Electrical Installation

Transcription

1 Electrical Installation InfraStruXure TM Power Generation System 250 A 208/480 V

2

3 About This Manual Audience This manual is intended for certified electricians who will be installing the InfraStruXure Power Generation System. It provides detailed electrical and physical specifications, diagrams, and instructions on how to position and install the generator and the Smart Distribution Panel with Automatic Transfer Switch (ATS). Companion manuals For additional information about your InfraStruXure Power Generation System, refer to the following sheets and manuals. The initial part numbers are listed below. Be aware that some of the documentation may have undergone one or more revisions (A, B, etc.): ATS Unpacking Sheet ( ) Operation Manual ( ) Generator Reference Manual ( ) Network Management Interface User s Guide (available on the APC Web site or the Utility CD) ( ) How to find updates to this manual You can check for updates to this manual by clicking on the User Manuals link on the Support page of the APC Web site ( Choose Power Generation and then InfraStruXure Power Generation. From the list of InfraStruXure Power Generation manuals, look for the latest letter revision (A, B, etc.) of the initial part number appearing on the back cover of this manual ( ). InfraStruXure Power Generation System i

4

5 Contents Safety...1 Overview Save these instructions Safety symbols used in this manual Cross-reference symbols used in this manual Warnings Read these instructions The InfraStruXure Power Generation System is an optional standby system Fuel and fumes are flammable Exhaust gases are deadly Moving parts can cause severe personal injury or death Do not operate in flammable and explosive environments Electrical shock can cause severe personal injury or death General safety precautions Battery considerations System Data...7 Electrical Power and communication connections Physical Generator kw generator pad kw generator pad Special considerations for generator installations Smart Distribution Panel with ATS Piping...15 Overview InfraStruXure Power Generation System iii

6 Procedures Run conduit from the generator to the ATS Pour the generator pad Install the generator Install the ATS Wiring Overview Procedures Connect power from the generator to the ATS Connect utility inputs to the ATS Connect the DC power input, start, and E-stop contacts Connect the communication cable from the ATS to the generator Run AC power from the ATS to the generator for the heater and battery charger Connect branch distribution equipment to the ATS Connect an EPO switch to the user interface board and test the switch Connect contacts to the user interface board Connect the ATS to the network at the surge-protected ethernet port Installation Checklist Appendix: Adding ATS Circuit Breakers How to Add Sub-Feed Output Distribution Circuit Breakers to the ATS Output distribution circuit breakers available from APC Circuit breaker adapter modules available from APC Determine the configuration of the panel Allowed circuit breaker combinations Preparing the breakers for installation Parts and tools needed for installation procedures Installing circuit breakers on the ATS panel bus iv InfraStruXure Power Generation System

7 Safety Overview Save these instructions This manual contains important instructions that must be followed during installation, operation, and maintenance of the InfraStruXure Power Generation System. Safety symbols used in this manual Electrical Hazard Indicates an electrical hazard, which, if not avoided, could result in injury or death. DANGER Indicates a hazard, which, if not avoided, could result in severe personal injury or substantial damage to product or other property. Caution Indicates a potential hazard, which, if not avoided, could result in personal injury or damage to product or other property. Indicates a heavy load that should not be lifted without assistance. Heavy Indicates important information. Note Cross-reference symbols used in this manual Indicates that more information is available on the same subject in a different section of this manual. See also Indicates that more information is available on the same subject in a different manual. InfraStruXure Power Generation System 1

8 Warnings Note Read these instructions The components in the InfraStruXure Power Generation System can pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents, be aware of the dangers and act safely. Read and follow all of the safety instructions and warnings in this manual and in all of your component manuals. Note The InfraStruXure Power Generation System is an optional standby system The Generator and Automatic Transfer Switch (ATS) that you purchased from APC is classified as an Optional Standby System because it provides backup or standby power to data centers in the event of a sustained power failure. The InfraStruXure Power Generation System is not to be classified as an Emergency System that is essential for safety to human life (e.g., fire pumps, operating room and life-support equipment in hospitals) as legally required by municipal, state, federal, or other governmental codes. The InfraStruXure Power Generation System is not to be classified as a Legally Required Standby System, as it is not supplying power to aid in fire fighting, rescue operations, control of health hazards (e.g., sewage) and similar operations as required by municipal, state, federal, or other governmental codes. Emergency and Legally Required Systems are not allowed to rely on municipal fuel for operation, or municipal water for cooling. Emergency and Legally Required Systems specify dual-fuel systems, with one of them being a two-hour, on-site fuel supply. Your InfraStruXure Power Generation System is not to be classified as an Integrated Electrical System, as an orderly shutdown is not required to prevent damage to the generator. The generator is not to be paralleled with another generator. Your generator will operate at its rated load without being refueled for a minimum of six hours, and should be able to run with no load for a minimum of 12 hours. Your generator can be without electrical power to the load terminals of the ATS for a maximum of 60 seconds, but will typically be without power for no more than 10 seconds. 2 InfraStruXure Power Generation System

9 Warnings Fuel and fumes are flammable DANGER Fire, explosion, and personal injury or death can result from improper practices. DO NOT fill fuel tanks while engine is running, unless tanks are outside the engine compartment. Fuel contact with a hot engine or exhaust is a potential fire hazard. DO NOT permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator or fuel tank. Exhaust gases are deadly DANGER Ensure exhaust gases are properly discharged away from enclosed or sheltered areas, as well as areas where individuals are likely to congregate. Ensure the unit is well ventilated. Engine exhaust and some of its constituents are known to cause cancer, birth defects, and other reproductive harm. Take care not to breathe, ingest, or come in contact with exhaust gases. Moving parts can cause severe personal injury or death DANGER Keep your hands, clothing, and jewelry away from moving parts. Before starting work on the generator, disconnect the battery charger from its AC source, then disconnect the battery. Disconnect the battery s negative ( ) cable first. This will prevent accidental starting. Make sure the fasteners on the generator are secure. Tighten supports and clamps, and keep guards in position over fans, drive belts, etc. Do not wear loose clothing or jewelry in the vicinity of moving parts, or while working on electrical equipment. Loose clothing and jewelry can become caught in moving parts. If an adjustment must be made while the unit is running, use extreme caution around hot manifolds, moving parts, etc. InfraStruXure Power Generation System 3

10 Warnings Do not operate in flammable and explosive environments DANGER Flammable vapor can cause an engine to overspeed and become difficult to stop, resulting in possible fire, explosion, severe personal injury, or death. Do not operate a generator where a flammable vapor environment can be created by a fuel spill, leak, etc., unless the generator is equipped with an automatic safety device to block the air intake and stop the engine. The owners and operators of the generator are solely responsible for operating the generator safely. Electrical shock can cause severe personal injury or death Electrical Hazard Switch off all electric power before removing protective shields or touching electrical equipment. Wear rubber boots when working on electrical equipment. Do not wear damp clothing (particularly wet shoes) or have damp skin when handling electrical equipment. Do not wear jewelry, which can short out electrical contacts and cause shock or burns. Use extreme caution when working on electrical components. High voltages can cause injury or death. DO NOT tamper with interlocks. Follow all applicable state and local electrical codes. Have all electrical installations performed by a qualified licensed electrician. Lock out and tag open switches to avoid accidental closure. Hazardous voltages can flow from the generator into the utility line. This creates a potential for electrocution of service personnel or property damage. DO NOT CONNECT THE GENERATOR DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM. CONNECT ONLY TO THE AUTOMATIC TRANSFER SWITCH. 4 InfraStruXure Power Generation System

11 Warnings General safety precautions Note Coolants under pressure have a higher boiling point than water. DO NOT open a radiator or heat exchanger pressure cap while the engine is running or remains hot. Allow the generator to cool, thereby decreasing the system pressure. Used engine oils are known to cause cancer or reproductive toxicity. When checking or changing engine oil, take care not to ingest, breathe the fumes, or make bodily contact with used oil. Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible materials such as wood and cloth; Class B fires involve combustible and flammable liquid fuels and gaseous fuels; Class C fires involve live electrical equipment (ref. NFPA No. 10). Make sure rags are not left on or near the engine. Make sure the generator is mounted in a manner that will prevent combustible materials from accumulating under its base. Remove all unnecessary grease and oil from the generator. Accumulated grease and oil can cause overheating and engine damage, and presents a potential fire hazard. Keep the generator and the surrounding area clean and free from obstructions. Remove any debris and keep the floor clean and dry. Do not work on this equipment when mentally or physically fatigued, or after consuming any alcohol or drug that makes the operation of equipment unsafe. Do not store any flammable liquids such as fuel, cleaners, oil, etc., near the generator. A fire or explosion could result. Wear hearing protection when going near an operating generator. To prevent serious burns, avoid contact with hot metal parts such as the radiator, turbo charger, and exhaust system. InfraStruXure Power Generation System 5

12 Warnings Battery considerations Note Battery servicing must be performed or supervised by personnel knowledgeable about working with batteries and of the safety precautions that should be closely observed throughout the process. Keep unauthorized personnel away from the battery. When replacing the battery, use the same model number with these specifications: 80 kw generators: 12 V, 225 A, 1000 cold-cranking amps, sealed lead acid. 125 kw generators: 12 V, 225 A, 1400 cold-cranking amps, sealed lead acid. Do not dispose of a battery in a fire. It is capable of exploding. Do not open or mutilate a battery. Released electrolyte has been known to be harmful to the skin and eyes, and to be toxic. A battery presents a risk of high short-circuit current. The following precautions must be observed when working on batteries: Remove watches, rings, or other metal objects. Use tools with insulated handles. Do not lay tools or metal parts on top of a battery. Electrolyte is a diluted sulfuric acid that is harmful to the skin and eyes. It is electrically conductive and corrosive. The following procedures should be observed: Wear full eye protection and protective clothing. If electrolyte contacts the skin, wash it off immediately with water. If electrolyte contacts the eyes, flush thoroughly and immediately with water and seek medical attention. Spilled electrolyte should be washed down with an acid neutralizing agent. Use a solution of one pound (500 grams) bicarbonate of soda to one gallon (4 liters) of water. Keep adding bicarbonate of soda solution until any evidence of a reaction (foaming) has ceased. The resulting liquid should then be flushed with water and the area dried. A lead-acid battery presents a risk of fire because it generates hydrogen gas. The following precautions must be observed: DO NOT SMOKE near the battery. DO NOT cause flame or spark in the battery area. Discharge static electricity from your body before touching the battery by first touching a grounded metal surface. 6 InfraStruXure Power Generation System

13 System Data Electrical Power and communication connections Two sources supply power to the ATS. The typical installation has the utility connected to Source 1 (S1) and a generator connected to Source 2 (S2). If you purchased your ATS as an InfraStruXure Extended Runtime Solution, the ATS was supplied with either an 80 kw or 125 kw generator. To ensure a successful transition from S1 to S2, APC recommends that the utility circuit breaker rating match the generator s circuit breaker rating as presented in the table below. AC Power Input to ATS from Generator Voltage (L-L) 208 V 480 V Output power of generator 80 kw 125 kw Size of generator output circuit breaker 250 A 200 A Connection type 4W + G 3W + G or 4W + G Recommended wire size if 30 C 4/0 AWG 3/0 AWG Recommended wire size if 40 C 300 kcmil 3/0 AWG Recommended equipment grounding conductor (EGC) size 4 AWG 6 AWG AC Power Input to ATS from Utility Voltage (L-L) 208 V 480 V Size of upstream utility circuit breaker 250 A 200 A Connection type 4W + G 3W + G or 4W + G Recommended wire size if 30 C 4/0 AWG 3/0 AWG Recommended wire size if 40 C 300 kcmil 3/0 AWG Recommended equipment grounding conductor (EGC) size 4 AWG 6 AWG 12 VDC to ATS from Generator Recommended wire size Voltage Connection point Two 12 AWG stranded copper 12 VDC Hard-wire to generator controller terminal block Communication Connection from Generator to ATS Recommended wire size Connection point Belden 9830 cable or equivalent (24 AWG; 3 twisted, shielded pairs; 100 ohms nominal impedance; 60 pf/ft nominal capacity) RS485/RS232 converter on ATS to identical converter on generator (requires installation) InfraStruXure Power Generation System 7

14 Electrical AC Power from ATS to Generator Heater and Battery Charger Recommended wire size Two 12 AWG stranded copper Voltage 120 VAC Connection style Hard-wire from transformer in ATS to double duplex NEMA 5-20 outlet box on generator Start Signal Connection to Generator from ATS Recommended wire size Connection point Two AWG stranded copper Hard-wire to generator controller terminal block Emergency Stop Signal Connection to Generator from ATS Recommended wire size Two AWG stranded copper Connection point Hard-wire to generator controller terminal block ATS Branch Distribution to Equipment Circuit breaker style ATS Ethernet Connection Connection type ATS EPO Connection Connection type ATS User Input Contacts/Relay Outputs Connection type MCCB ABB Tmax T1 or T3 up to 225 A CAT-5 network cable connected to the surge-protected ethernet port on the ATS user connection plate Voltage-free contact (NO or NC) or 24 VDC on the ATS user interface board Voltage-free contact (NO or NC) on the ATS user interface board Always follow the National Electrical Code (NFPA 75) or the Canadian Electrical Code (CSA C ) and local codes when installing the InfraStruXure Power Generation System. The AC Power Input wire sizes provided in this document are recommendations only. The ATS is provided with a panel board to supply power to multiple loads. Since loading could increase after the product s initial installation, the AC Power Input wires were selected for the maximum current that can be delivered by the panel board. If the ATS is purchased to supply a calculated load rated less than the panel board, and the load will never increase, smaller wires can be used if the requirements specified in the NEC, the CEC, and local codes are followed. Wire sizes to loads shall be in accordance with the ratings of the circuit breakers selected to power the loads. 8 InfraStruXure Power Generation System

15 Physical Generator The 125 kw generator is shown in this and other graphic representations throughout this manual 80 kw: 83.9 in/2131 mm 125 kw: 98.4 in/2499 mm 40.0in/1016mm 80 kw: 82.8 in/2103 mm 125 kw: in/2743 mm 80 kw 125 kw Height 83.9 in/2131 mm 98.4 in/2499 mm Width 40.0 in/1016 mm 40.0 in/1016 mm Length 82.8 in/2103 mm in/2743 mm Weight 3294 lb/1494 kg 5109 lb/2317 kg Operating Temperature Range 30 to 40 C 30 to 40 C Operating Relative Humidity 5 to 100% 5 to 100% Operating Elevation 12,800 ft/3900 m 12,800 ft/3900 m Tank Type Double-wall, steel base Double-wall, steel base Fuel Type Diesel Diesel Tank Size 70 gal/265 L 173 gal/655 L NEC Access Clearances Three feet to an insulated surface Three feet to grounded parts, including concrete walls, if 208/120 V Three and 1/2 feet to grounded parts, including concrete walls, if 480/277 V Three feet to other live parts, if 208/120 V Four feet to other live parts, if 480/277 V InfraStruXure Power Generation System 9

16 Physical 80 kw generator pad in/1793 mm in/1714 mm 3.99 in/101 mm 0.98 in/25 mm Controller End in/ 834 mm in/ 856 mm Fuel Tank Stub-Up Area in/ 966 mm in/ 1016 mm Radiator End 3.15 in/ 80 mm 9.21 in/ 234 mm in/1050 mm in/356 mm in/2713 mm 104.8in/2662mm 82.8 in/2103 mm See Anchoring Detail 2500PSI (173 kpa) reinforced concrete foundation 6.0 in/152 mm Controller End Anchoring Detail Type J or L Bolt Anchoring at least 8 inches (200 mm) of sand or gravel Korfund high resiliency pad isolation material or equivalent at all contact points Radiator End 72 in/1829 mm 40 in/1016 mm 2.00 in/ 50.8 mm The above drawing is only a representation. The actual bolt length shall be determined by the mechanical contractor. 10 InfraStruXure Power Generation System

17 Physical 125 kw generator pad 3.03 in/77 mm in/ 698 mm in/ 557 mm 3.15 in/80 mm 0.98 in/25 mm Controller End in/428 mm in/ 966 mm Radiator End Electrical Stub-Up Area 0.98 in/ 25 mm in/ 360 mm in/ 1244 mm in/ 532 mm 132 in/3353 mm in/2662mm in/2743 See Anchoring Detail 2500PSI (173 kpa) reinforced concrete foundation 6.0 in/152 mm Controller End at least 8 inches (200 mm) of sand or gravel Radiator End Anchoring Detail Type J or L Bolt Anchoring Korfund high resiliency pad isolation material or equivalent at all contact points 72 in/1829 mm 40 in/1016 mm 2.00 in/ 50.8 mm The above drawing is only a representation. The actual bolt length shall be determined by the mechanical contractor. InfraStruXure Power Generation System 11

18 Physical Special considerations for generator installations Installation considerations. Use the instructions in this manual as a general guide only. Follow the instructions of the consulting engineer regarding the placement of system components. The complete installation must comply with all local and state building codes, fire ordinances, and other applicable regulations. Consider these requirements prior to installation: Level mounting surface Adequate cooling air Adequate fresh induction air Discharge of generator air Non-combustible mounting surface Discharge of exhaust gases Electrical connections Accessibility for operation and servicing Noise levels Location considerations. Generator location is mainly decided by such criteria as ventilation, wiring, fuel, and exhaust. The generator should be located as near as possible to the main power service entrance. Exhaust must not be able to enter or accumulate around inhabited areas. It is recommended you provide at least 3.5 feet (1 meter) of clearance on all sides. The radiator end should have a minimum clearance of 6 feet (1.82 meters). See the product specifications on page 9 for service clearances. 12 InfraStruXure Power Generation System

19 Physical Smart Distribution Panel with ATS 74.6 in/1895 mm 28.0 in /711mm 14.1 in /358 mm Height 74.6 in /1895 mm Width 28.0 in /711 mm Depth 14.1 in /358 mm Weight (lb/kg) 482 lb/218 kg Operating Temperature Range 23 to 104 F ( 5 to 40 C) Operating Relative Humidity 5 to 95%, non-condensing Operating Elevation 0 to 6562 ft/0 to 2000 m Enclosure Rating NEMA 1 NEC Access Clearances Three feet to an insulated surface Three feet to grounded parts, including concrete walls, if 208/120 V Three and 1/2 feet to grounded parts, including concrete walls, if 480/277 V Three feet to other live parts, if 208/120 V Four feet to other live parts, if 480/277 V InfraStruXure Power Generation System 13

20

21 Piping Overview Run conduit from the generator to the ATS. Pour the generator pad. Install the generator. Install the ATS. InfraStruXure Power Generation System 15

22 Procedures Run conduit from the generator to the ATS Run at least four conduits from the generator to the ATS (see the table beginning on page 7 for recommended wiring specifications, and Wiring on page 25 for instructions about connecting to the ATS). Run wires in conduits in accordance with the following guidelines: Conduit 1: Input power from the generator to the ATS Conduit 2: 120 VAC from the ATS to the generator for the heater and battery charger Conduit 3: 12 VDC from the generator to the ATS Start contact from the generator to the ATS E-stop contact from the generator to the ATS Conduit 4: Communication cable from the ATS to the generator (use Class 1 wiring methods when making field wiring connections to Class 2 circuit terminals). Note These instructions are recommendations only. Always follow the applicable NEC, CEC, and local codes when installing conduit. Pour the generator pad See pages 10 and 11 for recommended pouring specifications. Use 2500 PSI (173 kpa) reinforced concrete above at least 8 inches (200 mm) of sand or gravel. Anchoring hardware 6 in/152 mm Electrical stub-up area Controller End Radiator End Sand or gravel See Install the generator on next page for recommendations about anchoring hardware. 16 InfraStruXure Power Generation System

23 Procedures Install the generator After placing the generator on its pad, verify that all four mounting pads at the bottom of the fuel tank make full contact with the generator pad. Level shims are included with the generator s literature pack, and can be used to fill any gaps between the mounting pads and the generator pad. The shims are inches thick. Insert the maximum height stack of shims that will slide into the gap. 80 kw generator. Fuel Tank Stub-Up Area in/1050 mm in/356 mm Controller End in/ 856 mm in/ 966 mm Radiator End 9.21 in/234 mm Mounting Pad Locations 125 kw generator. Electrical Stub-Up Area 34.7in/882mm 49.0in/1244mm Controller End 33.7in/ 856mm 38.0in/ 966mm Radiator End 17.9in/ 454mm Mounting Pad Locations InfraStruXure Power Generation System 17

24 Procedures Secure the generator to the generator pad using the appropriate mounting hardware. Use type J or L bolt anchoring (not supplied) as shown in the illustration below: Korfund high resiliency pad isolation material or equivalent at all contact points 2.00 in (50.8 mm) Ensure that a significant portion of the bolt is sticking out of the generator pad after anchoring, per the above illustration. Be aware this illustration is only a representation. The actual bolt length shall be determined by the mechanical contractor. 18 InfraStruXure Power Generation System

25 Procedures Install the ATS Remove the ATS panel board from the enclosure. The following set of steps is optional, but they are also recommended. Note Removing the panel board assembly makes it easier to mount the ATS to the wall. If you decide not to remove this assembly beforehand, continue with the procedure on page Open the front door of the ATS. Front Door Open, Dead Front Closed 2. Remove the screw on the left that secures the bottom access panel. Remove 3. Open the dead front by pulling the top and bottom latches toward each other. 4. Remove the screw on the right that secures the bottom access panel. Front Door Open, Dead Front Open Remove 5. Remove the bottom access panel from the enclosure. First, pull up Second, pull out InfraStruXure Power Generation System 19

26 Procedures 6. Disconnect the panel board assembly wires that are connected to the following components inside the ATS enclosure: User interface circuit board Surge-protected ethernet port Door relay Auto switch and LEDs Display interface Neutral wire (if applicable) Each wire has a yellow label attached that specifies its point of connection. Note 7. Use a 13-mm wrench to remove the M8 nuts located at the top and bottom of the panel board assembly (4 total). Remove TOP Use 13-mm Wrench to Remove Remove 8. Using the handle at the top of the panel board assembly, slowly pull the entire assembly toward you. BOTTOM 20 InfraStruXure Power Generation System

27 Procedures At least two people should be involved in removing the panel board! Caution 9. Walk the panel board out of the enclosure one wheel at a time, and then roll the assembly away from the enclosure. 10. Carefully lay the panel board assembly on its back at a location apart from the enclosure. Note Do not reinstall the panel board until after you have mounted and pulled wires into the ATS enclosure. 11. Remove the covers positioned across the horizontal slots inside the enclosure. Use a 10-mm wrench to first remove the two M6 nuts securing each cover in place. InfraStruXure Power Generation System 21

28 Procedures Mount the ATS to a wall. The ATS can be mounted to wall studs or to a cement wall surface. The necessary hardware is included. A 10-mm wrench is required. Use the diagram on this page as a guide. Mounting Hardware Four, -inch (6-mm) anchoring screws, 3.0 in / 76 mm long 2.3 in /59 mm 28.3 in /718 mm 2.35 in /60 mm Note There is no need to mount plywood or Unistrut metal framing to the wall. Mounting to studs: 1. Locate wall studs and draw vertical chalk lines to show where the studs are located. 2. Place the enclosure against the wall. 3. Find appropriate chalk lines/studs through the horizontal slots at the rear of the enclosure in /1748 mm 68.3 in /1734 mm 74.6 in /1895 mm 4. Drive the (supplied) anchoring screws into the wall studs in four places. 5. Reinstall the previously removed covers to the horizontal mounting slots using the M6 nuts. Mounting to concrete: 1. Place the enclosure against the wall. 2. Drill four holes (with a 4.5-mm diameter masonry drill bit) into the concrete through the horizontal slots at the rear of the enclosure in /399 mm 15.2 in /385 mm 23.4 in /594 mm 3. Drive the (supplied) anchoring screws into the drilled holes. 4. Reinstall the previously removed covers to the horizontal mounting slots using the M6 nuts. 22 InfraStruXure Power Generation System

29 Procedures Install conduit and pull wires into the ATS. After wall-mounting the ATS, connect the conduit originating from the generator (see page 16). Pull the wires from the generator into the ATS (in accordance with the specifications on pages 16 and 25). You can attach conduit to the roof, the floor, or the sides of the ATS. However, if running wires through the roof or floor, it is recommended you connect conduit to the far left or far right side of the (top or bottom) plate. This will prevent congestion when wiring to breakers on the ATS panel board. Note Properly seal any knockouts you create in the top or bottom plate of the ATS according to local codes. InfraStruXure Power Generation System 23

30 Procedures Re-install the ATS panel board in the enclosure. 1. Roll the panel board assembly back to the ATS and walk it into the enclosure one wheel at a time. 2. Align the mounting holes at the top and bottom of the assembly with the proper studs in the enclosure. 3. Re-attach the four previously removed M8 nuts to the studs (see step 7 on page 20). Note: You can re-install the bottom access panel now, or you can reinstall it after connecting wires to the panel board. To re-install, perform the reverse of the panel board removal procedures on page 19. Install Install Use 13-mm Wrench to Install TOP BOTTOM 4. Reconnect the panel board assembly wires that were previously disconnected from the following ATS components: User interface circuit board Surge-protected ethernet port Door relay Auto switch and LEDs Display interface Neutral wire (if applicable) Refer to the yellow label on each wire for its point of connection. Note 24 InfraStruXure Power Generation System

31 Wiring Overview Connect generator power to the ATS. Connect utility inputs to the ATS. Connect the 12 VDC, Start, and E-stop contacts. Connect the communication cable from the ATS to the generator. Run AC power from the ATS to the generator for the heater and battery charger. Connect the branch distribution equipment to the ATS. Connect an EPO switch and test the switch. Connect contacts to the user interface board. Connect to the network at the surge-protected ethernet port. InfraStruXure Power Generation System 25

32 Procedures Connect power from the generator to the ATS L1, L2, and L3 from generator output breaker Source 2 input switch L1, L2, and L3 EGC Neutral bar Ground bar Equipment grounding conductor (EGC) from generator Generator output breaker (250 A ATS 480 V input shown) Specifications and tools. The generator output breaker is equipped with saddle lugs, while the ATS input switches are equipped with box lugs (see Power and communication connections on page 7 for recommended wiring specifications). Torque generator input wires to 250 in lb (28 n m) using an 8-mm Allen wrench. Routing wires. Route conduit containing the generator input wires into the ATS using the knockouts provided on the ATS enclosure. Use a knockout punch to create an appropriate size hole. You can bring these wires into the ATS through the roof or the floor. See the illustration on the next page for suggested wiring paths for both options. If possible, use the knockouts on either side of the roof or floor rather than knockouts in the middle of the roof or floor (see page 23). Note If you are running wires through the roof of the ATS to connect to the Source 2 input switch, these wires will need to be at least 9.5 ft (2.9 m) longer than wires run through the floor of the ATS. 26 InfraStruXure Power Generation System

33 Procedures Making connections. 1. Connect the phase wires (L1, L2, L3) from the output breaker in the generator to the Source 2 input switch in the ATS, and the neutral wire (if applicable) to the neutral bar in the ATS. 2. Connect the equipment grounding conductor (GEC) from the generator to the ground bar in the ATS. Optional wiring through the roof Generator output breaker Source 2 input switch (250 A ATS 208 V input shown) Preferred wiring through the floor InfraStruXure Power Generation System 27

34 Procedures Connect utility inputs to the ATS L1, L2, L3 and EGC ATS panel board Source 1 input switch Ground Bar Neutral bar (250 A ATS 480 V input shown) Specifications and tools. The ATS input switches are equipped with box lugs (see Power and communication connections on page 7 for recommended wiring specifications). Torque utility input wires to 250 in lb (28 n m) using an 8-mm Allen wrench. Routing wires. Route conduit containing the utility input wires into the ATS using the knockouts provided on the ATS enclosure. Use a knockout punch to create an appropriate size hole. You can bring these wires into the ATS through the roof or the floor. See the illustration on the next page for suggested wiring paths for both options. If possible, use the knockouts on either side of the roof or floor rather than knockouts in the middle of the roof or floor (see page 23). Note If you are running wires through the floor of the ATS to connect to the Source 1 input switch, the phase wires will need to be at least 6.6 ft (2.0 m) longer than the equipment grounding conductor and the neutral wire. If you are running wires through the roof of the ATS to connect to the Source 1 input switch, the equipment grounding conductor and the neutral wire will need to be at least 6.6 ft (2.0 m) longer than the phase wires. 28 InfraStruXure Power Generation System

35 Procedures Making connections. 1. Connect the phase wires (L1, L2, L3) from the utility to the Source 1 input switch in the ATS. Use phase sequence (A-B-C) clockwise rotation. 2. Connect the equipment grounding conductor (EGC) from the utility to the ground bar in the ATS, and the neutral wire (if applicable) to the neutral bar in the ATS. Preferred wiring through the roof Input from utility Source 1 input switch (250 A ATS 208 V input shown) Optional wiring through the floor InfraStruXure Power Generation System 29

36 Procedures Connect the DC power input, start, and E-stop contacts Start contact TB1, terminal 1 E-stop contact TB1, terminal 2 DC contact TB1, terminal TB2 TB1 Connect ground wires at TB1, terminals 20, 21, and 22 ATS interface circuit board Connect start contact, E-stop contact, and DC contact to J51, J52, and J53 Generator controller Note: It does not matter which pin you connect the contact wire or ground wire to at J52 or J53. Specifications and tools. Use a 2.5-mm standard screwdriver to make connections to the terminal block (see Power and communication connections on page 7 for recommended wiring specifications). 30 InfraStruXure Power Generation System

37 Procedures Making connections. Make connections between the generator controller terminal block and the generator interface on the ATS interface board according to the table and diagram below: Note The ATS is shipped with its Automatic Operation Switch set to Disable and its Engine Run contacts closed. The Generator Control Switch must therefore be set to OFF before making the following connections. The Engine Run contacts will remain closed until the Automatic Operation Switch is Enabled at start-up by an APC-trained technician. Generator Terminal Block ATS Interface Board DC Input Contact Terminal 17, TB1 J51 (+) connects to Ground Terminal 20, TB1 J51 ( ) Start Contact Ground Terminal 1, TB1 Terminal 22, TB1 connects to J52 E-Stop Contact Ground Terminal 2, TB1 Terminal 21, TB1 connects to J53 Generator controller terminal blocks Generator interface on ATS interface board TB2 TB1 pg0056a InfraStruXure Power Generation System 31

38 Procedures Connect the communication cable from the ATS to the generator Install converter DB9 connection to converter ATS panel board Power connection for converter ATS monitoring unit Generator controller Specifications and tools. Use a 2.5-mm standard screwdriver to make connections to the terminal block and the converter (see Power and communication connections on page 7 for recommended wiring specifications). Installing the converter in the generator. 1. Attach the converter mounting rail (supplied) to the inside door of the generator controller using the screws included with the converter kit and a #2 Philips screwdriver. 2. Snap the converter and the converter brackets onto the rail. 3. Secure the converter on the rail by tightening the converter brackets using a 2.5-mm standard screwdriver. 32 InfraStruXure Power Generation System

39 Procedures Making Connections. 1. Connect the generator s communication converter to the generator controller according to the table below and the right side of the diagram at the bottom of this page. Generator Converter Connector Connection Point in Generator Controller [K] Tx [M] Rx [G] Ground DB9 cable connects to DB9 connector above terminal block [6] V+ Cable with Minifit connects to B+; Terminal 17 or 18 on TB1 [5] V Cable with Minifit connects to GND; Terminal 20, 21, or 22 on TB1 Cut the Minifit connector off of the cable, strip the wire ends inch, and connect to the appropriate terminals on TB1. 2. Make connections between the generator s communication converter and the communication converter in the ATS according to the table below and the diagram at the bottom of this page. ATS Converter Generator Converter Pair 1 [A] Tx+ connects to [B] Rx+ [D] Tx connects to [E] Rx Pair 2 [E] Rx connects to [D] Tx [B] Rx+ connects to [A] Tx+ Pair 3 [C] Ground connects to [C] Ground Shield/bare [F] Shield Ground No connection InfraStruXure Power Generation System 33

40 Procedures Run AC power from the ATS to the generator for the heater and battery charger ATS with 480 V input. Transformer Run line and neutral wires, and an equipment grounding conductor, in conduit from the ATS to the outlet box in the generator Run an equipment grounding conductor from the ground bar to the generator Connect the line and neutral wires to the box lugs Connect the battery charger and the block heater to the standard 120 V receptacles The GFCI receptacles are for customer use; do not connect battery charger or block heater to these receptacles Specifications and tools. Use a 2.5-mm standard screwdriver to connect wires to the transformer (see Power and communication connections on page 7 for recommended wiring specifications). Procedure for ATS with 480 V input. Run three wires (line, neutral, and equipment grounding conductor) in conduit from the ATS to the outlet box in the generator: Run an equipment grounding conductor from the ground bar to the transformer in the ATS, and from the ground bar to the outlet box in the generator. Run line and neutral wires from the transformer in the ATS to the outlet box in the generator. Equipment grounding conductor from ATS ground bar Neutral Line ATS transformer Plug the battery charger and heater into the standard 120 V receptacles in the outlet box. 34 InfraStruXure Power Generation System

41 Procedures ATS with 208 V input. Fuse block Run line and neutral wires, and an equipment grounding conductor, in conduit from the ATS to the outlet box in the generator Run an equipment grounding conductor from the ground bar to the generator Connect the line and neutral wires to the fuse block Connect the battery charger and the block heater to the standard 120 V receptacles The GFCI receptacles are for customer use; do not connect battery charger or block heater to these receptacles Specifications and tools. Use a 2.5-mm standard or #1 Philips screwdriver to make connections to the fuse block (see Power and communication connections on page 7 for recommended wiring specifications). Procedure for ATS with 208 V input. Run three wires (line, neutral, and equipment grounding conductor) in conduit from the ATS to the outlet box in the generator: Run an equipment grounding conductor from the ground bar in the ATS to the outlet box in the generator. Run line and neutral wires from the fuse block in the ATS to the outlet box in the generator. Plug the battery charger and heater into the standard 120 V receptacles in the outlet box. InfraStruXure Power Generation System 35

42 Procedures Connect branch distribution equipment to the ATS L1, L2, and L3 from data center equipment Neutral bar Ground bar Specifications and tools. Connect data center equipment to the ATS according to NEC and local codes (see Power and communication connections on page 7 for recommended circuit breaker specifications). The following table provides recommended wire sizes and torque specifications for consideration when connecting circuit breakers to the ATS panel bus. ABB Breaker Wire Size Torque T AWG 20 in lb (2.26 n m) 8 AWG 40 in lb (4.52 n m) 6 1/0AWG 45 in lb (5.08 n m) T3 1/0 14 AWG 50 in lb (5.65 n m) 300 Kcmil 4 AWG 200 in lb (22.58 n m) Installation. Install conduits to the ATS using the knockouts provided on the ATS enclosure. Use a knockout punch to create an appropriate size hole. You can run wires to the ATS through the knockouts on the roof, the floor, or the sides of the enclosure. See Appendix: Adding ATS Circuit Breakers on page 45 for instructions about installing breakers on the ATS panel bus. Electrical Hazard Hazardous voltages from the branch circuit must be isolated from the 24 VAC, the 24 VDC, and all contact closure terminals. 36 InfraStruXure Power Generation System

43 Procedures Connect an EPO switch to the user interface board and test the switch User interface board Connect the EPO switch here User connection plate ( the user connection plate has been turned upside down to clarify this connection) Specifications and tools. Connect an EPO switch to the ATS according to NEC, CEC, and local codes (see Power and communication connections on page 7 for recommended wiring specifications). Use a 2.5-mm standard screwdriver to make these connections. Caution If you are not connecting an EPO switch to the ATS, ensure the Arm/Test rocker switch on the ATS monitoring unit is in the Test position. Note APC offers an InfraStruXure EPO System (EPW9). Contact your sales representative, or go to the APC Web site for more information ( EPO switch installation instructions begin on the next page. InfraStruXure Power Generation System 37

44 Procedures Installing the EPO switch to the user interface board. 1. Connect the switch to the EPO connection terminals on the user interface board. Read the label next to the terminal block to determine which terminals correspond to your signal type: Contact Closure Normally Open USER INTERFACE 2001 APC MADE IN USA Contact Inputs Contact Outputs ATS 0 ATS 1 ATS 2 ATS EN + EPO 24V EPO AC/DC Contact External set of Normally Open Voltage-free Contacts Contact Closure Normally Closed USER INTERFACE 2001 APC MADE IN USA Contact Inputs Contact Outputs ATS 0 ATS 1 ATS 2 ATS EN + EPO 24V EPO AC/DC Contact External set of Normally Closed Voltage-free Contacts 24VAC/VDC Normally Open USER INTERFACE 2001 APC MADE IN USA External set of Normally Open Voltage-free Contacts 24 VAC or 24 VDC Power Supply Contact Inputs Contact Outputs ATS 0 ATS 1 ATS 2 ATS EN + EPO 24V EPO AC/DC Contact 2. Verify that the EPO DIP switches on the ATS monitoring unit are configured properly for your signal type. The labels above the switches and the figure below show the correct settings for both the Normally Open (NO) and Normally Closed (NC) configurations. Location of switches on ATS monitoring unit 38 InfraStruXure Power Generation System

45 Procedures Test the EPO switch. 1. Test the EPO switch to ensure it is wired properly and working correctly: a. Place the Arm/Test rocker switch on the ATS monitoring unit in the Test position. The EPO state LEDs should be off and the ATS display interface should show the following alarm (in addition to any other active alarms): Active Alarm xxofxx EPO Ready To Test b. Engage the EPO switch (if your switch is momentary, engage while one person is watching the EPO state LEDs and another is at the EPO switch). c. Observe the EPO LEDs. If the switch is wired properly and working correctly, both of the EPO state LEDs should light red when the switch is engaged. d. If the test was successful, return the Arm/Test rocker switch to the Arm position. The ATS display interface will clear the EPO test mode alarm. If the test was not successful, refer to the troubleshooting chart: Problem Neither state LED was lit red when the EPO switch was engaged Only one of the state LEDs was lit red when the EPO switch was engaged Action Check the wiring to your EPO switch. Check to make sure the EPO DIP switch configuration is correct for your switch (NO or NC). See step 2 on the previous page for proper configuration instructions. Check to make sure the EPO DIP switch configuration is correct for your switch (NO or NC) and retest. See step 2 on the previous page for proper configuration instructions. If the switch is configured correctly and both LEDs did not light red after retesting, contact APC customer support (see the back cover of this manual). e. Repeat this test for each EPO switch installed. 2. After testing is completed, ensure the Arm/Test rocker switch is in the Arm position on the ATS monitoring unit. InfraStruXure Power Generation System 39

46 Procedures Connect contacts to the user interface board User interface board Connect user input contacts and relay outputs here User connection plate (the user connection plate has been turned upside down to clarify these connections) Specifications and tools. See Power and communication connections on page 7 for recommended wiring specifications. Use a 2.5-mm standard screwdriver to make these connections. Connecting contacts. See also Refer to the Operation Manual for more information about user contacts and the types of equipment that can be connected to these contacts. 1. Choose one or more contact numbers on the user interface board for connecting contacts. The user interface board is connected to the User/EPO port on the ATS monitoring unit. 2. From the ATS display interface: a. Press ESC or ENTER to go to the top-level menu screen. b. Select Config from the top-level menu screen and press ENTER. Load-Meter ATS/Voltage Generator Testing Stats Alarms Config Help c. Select Contacts & Relays on the Config menu screen and press ENTER. System/Network Contacts & Relays Sub-Feed Config. Electrical Config. 40 InfraStruXure Power Generation System

47 Procedures d. Select the type of contact you are connecting: Contact Inputs or Relay Outputs. Contact Inputs Relay Outputs Output Relay Map Note You will be prompted for your password to configure these items. e. Press the Up or Down arrow to select the appropriate contact number and press ENTER. f. Press the Down arrow to enter a unique Name for the contact and to configure the Normal state of the contact (Open or Closed). The default Normal state is Open. Press ENTER to select the item you wish to configure. Contact In 02 of 04 Name User Contact 4 Normal: Open Status: Open g. Connect contact wires (300 V-rated cabling required) to the terminal block on the user interface board. Use a 2.5-mm standard screwdriver to make these connections. h. Run the wires from the terminal block out the roof of the ATS to your contact s location. Electrical Hazard Ensure all of these wires are properly retained and kept away from high-voltage wires and circuit breakers. InfraStruXure Power Generation System 41

48 Procedures Connect the ATS to the network at the surge-protected ethernet port Use CAT-5 cable to connect User connection plate Surge-protected ethernet port (the user connection plate has been turned upside down to clarify these connections) Management options. There are two options for managing your system: You can manage the ATS, along with the rest of your InfraStruXure equipment, through the InfraStruXure Manager (APC LAN); or you can manage your system through APC s network management interfaces (User LAN). Managing through the InfraStruXure Manager. The InfraStruXure Manager is a rack-mount management device that coordinates the management functions of APC InfraStruXure-Certified devices installed in your data center. It provides a single interface to view and configure all APC InfraStruXure-Certified devices. Refer to Configuring the InfraStruXure Manager in the Operation Manual for configuration instructions. See also For more information about the InfraStruXure Manager, refer to the Installation and Configuration Manual included with the InfraStruXure Manager. Managing through the network management interfaces. The control console and Web interfaces provide menus with options for managing your system. Refer to Configuring the ATS Network Management Interface in the Operation Manual for configuration instructions. See also For more information about the internal user interfaces, refer to the InfraStruXure Power Generation System s on-line Network Management User s Guide. The SNMP interface allows you to use an SNMP browser with the PowerNet Management Information Base (MIB) to manage your system. Refer to Configuring the ATS Network Management Interface in the Operation Manual for configuration instructions. See also To use the PowerNet MIB with an SNMP browser, refer to the PowerNet SNMP Management Information Base (MIB) Reference Guide, which is provided on the InfraStruXure Power Generation System s Utility CD. 42 InfraStruXure Power Generation System