Eaton APS3-400 Series Installation And Operation Manual Download

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Access Power Solutions Installation Guide (APS3-400 Series)

IPN 997-00012-52D July 2010

Standard Torque Settings

Use the following torque settings unless specific values are stated on the fastener or elsewhere.

Fastener Torque

1/4" cable terminals

3.9 - 4.5Nm (35 - 39 inch-pounds)

3/8" cable terminals

18.7 - 21.9Nm (166 - 194 inch-pounds)

#6-32 nuts

1.1Nm (10 inch-pounds)

#10-32 screw for ac and dc covers

3.9Nm (35 inch-pounds)

#12-24 rack/frame-mounting screws 3.9Nm

(35

inch-pounds)

Notes:

When a bolt and nut is torqued use a spanner to prevent rotation.

For battery terminals use the torque values specified by the battery manufacturer.

Summary of Contents for APS3-400 Series

Page 1: ...7 00012 52D Issue Date July 2010 Refer to the separate SC200 or SC100 system controller handbook for full details of the system controller operation www powerquality eaton com DC Manuals Eaton Corpora...

Page 2: ...e use of existing power facilities or claims against the purchaser or user by its customers resulting from the use of the information recommendations and descriptions contained herein The information...

Page 3: ...l electrical safety regulations and wiring standards Operators and maintenance staff competent in operation of dc power systems safe working practices for ac and dc powered equipment Related Informati...

Page 5: ...attery Time Remaining 8 Chapter 2 Preparation Overview 9 Warnings 10 Inspecting the Equipment and Reporting Damage 12 Chapter 3 Installation Overview 13 Installation Tasks 14 Task 1 Check the AC Suppl...

Page 6: ...ng a Rectifier 58 Replacing or Adding a Load circuit breaker 59 Replacing the System Controller 60 Replacing the Input Output Board 62 Battery Mid point Monitoring String Fail Alarm SC200 only 64 Batt...

Page 7: ...007 2010 Eaton Corporation All Rights Reserved IPN 997 00012 52D July 2010 1 C h a p t e r 1 General Description Overview Topic Page Access Power Solutions DC Power Systems 2 Model Numbers 4 Rectifier...

Page 8: ...s Front View AC supplementary protector if fitted Rectifier modules see details on page 4 SC200 or SC100 system controller see details on page 5 DC Distribution with up to 8 Load and 2 Battery Circuit...

Page 9: ...page 22 Hole to suit up to 1 conduit Some models are fitted with three ac cord sockets to suit IEC plugs see inset Load and battery cable entries Input Output I O cover 3 I O and communications cable...

Page 10: ...n conduit 50A 2 pole APS3 411 A0A APS3 421 A0A Yes Permanently connected with 3 wire in conduit No APS3 411 B0A APS3 421 B0A Yes Pluggable with 3x ac cord with IEC plugs No APS3 411 A1A APS3 421 A1A Y...

Page 11: ...k for details of system controller alarms SC200 System Controller The SC200 system controller is an advanced control and monitoring solution which provides a full suite of communications options inclu...

Page 12: ...tions connector Compatible Software The following software is compatible with the SC200 or SC100 system controller DCTools Configuration Software Latest version is available free from www powerquality...

Page 13: ...Low Voltage Disconnect LVD is fitted in some models of the Access Power Solutions APS3 400 Series see Model Numbers on page 4 This is connected as a battery disconnect For information on operation se...

Page 14: ...ining calculation will be reduced if the dc power system is connected to a predominantly resistive constant current load The following information is available about Battery Time Remaining Parameter D...

Page 15: ...Preparation Copyright 2007 2010 Eaton Corporation All Rights Reserved IPN 997 00012 52D July 2010 9 C h a p t e r 2 Preparation Overview Topic Page Warnings 10 Inspecting the Equipment and Reporting...

Page 16: ...guide Location and Environment The APS must be installed in a Restricted Access Location dedicated equipment rooms equipment closets or similar in accordance with the U S National Electric Code NEC A...

Page 17: ...short circuit Always tighten battery terminal bolts according to the battery manufacturer s specification Failing to do so can cause erratic battery performance possible damage to the battery and or p...

Page 18: ...c c Le circuit d alimentation c c ne doit comporter aucune autre prise de terre La source d alimentation du circuit c c doit tre situ e dans la m me pi ce que le mat riel Il ne doit y avoir aucun disp...

Page 19: ...Check the AC Supply and Grounding 14 Task 2 Customize APS 17 Task 3 Mount the APS in the Rack 19 Task 4 Connect External Input Output Cabling if required 23 Task 5 Connect the DC Load and Battery Cabl...

Page 20: ...teries See details on page 28 7 Mount the Battery Temperature Sensor See details on page 29 8 Connect the AC Supply Cable See details on page 29 9 Connect to the AC Supply Point See details on page 30...

Page 21: ...an integral ac supplementary protector See Model Numbers on page 4 Confirm that the following requirements are complied with 1 For permanently connected models without an integral ac supplementary pr...

Page 22: ...g curves 2 No action is required if the time current curves of the upstream ac supply disconnect devices are entirely to the right of the curves for the rectifier fuses 3 If the curve of an upstream a...

Page 23: ...d Battery circuit breakers are already fitted 1 Remove the dc circuit breaker cover see following diagram 2 Starting at the left hand end push in the load circuit breakers Leave a space either side of...

Page 24: ...nn AMA1R B2 AI 20 D DU 52 15 1 4 20A 80V dc derates to 16A Heinemann AMA1R B2 AI 20 D DU 52 20 1 5 25A 80V dc derates to 20A Heinemann AMA1R B2 AI 20 D DU 52 25 1 6 30A 80V dc derates to 24A Heinemann...

Page 25: ...ttery circuit breaker is fitted then install the supplied link between the two battery circuit breaker terminals Do not tighten the terminals until the battery cables are connected Battery circuit bre...

Page 26: ...ect position in the rack A suitable mechanical support or a second person must support the weight of the APS 3 Attach the APS using four rack mounting screws Tighten the screws Step 4 Grounding The gr...

Page 27: ...e link that bonds the dc common bar to the chassis 2 Connect a telecom ground link cable to the dc common bar as shown in the following diagram Use Wire Multi strand copper conductor 1 AWG with green...

Page 28: ...AV1CL TC12 90 Crimp tool FCI Burndy type MY29 11 2 Tighten terminal to 18 7 21 9Nm 166 194 inch pounds 3 Terminate the cable at the site s telecom ground electrode directly or via the site s telecom g...

Page 29: ...en terminal to 18 7 21 9Nm 166 194 inch pounds Terminate the Protective Earthing Conductor at a point connected to the protective earth wire in the building IEC connectors Protective earthing conducto...

Page 30: ...3 Terminate the wires into the push connect terminals see following diagram 4 Replace the I O board Input Output I O cover I O board Digital input terminals push connect type Alarm relay digital outpu...

Page 31: ...ch cable 4 pair 26AWG UTP 75 C from the SiteSure 3G module to the rear of the dc power system 2 Terminate the cable with RJ45 plugs 3 Test the insulation and continuity of the conductors 4 Connect the...

Page 32: ...ble extension Farnell part number 869 6411 or similar 4 Replace the SC200 and tighten the retaining screw For details on setup refer to Communications in the SC200 or SC100 Operation Handbook See Rela...

Page 33: ...llowing table 4 Connect the load common cable s on the common bar at the load termination points 5 Terminate the load live cable s at the load circuit breaker terminal s 6 Tighten all terminations to...

Page 34: ...p 1 Install the batteries Follow the battery supplier s manufacturer s installation instructions Step 2 Connect Mid point Monitoring sense wires SC200 only The Mid point Monitoring sense wires must ha...

Page 35: ...d for the temperature compensation control process see details in the System Controller Operation Handbook The best location for the battery temperature sensor is in the middle of the battery stand ab...

Page 36: ...ect and are tightened 2 Test the insulation resistance of the conductors according to local ac wiring regulations 3 Replace the ac terminal covers Procedure complete Task 9 Connect to the AC Supply Po...

Page 37: ...27604 1655 Tel 919 861 0225 www powerfig com Stay Online Corp 3301 Bramer Drive Raleigh NC 27604 1655 Tel 888 346 4688 Fax 919 510 5466 www stayonline com World Cord Sets P O Box 1111 Enfield CT 06083...

Page 38: ...S3 400 Series 32 Copyright 2007 2010 Eaton Corporation All Rights Reserved IPN 997 00012 52D July 2010 Installation Completed Installation of the APS is now complete Follow the instructions in Start U...

Page 39: ...2 52D July 2010 33 C h a p t e r 4 Start Up Overview Topic Page Start Up Tasks 34 Task 1 Inserting the Rectifiers 34 Task 2 Pre Power Up Checklist 35 Task 3 Applying AC Power 35 Task 4 Configuring the...

Page 40: ...ask 1 Inserting the Rectifiers Do NOT install the rectifiers until the room has been cleaned and is dust free Do NOT switch on the ac supply at this stage Step 1 Unpack the rectifiers Unpack the recti...

Page 41: ...place and all empty rectifier slots are covered with blanking panels AC supplementary protector if fitted switched off All dc circuit breakers are switched off and or fuses removed AC supply is isolat...

Page 42: ...00 system controller See details on page 40 The system controller is supplied pre loaded with a configuration file If this configuration file has been customized for the site then no further configura...

Page 43: ...onization Task 5 Applying DC Power to Battery and Load Reverse Polarity Always check that the battery cables have been terminated to the correct system polarity BEFORE connecting the batteries or clos...

Page 44: ...Equalize increases the system voltage to the Equalize voltage for the Equalize duration After the Equalize duration has expired the dc power system voltage reverts to float voltage automatically Proc...

Page 45: ...eserved IPN 997 00012 52D July 2010 39 C h a p t e r 5 System Controller Topic Page Configuration File 40 Starting the SC200 or SC100 41 SC200 or SC100 Operation using the Keypad and Screen 42 SC200 o...

Page 46: ...Restore The configuration file settings in the SC200 or SC100 can be saved to Backup or loaded from Restore a PC laptop using DCTools Web Backup and Restore can be used to Load a standard master confi...

Page 47: ...ettings Site Identity IP Address S3P Address battery characterization data Fragment dcf Restore part of a configuration file such as battery characterization data 5 Click Next and then select a file n...

Page 48: ...oft key 2 SC200 only Soft key 2 label SC200 only Keypad Access Security SC200 System Controller This feature prevents accidental or unauthorized changes to settings from the SC200 keypad All access to...

Page 49: ...ition Use the Up and Down keys to change the digits When the correct digits are entered press Logon Keypad access will return to PIN Protected mode when the display returns to the Main Screen SC100 Sy...

Page 50: ...icator will still indicate an invalid key press SC200 or SC100 Operation Using a PC Laptop DCTools is configuration software for editing a system controller s configuration file on line and monitoring...

Page 51: ...eration Handbook Before you start you will need The latest version of DCTools available from www powerquality eaton com downloads A PC laptop with USB port and USB A B cable RadioShack 55010997 Jaycar...

Page 52: ...n in the System Controller Operation Handbook For help using DCTools press F1 SC200 or SC100 Identity Information The following identity information is stored in the SC200 or SC100 Parameter Descripti...

Page 53: ...Manufacturer The manufacturer of the dc power system System Type The APS model number System Serial Number The APS serial number System Location Location of APS at the site Site Name Name of the site...

Page 55: ...the site Only perform the maintenance tasks described in the Maintenance chapter All other tasks are classified as Servicing Servicing must only be performed according to specific instructions and onl...

Page 56: ...one or more rectifiers is off Internal rectifier fault Remove the rectifier and insert another one in the same slot If second rectifier fails to start then there is a fault with the rectifier position...

Page 57: ...system will return to normal operation when the ac supply voltage is within the specified range See Specifications on page 71 DC overvoltage Remove and re insert rectifier s or shut down and restart...

Page 58: ...voltage returns to normal when faulty rectifier is removed Replace faulty rectifier with one that is working Return the faulty rectifier for service System has no dc output rectifiers are on Load cir...

Page 59: ...Starting the SC200 or SC100 on page 41 SC200 or SC100 LCD is blank and green Power On LED is on Faulty SC200 or SC100 Replace faulty SC200 or SC100 SC200 or SC100 Red LED or Yellow LED is on An alarm...

Page 60: ...ng the SC200 or SC100 keypad or DCTools SC200 or SC100 displays Config Error Incorrect rectifier voltage because installed rectifiers have different output voltages Check that all rectifiers are of th...

Page 61: ...o change settings See Write Access Password in the System Controller Operation Handbook Serial communications are disabled SC200 only S3P Access is disabled Set S3P Access to Enabled See details in th...

Page 62: ...ry Check web browser type and version See Compatible Software on page 6 Lost Logon ID and or Password Use DCTools to set up a new Logon ID and or Password See Web Access Security in the System Control...

Page 63: ...contactor is de energized None this is normal operation LVD Status LED s flashing The contactor is in the wrong state SC200 or SC100 internal state does not match signal from contactor auxiliary swit...

Page 64: ...helf Do not attempt to disassemble faulty rectifiers Return them in their original packaging with a completed Equipment Incident Report on page 101 Removing a Rectifier Step 1 Undo the rectifier retai...

Page 65: ...ar connector 4 Check that the rectifier s Power On LED turns on after the startup delay and the alarm LEDs turn off The rectifier will automatically register with the system controller and download it...

Page 66: ...ntroller However a system controller configured for a particular nominal system voltage 48V or 24V can only be converted to the other nominal system voltage by loading a new configuration file A copy...

Page 67: ...a master configuration file is not available then use the keypad or DCTools Web to change the configuration settings to the correct values provided the system controller is set for the correct nomina...

Page 68: ...l be powered by the rectifiers On the SC200 go to Battery LVDs LVD x Not Characterized Edit or on the SC100 go to Menu Configuration LVD1 LVD2 Select Characterize Press Enter The LVD contactor will di...

Page 69: ...200 or SC100 will show various alarms Press any button to silence the alarm 3 Return the board for service See Equipment Incident Report on page 101 4 Connect all cables to the new I O board 5 Check t...

Page 70: ...ation Error alarm will clear Procedure complete Battery Mid point Monitoring String Fail Alarm SC200 only Use the following procedure if a String Fail alarm is generated Step 1 Identify the faulty bat...

Page 71: ...nobloc 2 After the faulty cell monobloc has been serviced or replaced clear the alarm see Step 3 Procedure complete Battery Disposal and Recycling Follow Environmental Protection Agency EPA guidelines...

Page 73: ...platform s and access for working at height if required Essential Tools Standard electrical toolkit with insulated tools plus Cable crimping tool and crimp lugs suitable for all cable sizes and connec...

Page 74: ...on the fastener or elsewhere Fastener Torque 1 4 cable terminals 3 9 4 5Nm 35 39 inch pounds 3 8 cable terminals 18 7 21 9Nm 166 194 inch pounds 6 32 nuts 1 1Nm 10 inch pounds 10 32 screw for ac and d...

Page 75: ...em controller See replacement procedure on page 60 Eaton SC200 00 or SC100 00 4 Input Output Board See replacement procedure on page 62 Eaton IOBGP 01 5 Circuit breaker blank panel to cover un used ci...

Page 76: ...A Heinemann AMA1R B2 AI 20 D DU 52 30 1 7 40A 80V dc derates to 32A Heinemann AMA1R B2 AI 20 D DU 52 40 1 8 50A 80V dc derates to 40A Heinemann AMA1R B2 AI 20 D DU 52 50 1 9 60A 80V dc derates to 48A...

Page 77: ...8 AWG See details on page 29 14 AWG See details on page 30 Maximum Ground Leakage Current 1 3mA per rectifier System Output Output Voltage nominal 48V Output Voltage Range Preset Voltage 43 58V 54 5V...

Page 78: ...3 400 3U 19 or 23 mounting 13 6 345 mm Additional clear air space is required at rear for rectifier exhaust air venting See details on page 19 Weight APS3 400 30 lb 13 8kg Rectifier modules 3 7 lb 1 7...

Page 79: ...Types Voltage free switch or relay contacts only Input Range Live Bus to Live Bus 5V Input Common Same bus as used for current shunts Live bus is standard Input Protection Protected against damage fro...

Page 80: ...o 35V Resolution 30mV Accuracy 0 5 at 25 C 77 F 1 over rated temperature range Communications USB SC200 only Version Connector 1 1 12Mbits s USB B female RS232 Interface Connector RS232 DTE DB9M Ether...

Page 81: ...eserved IPN 997 00012 52D July 2010 75 A p p e n d i x D Controller Menus SC200 Menu At each menu screen press Enter to access the associated configuration menu screen s These menus have multiple conf...

Page 82: ...IPN 997 00012 52D July 2010 SC100 Menu The following diagram shows the Status Screens and main navigation Any active alarms are displayed in rotation Scroll to show any other rectifiers List of any a...

Page 83: ...scription 1 2 RD Receive Data 3 TD Transmit Data 4 DTR Data Terminal Ready 5 Common Ground 6 7 RTS Request to Send 8 XS1 DB9M RS232 Serial Interface 9 1 Rx 2 Rx 3 Tx 4 5 6 Tx 7 XS31 SC200 only RJ45 Et...

Page 84: ...Power Solutions Installation Guide APS3 400 Series 78 Copyright 2007 2010 Eaton Corporation All Rights Reserved IPN 997 00012 52D July 2010 8 1 1 8 RS232 D9M and RJ45 connector pin outs RJ45 plug pin...

Page 85: ...h common 1 Current Input 1 Common 2 Current Input 1 3 12V out 4 Current Input 2 Common 5 Current Input 2 6 0V out 7 Current Input 3 Common XH6 RJ45 Current Sense Inputs 8 Current Input 3 1 2 3 4 Temp...

Page 86: ...1 Relay 3 normally closed NC 2 Relay 3 normally open NO 3 Relay 3 Common COM 4 Relay 4 normally closed NC 5 Relay 4 normally open NO XH18 XH19 Digital relay outputs 3 4 6 Relay 4 Common COM 1 Relay 5...

Page 87: ...and connections for the SC200 or SC100 system controller The I O board allows real time data collection from building services and other external devices and relay outputs for alarm signals or control...

Page 88: ...ower and RXP comms input YH11 Current sense input XH6 Temperature sense input XH7 Battery Mid point Monitoring sense inputs XH12 SC200 only DC power system digital inputs YH3 3 Bus voltage sense input...

Page 89: ...s 6 from external voltage free switches or relay contacts 5 Connection to additional I O board s and or SiteSure 3G I O module s SC200 only Connection to dc common bus Connection to dc live bus Commun...

Page 91: ...tion tasks see details on page 14 Complete all the Start Up tasks see details on page 34 Save a copy of the configuration file Complete the Commissioning tasks in the following order During the testin...

Page 92: ...correct polarity Adjust the gain setting on the current sensor by moving the trim pot Adjust the gain setting in DCTools Web Total System Current High current test Repeat the load test Ensure the sys...

Page 93: ...us If batteries are not installed on the system connect the load bank to the battery bus If the battery current is determined by a summation conduct the load current test before the battery current te...

Page 94: ...to a value approximately 1V below the system float voltage Connect load to the system Turn off the ac to the system Allow the system voltage to fall below the Fast Charge Voltage Threshold Turn on the...

Page 95: ...he SC200 or SC100 Ensure the Battery Test stops and the system voltage returns to the float voltage setting Clear the Battery Test Fail alarm in DCTools Web Set the Battery Test Duration to 1 minute S...

Page 96: ...hreshold Wait for the configured Recognition Period Ensure the LVD disconnects Ensure the SC200 or SC100 displays an LVD Disconnected alarm Ensure the I O board LVD LED is off Increase the system volt...

Page 97: ...nt fluctuations above and below the configured current limit setting This can be due to the current control within the factory preset deadband Confirmation of this control process may be witnessed in...

Page 98: ...t the battery from the system Start a Battery Test The system voltage will fall Ensure alarm operates Low Load Test as for the Low Float test Note that the Low Load Threshold is lower than the Low Flo...

Page 99: ...e Ensure alarm operates Battery Test Fail See Battery Test in the System Controller Operation Handbook for details MOV Fail Remove a MOV cartridge from the MOV housing if fitted Ensure alarm operates...

Page 100: ...details see Battery Current Limit test in System Controls on page 88 Rectifier No Load Ensure the dc load and batteries are isolated from the system Ensure alarm operates Rectifier Current Limit Apply...

Page 101: ...configuration to be installed after commissioning 5 This alarm is originated from the rectifier It can only be tested by increasing the internal temperature of the rectifier 6 These alarms are only av...

Page 102: ...e Digital Output 2 As for Digital Output 1 Digital Output 3 As for Digital Output 1 Digital Output 4 As for Digital Output 1 Digital Output 5 As for Digital Output 1 Digital Output 6 Note 2 As for Dig...

Page 103: ...rcuit Diagrams Copyright 2007 2010 Eaton Corporation All Rights Reserved IPN 997 00012 52D July 2010 97 A p p e n d i x G Circuit Diagrams Drawing Number Issue Title 3693387 F WIRING DIAGRAM APS3 4XX...

Page 107: ..._____________________________________________________________ Location of Failure Product code ___________ Serial number __________ Document number _____________ System type installed in _____________...

Page 108: ...___________________________________________ ______________________________________________________________________________________ _____________________________________________________________________...

Page 109: ...est office from the following list telephone 64 3 343 7448 or email CustomerServiceNZ eaton com Australia 1300 877 359 Canada 1 800 461 9166 Central America 52 55 9000 5252 China 86 571 8848 0166 86 5...

Page 111: ...stallation 28 Disposal and Recycling 65 Mid Point Monitoring MPM 7 28 74 Reverse Polarity 37 String Fail Alarm 52 64 Temperature Sensor 73 83 Time Remaining 8 Battery Circuit Breakers 52 70 Connecting...

Page 112: ...round Connection 20 Ground Leakage Current 71 Site Ground 16 GSM Modem Communications 7 55 H High AC Voltage Protection 14 I Identity Information 46 IEC Sockets Cords 3 30 Input Output I O Board Conne...

Page 113: ...imination Rectifier LEDs 4 Rectifier Replacement 58 Registration 35 Repair and Return 101 Startup 35 Relays See Digital Outputs Relays Monitor OK Alarm 53 Repair and Return 101 Reverse Polarity 37 RS2...

Page 114: ...Temperature Sensor 73 83 Text Messaging SMS See GSM Modem Communications Time See Internal Clock Time Remaining 8 Tools 67 Torque Settings 68 Troubleshooting 50 Damage transport 12 34 Repair and Retu...

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