 +10 / -15 +/- 10 +10 /[...]

  • Page 36

    36 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 990-1401 Technical Specifications 7.2 Battery Specifications 7.3 Dimensions/Weight 40kW Nominal DC current - Amps 200 UL rating of terminal blocks - AWG a a.Terminal block has two positive and two negative 8 mm (=5/16 ” ) studs, hardware provided. Lug re- quired. Conductor size may vary[...]

  • Page 37

    How to Contact APC 990-1401 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 37 8.0 How to Contact APC APC Corporate 132 Fairgrounds Road West Kingston, RI 02892 USA Tel.: +1 401 789-5735 Fax: +1 401 789-3710 Pre-sales Technical Support +1 877-474-5266 Post-sales Technical Support +1 877-287-7835 Web: www.apc.com/support[...]

  • Page 38

    38 Installation Guide APC BC300 Series 40kW 208/450/480V UPS 990-1401 How to Contact APC[...]