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
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, state, municipal and local codes. IMPORTANT SAFETY INSTRUCTIONS – SAVE THESE INSTRUCTIONS Safety Symbols used in this manual WARNING! Indicates a hazard which, if not avoided, could result in injury or death.
Contents: 1.0 2.0 3.0 Introduction 4 1.1 Tools and Equipment Needed 4 Receiving, Unpacking, Moving and Storing the UPS and Batteries 5 2.1 2.2 5 5 Installation 3.1 3.1.1 3.2 3.2.1 3.2.2 3.2.3 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.4 3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.5.6 3.6 3.6.1 3.6.2 4.0 5.0 6.0 7.0 8.
Introduction 1.0 Introduction This Installation Guide provides information on UPS installation, wiring, start-up and shutdown procedures along with Maintenance Bypass Panel phase check and external battery installation. Refer to national and local electrical codes prior to installing the UPS system. 1.1 Tools and Equipment Needed This section lists all tools and equipment required to connect the UPS to the Maintenance Bypass Panel.
Receiving, Unpacking, Moving and Storing the UPS and Batteries 2.0 Receiving, Unpacking, Moving and Storing the UPS and Batteries 2.1 Receiving, Unpacking and Moving to Site CAUTION! Heavy equipment. To prevent personal injury or equipment damage, use caution when handling and transporting UPS cabinet and equipment. 1. While the UPS system is still on the truck, inspect the equipment and shipping container(s) for any signs of damage. Do not install the system if damage is apparent.
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. • Ambient temperature range: 32 to 104° F (0 to 40° C). Ideal temperature: 77° F (25° C) NOTE: At 92° F (33° C), battery life would be approx. 50% compared to storage at a normal temperature of 77° F (25° C). At 113° F (45° C).
Installation 3.1.1 UPS Footprint (measurements in inches & mm) Figure 1 - Footprint 39.4 (1000) 39.4 (1000) 17.9 (455) 17.9 (455) (Rear) 31.7 (804) Conduit Connection Box 27.9 (708) 19.8 31.7 (504) (804) Cable Entry (Front) 36.00 (914) Minimum Service Clearance Section A-A View From Inside Cabinet, Looking Down 36.00 (914) Recommended Cooling Clearance 31.7 (804) 59.1 (1500) A A Front View Side View Notes: 1. All dimensions are in inches (millimeters). 2.
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 • 11 M5 flat washers For Base Covers: • 2 Side Base Covers • 2 Front/Rear Base Covers • Hook and loop fasteners 3.2.2 Installing Pedestals CAUTION! Heavy Equipment.
Installation 3) Use four T20 torx screws and washers to fasten the conduit box to the front legs of the UPS NOTICE! Place flat washer, lock washer and screw in this particular order. 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.
Installation Maintenance Bypass Switch UPS Input Disc. Switch AC Line Input Shown in Open Position 4 L1 L1 3 4 5 6 U AC Output to Critical Load L1 L1 3 F2 L2 F6 L3 F1 2 1 F5 L2 AC Output from UPS Uninterruptible Power Supply L1 F4 L1 AC Input to UPS TO CRITICAL LOAD CENTER Contacts marked "U" closed in "UPS". Contacts marked "BP" closed in Bypass. Contacts are Make before Break.
Installation 3.3.
Installation 3.3.
Installation 3.3.3 Wiring Diagram for BC300 System input 3- or 4-wire + ground L1 L2 L3 N G System output 3- or 4-wire + ground Maintenance Bypass Panel L1 L2 L3 N G X001 X004 Utility output Utility input 1 X002 UPS AUX L1 L2 L3 N G 1 2 3 X003 L1 L2 L3 N G L1 L2 L3 N G X001 External Connection Board 1 2 3 X009 L1 L2 L3 N G E X004 Grounding Electrode X0012 1 2 3 4 5 6 7 8 11 12 13 14 15 16 17 UPS Figure 6 Wiring Diagram Notes: 1. All systems are 3-wire+ground. 2.
Installation 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. Conduit is not an acceptable grounding electrode conductor see National Electrical Code Section 250-91(a). NOTICE! The unit is wired from the factory as a separately derived system. Output neutral is bonded to equipment ground through main bonding jumper inside the UPS.
Installation Utility Source (provided by others) 450V 3 Wire + Ground MIB 95AT 75A Service Bypass Panel F4, 5, 6 UIF Q001 UIS 51A 75A UPS 200A 51A F1, 2, 3 UOF Q002 UOS Q003 BS Notes: 1. Must be 3 wire + Ground 2. Must be 3 wire + Ground cabling provided by others. 3. Input overcurrent protection is based on 80% rating - any deviation, please contact APC. 4. F1, F2, F3 = 60A 5. F4, F5, F6 = 80A 6. All AC power cabling is 3 wire + Ground at 208VAC 3-phase. 7.
Installation Utility Source (provided by others) 480V 3 or 4 Wire + Ground MIB 90AT 69A Service Bypass Panel F4, 5, 6 UIF Q001 UIS 48A 69A UPS 300A 400AT 48A F1, 2, 3 UOF Q002 UOS Q003 BS 48A Notes: 1. Must be 3- or 4-wire + Ground 2. Must be 3- or 4-wire + Ground cabling provided by others. 3. Input overcurrent protection is based on 80% rating - any deviation, please contact APC. 4. F1, F2, F3 = 55A 5. F4, F5, F6 = 75A 6. All AC power cabling is 3- or 4-wire + Ground at 480VAC 3-phase. 7.
Installation UPS Model Input Current Output Current Recommended MIB DC Voltage DC Current 40kW 208V 161A 111A 200AT 216V 200A 40 kW 450V 75A 51A 95AT 216V 200A 40kW 480V 69A 48A 130AT 216V 200A 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. 6.
Installation 3.3.5 External Connection Board Use Class 1 wiring methods.
Installation 3.3.6 Communication Interface Board (Option) Use Class 1 wiring methods. X002 X001 X003 25 PIN SUB D MALE X004 25 PIN SUB D MALE Communication Interface Board X005 X004 X005 25 PIN SUB D FEMALE X003 Serial Port RS232 Serial Port 0-20 mA current loop Relay Contacts: 30VAC, 60 VDC Maximum 0.5 A, minimum 0.
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.
Installation 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 Use the APC BC300 Triple Chassis only with an APC BC300 UPS. Do not connect a computer to any APC BC300 Triple Chassis port using a straight-through extension cable.
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 LEDs IF the LED is… THEN the Silcon Triple Chassis… off is not receiving power. flashing quickly (5 times per second) has not been configured. See the Web/SNMP Management Card Installation Guide on the CD for more information.
Installation 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 Triple Chassis: Connect the UPS cable (supplied with the management card) to the monitoring port of the chassis and to the “To UPS” port of the other management products (Share-UPS, MasterSwitch, etc.).
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 “Determining power requirements”. 3.5.4.
Installation 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 help solve the problem over the phone, if possible, or will give you a return material authorization (RMA) number. 3) If the APC BC300 Triple Chassis is under warranty, repairs are free of charge.
Installation Normally Open Line Fail Signal Normally Open Low Battery Signal Normally Closed Line Fail Signal Common 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 Chassis Figure 14 Monitoring Port Pin Assignment 990-1401 26 Installation Guide APC BC300 Series 40kW 208/450/480V UPS
Installation 3.5.6.2 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 mm (1.75 x 17.0 x 5.0 in) Weight: 1.81 kg (4.02 lb) Shipping weight: 3.65 kg (8.
Installation CAUTION! Qualified service personnel must take these precautions: 1. Wear protective clothing, such as rubber gloves and boots and protective eye wear. Batteries contain caustic acids and toxic materials and can rupture or leak if mistreated. Remove rings, metal wristwatches, other metal objects and jewellery. Do not carry metal objects in your pockets where the objects can fall into the battery cabinet. 2.
Installation • 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 battery manufacturer’s specifications. Follow below battery system guidelines and any instructions shipped with the battery system: 1. Verify that the DC fuses are removed from the UPS.
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. CAUTION! Study all warnings at the beginning of this section before replacing the batteries.
Initial Start-up and Phase Check 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 external battery breaker for the battery system is set to “OFF”. 2. Turn the pre-charge/discharge switch to the “pre-charge” position and hold it until the LED turns off. 3. Switch the battery breaker “ON”.
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, enter “920701”. The display should show “Logging stack is reset”. The events log is now cleared. 3. Press . The display should show “Normal operation load power xx%”.
Start-up and Shutdown Procedure 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. Make sure that the following switches are in the following positions: The UPS AC disconnect switch should be “OFF”. The UPS bypass switch should be on “LINE”. The battery breaker should be “OFF”. 2.
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 remain powered: Program the unit into static bypass operation: a. Press to access the user parameters. b. Press the c. Press to turn static bypass operation on. The display should show “Bypass operation”. d.
Technical Specifications 7.0 Technical Specifications 7.
Technical Specifications 7.2 Battery Specifications 40kW Nominal DC current - Amps UL rating of terminal blocks - 200 AWGa Nominal DC voltage 14 - 2/0 216 Nominal number of cells Factory-set float charge 108 voltageb 246 Charger current limit - Ampsc 20 Inverter efficiency -% 100% load 91 75% load 91 50% load 89 25% load 86 a.Terminal block has two positive and two negative 8 mm (=5/16”) studs, hardware provided. Lug required. Conductor size may vary based on installation requirements.
How to Contact APC 8.0 How to Contact APC APC Corporate 132 Fairgrounds Road West Kingston, RI 02892 USA Tel.: Fax: +1 401 789-5735 +1 401 789-3710 Pre-sales Technical Support +1 877-474-5266 Post-sales Technical Support +1 877-287-7835 Web: www.apc.
How to Contact APC 990-1401 38 Installation Guide APC BC300 Series 40kW 208/450/480V UPS
