Eaton APS6-400 Series Installation And Operation Manual Download Page 74

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Access Power Solutions Installation Guide (APS6-400 Series)

IPN 997-00012-53B December 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 APS6-400 Series

Page 1: ...00012 53B Issue Date December 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 Corpo...

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: ...cal 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 Informa...

Page 5: ...g Option SC200 only 8 Battery 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 Ta...

Page 6: ...Access Security 44 Alarm Indicators 45 SC200 or SC100 Operation Using a PC Laptop 46 Using DCTools via USB SC200 only 46 Using DCTools via RS232 46 SC200 or SC100 Identity Information 48 Chapter 6 Mai...

Page 7: ...ppendix C Specifications LVD Specifications APS6 400 70 Appendix D Controller Menus SC200 Menu 73 SC100 Menu 74 Appendix E Connector Pin outs System Controller Connector Pin outs 75 I O Board IOBGP 00...

Page 9: ...9 2010 Eaton Corporation All Rights Reserved IPN 997 00012 53B December 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 Rectifi...

Page 10: ...er see details on page 5 Battery circuit breaker cover Battery circuit breakers up to 6 alarm on electrical trip or when switched off Connected to optional battery disconnect LVD if fitted Protective...

Page 11: ...covers with holes to suit up to 1 conduit Input Output I O cover I O Board see details on page 79 Load and Battery common bar DC common chassis ac ground link see details on page 23 Load live cable t...

Page 12: ...0 Battery and low priority load In APSs without an internal battery disconnect LVD either the total battery current must be less than 285A or the APS must be protected by an external battery LVD set t...

Page 13: ...ndbook 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...

Page 14: ...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 15: ...ent System BMS using Modbus Alarm and status messages to GSM Short Messaging Service SMS text capable cell phones Communication with an alarm management system using voltage free relay contacts on an...

Page 16: ...o calculate an estimated time until the battery will reach the specified end voltage If a battery disconnect LVD is fitted then the end voltage will usually be the voltage at which the LVD disconnects...

Page 17: ...reparation Copyright 2009 2010 Eaton Corporation All Rights Reserved IPN 997 00012 53B December 2010 9 C h a p t e r 2 Preparation Overview Topic Page Warnings 10 Inspecting the Equipment and Reportin...

Page 18: ...I NFPA No 70 and according to the applicable local codes For ease of access and to maintain optimum system cooling observe the clearances stated on page 22 Ensure the ambient temperature and humidity...

Page 19: ...ng to the battery manufacturer s specification Failing to do so can cause erratic battery performance possible damage to the battery and or personal injury There is a risk of electric shock if a batte...

Page 20: ...s au conducteur de terre du m me circuit d alimentation c c doivent tre install s proximit les uns des autres p ex dans des armoires adjacentes et proximit de la prise de terre du circuit d alimentat...

Page 21: ...lation Tasks 14 Task 1 Check the AC Supply and Grounding 14 Task 2 Customize APS 16 Task 3 Mount the APS in the Rack 22 Task 4 Connect External Input Output Cabling if required 25 Task 5 Connect the D...

Page 22: ...s on page 28 6 Install the Batteries See details on page 30 7 Mount the Battery Temperature Sensor See details on page 31 8 Connect the AC Supply Cable See details on page 32 Task 1 Check the AC Suppl...

Page 23: ...ernal circuit breaker s must be two pole type wired in each conductor if the ac supply is 2W see Specifications on page 69 or the ac supply is 1W N but the neutral is not clearly identified Step 4 Che...

Page 24: ...t all grounds are brought together at one star point so that surge currents cannot flow in ground loops and create large voltages Procedure complete Task 2 Customize APS Step 1 Change mounting bracket...

Page 25: ...m 2 Starting at the left hand end push in the load circuit breakers Leave a space either side of any 80A or 100A circuit breakers to maintain their thermal performance Use only Heinemann UL Listed DIV...

Page 26: ...20 D DU 52 20 1 5 25A 1 pole 80V dc derates to 20A Heinemann AMA1R B2 AI 20 D DU 52 25 1 6 30A 1 pole 80V dc derates to 24A Heinemann AMA1R B2 AI 20 D DU 52 30 1 7 40A 1 pole 80V dc derates to 32A He...

Page 27: ...51 5 150A 2 pole 80V dc Heinemann AM2R B39 LJ 20 D DU 52 150 251 6 200A 2 pole 80V dc Heinemann AM2R B39 LJ 20 D DU 52 200 251 Step 3 Link Load and or Battery circuit breaker terminals if required For...

Page 28: ...unds Fit the contactor and tighten the M10 nuts to 18 7 21 9Nm 166 194 inch pounds Connect the contactor control cable to the contactor Or to remove the battery LVD contactor Disconnect the contactor...

Page 29: ...d LVD contactor Disconnect the contactor control cable from the contactor Undo the two bolts and remove the contactor and bus work Fit the link bar and tighten the M8 bolts to 9 5 11 1Nm 85 98 inch po...

Page 30: ...upply N L2 L L1 to Rectifier 1 N L2 L L1 to Rectifier 2 N L2 L L1 to Rectifier 3 N L2 L L1 to Rectifier 4 N L2 L L1 to Rectifier 5 N L2 L L1 to Rectifier 6 Procedure complete Task 3 Mount the APS in t...

Page 31: ...ack 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 grounding arrangement o...

Page 32: ...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 3 0 AWG with green yellow insulation St...

Page 33: ...0 AWG cable is not available use 2 0 AWG cable and appropriate UL Listed Crimp Lug 2 Tighten terminal to 18 7 21 9Nm 166 194 inch pounds 3 Terminate the cable at the site s telecom ground electrode di...

Page 34: ...ns on page 70 1 Route the cabling through the access hole in the Input Output cover to the terminal blocks on the I O board 2 Test the insulation and continuity of the cabling 3 Terminate the wires in...

Page 35: ...ing features Digital Inputs 10 Digital Outputs relays 6 Analog Inputs 10V to 10V 4 Current Sense Inputs 3 Temperature Sense Inputs 2 Bus Voltage Input 0 60V 1 1 Route CAT 3 patch cable 4 pair 26AWG UT...

Page 36: ...imilar 4 Replace the SC200 and tighten the retaining screw For details on setup refer to Communications in the SC200 or SC100 Operation Handbook See Related Information on page i Procedure complete Ta...

Page 37: ...ent 2 Part numbers are for FCI BURNDY products In US Canada use these parts or equivalent UL listed crimp lugs 3 If 3 0 AWG cable is not available use 2 0 AWG cable and appropriate UL Listed Crimp Lug...

Page 38: ...DY products In US Canada use these parts or equivalent UL listed crimp lugs 4 If 3 AWG cable is not available use 2 AWG cable and YA2CL 2TC14 crimp lug Y1MR crimping tool Step 3 Check terminations sec...

Page 39: ...terminal 2 Tighten the terminals according to the battery supplier s manufacturer s installation instructions 3 Insulate any un connected sense wires 4 Secure all sense wires to avoid any strain on th...

Page 40: ...he diagram on page 3 2 Check that the APS is correctly wired for either two or three ac feeds as required See details on page 21 Step 2 Route the ac wiring 1 Use Two ac feeds 8 AWG wire rated 90 C Thr...

Page 41: ...ollow the manufacturer s instructions and local wiring regulations 3 Label the connection at the ac supply point Step 4 Check terminations secure cable and test insulation 1 Check all terminations are...

Page 43: ...53B December 2010 35 C h a p t e r 4 Start Up Overview Topic Page Start Up Tasks 36 Task 1 Inserting the Rectifiers 36 Task 2 Pre Power Up Checklist 37 Task 3 Applying AC Power 37 Task 4 Configuring t...

Page 44: ...Task 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 rec...

Page 45: ...lectrically isolated from the dc power system The site is clean Task 3 Applying AC Power A registered electrician or suitably qualified person must check the integrity of the installed cabling BEFORE...

Page 46: ...see Related Information on page i for details on how to customize the system s configuration Parameter Action Where to find Float Voltage Set to the value recommended by the battery manufacturer SC10...

Page 47: ...ect system polarity will damage the rectifiers and void all warranty claims Step 1 Check dc voltage and polarity Check the dc output voltage and polarity of the power system and the battery string s S...

Page 48: ...the Equalize duration After the Equalize duration has expired the dc power system voltage reverts to float voltage automatically Procedure complete Start Up Completed Start Up of the APS is now comple...

Page 49: ...erved IPN 997 00012 53B December 2010 41 C h a p t e r 5 System Controller Topic Page Configuration File 42 Starting the SC200 or SC100 43 SC200 or SC100 Operation using the Keypad and Screen 44 SC200...

Page 50: ...d 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 con...

Page 51: ...acterization data Fragment dcf Restore part of a configuration file such as battery characterization data 5 Click Next and then select a file name to Restore a configuration Starting the SC200 or SC10...

Page 52: ...hanges can be made Contact your Eaton dc product supplier or Eaton for advice see Worldwide Support on page 101 To use DCTools Web to enable disable keypad access In DCTools Web go to Communications F...

Page 53: ...r 5 seconds Keypad access is now temporarily enabled Keypad access control reverts back to Protected mode after the display goes back to the Summary screen Alarm Indicators Visual indicators Power on...

Page 54: ...PC laptop connection details see Communications Options in the System Controller Operation Handbook Before you start you will need The latest version of DCTools available from www powerquality eaton c...

Page 55: ...S232 port on the PC laptop to the RS232 connector on the SC200 or SC100 Ensure the cable is secured so that no force is applied to the RS232 connector as this may damage the connector If COM1 port is...

Page 56: ...e embedded software in the SC200 or SC100 factory set If required the following site specific information can be stored in the SC200 or SC100 to assist site management Parameter Description Where to f...

Page 57: ...o 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 o...

Page 58: ...ier and tighten retaining screw 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 positi...

Page 59: ...ac supply failed Power system will return to normal operation when the ac supply voltage is within the specified range See Specifications on page 69 DC overvoltage Remove and re insert rectifier s or...

Page 60: ...tifier 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 circuit breaker open Check for open circuit b...

Page 61: ...None The power system including the SC200 or SC100 will return to normal operation when the ac supply is within its specified voltage range Faulty Voltage Feed Module VFM or faulty SC200 or SC100 Repl...

Page 62: ...SC100 displays Config Error Missing or invalid configuration file Either Load a valid configuration file into the SC200 or SC100 See Backup and Restore on page 42 or Change one or more configuration s...

Page 63: ...to 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...

Page 64: ...nd or Password See Web Access Security in the System Controller Operation Handbook Default User log on is not available Default User is not setup or not active Use DCTools to set up a Default User See...

Page 65: ...set to AUTO See details in the System Controller Operation Handbook Check that the contactor is correctly configured and mapped to the I O board See details in the System Controller Operation Handbook...

Page 66: ...ted Step 2 Align the rectifier with the guides Step 3 Push in the rectifier 1 Push in the rectifier until the retaining screw contacts the shelf 2 Check the rectifier s rear connector is correctly ali...

Page 67: ...diagram on page 2 Step 2 Remove existing circuit breaker if required Pull circuit breaker forward to remove Step 3 Plug in new circuit breaker Remove circuit breaker blank panel if fitted Follow the...

Page 68: ...on file either use the configuration file saved from the existing system controller or contact your Eaton dc power system supplier to obtain a master configuration file to suit the dc power system Thi...

Page 69: ...e See details in the System Controller Operation Handbook 2 Check that the system controller has registered all rectifiers 3 Check all control processes alarms and current measurement s 4 Check the po...

Page 70: ...fitted then the equipment connected to circuit breakers 1 10 will be disconnected when the I O board is removed Before you start you will require A PC Laptop with DCTools connected to the system cont...

Page 71: ...f required Ignore this Step if there is no LVD Characterization alarm 1 On the SC200 go to Battery LVDs LVD x Not Characterized Edit or on the SC100 go to Menu Configuration LVD1 LVD2 2 If available s...

Page 72: ...e average Step 3 Check cell monobloc terminals 1 Check the terminal connections of the cell monobloc are correctly tightened and clean Refer to the battery manufacturer s instructions for correct term...

Page 73: ...e 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 conn...

Page 74: ...d 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...

Page 75: ...reaker blank panel to cover un used circuit breaker positions Eaton 621 05985 45 6 Crimp lugs for load and battery cables See details on page 28 7 2 pole load circuit breaker linking bus Eaton 621 107...

Page 76: ...20 D DU 52 50 1 9 60A 1 pole 80V dc derates to 48A Heinemann AMA1R B2 AI 20 D DU 52 60 1 10 80A 1 pole 80V dc derates to 64A Heinemann AMA1R B2 AI 20 D DU 52 80 1 11 100A 1 pole 80V dc derates to 70A...

Page 77: ...r Input Fuses internal 16A 250V System Output Output Voltage nominal 48V Output Voltage Range Preset Voltage 43 58V 54 5V 0 1V Total Output maximum APR48 ES rectifiers 120V ac 208 240V ac 7 2kW 150A m...

Page 78: ...40 C to 45 C Relative Humidity operating and storage 95 non condensing Dimensions H W D APS6 400 6U 19 or 23 mounting 15 3 390 mm Additional clear air space is required at rear for rectifier exhaust...

Page 79: ...Number of Temperature Sense Inputs 2 One only connected as standard Second input available requires additional temperature sensor Range 2 53V to 3 43V 20 to 70 C 4 to 158 F Resolution 0 01V 1 C 1 8 F...

Page 80: ...tions USB SC200 only Version Connector 1 1 12Mbits s USB B female RS232 Interface Connector RS232 DTE DB9M Ethernet SC200 only Interface Connector Protocols 10baseT RJ45 TCP IP SNMP S3P over IP http W...

Page 81: ...erved IPN 997 00012 53B December 2010 73 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 co...

Page 82: ...SC100 Menu The following diagram shows the Status Screens and main navigation See Analog System Values for details of the values displayed Any active alarms are displayed in rotation Scroll to show a...

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

Page 84: ...ower Solutions Installation Guide APS6 400 Series 76 Copyright 2009 2010 Eaton Corporation All Rights Reserved IPN 997 00012 53B December 2010 8 1 1 8 RS232 D9M and RJ45 connector pin outs RJ45 plug p...

Page 85: ...tch common XH6 RJ45 Current Sense Inputs 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 8 Current Input 3 XH7 RJ45 Te...

Page 86: ...M XH18 XH19 Digital relay outputs 3 4 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 6 Relay 4 Common COM XH20 XH2...

Page 87: ...n outs Input Output Board The input output I O board provides the I O interfaces and connections for the SC200 or SC100 system controller The I O board allows real time data collection from building s...

Page 88: ...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 Bus voltage sense input XH9 Po...

Page 89: ...ee switches or relay contacts 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 Communications to rectifiers DC powe...

Page 91: ...lation tasks see details on page 14 Complete all the Start Up tasks see details on page 36 Save a copy of the configuration file Complete the Commissioning tasks in the following order During the test...

Page 92: ...he 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 s...

Page 93: ...Bus 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...

Page 94: ...d 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 t...

Page 95: ...the 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...

Page 96: ...Threshold 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 vo...

Page 97: ...rent 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 i...

Page 98: ...ect 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 F...

Page 99: ...use 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 operate...

Page 100: ...r details see Battery Current Limit test in System Controls on page 86 Rectifier No Load Ensure the dc load and batteries are isolated from the system Ensure alarm operates Rectifier Current Limit App...

Page 101: ...t 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...

Page 102: ...igital 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 Digital Output 1 User assigned Digital Outputs...

Page 103: ...rcuit Diagrams Copyright 2009 2010 Eaton Corporation All Rights Reserved IPN 997 00012 53B December 2010 95 A p p e n d i x G Circuit Diagrams Drawing Number Issue Title 3700272 B WIRING DIAGRAM APS6...

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

Page 108: ..._____________________________________________ ______________________________________________________________________________________ ___________________________________________________________________...

Page 109: ...osest 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...

Page 111: ...ery Fuses 52 Battery Installation 30 Disposal and Recycling 65 Mid Point Monitoring MPM 8 30 74 Reverse Polarity 39 String Fail Alarm 53 64 Temperature Sensor 73 83 Time Remaining 8 Battery Circuit Br...

Page 112: ...d AC DC Ground Connection 23 Ground Leakage Current 71 Site Ground 15 GSM Modem Communications 7 55 H High AC Voltage Protection 14 I Identity Information 48 IEC Sockets Cords 3 Input Output I O Board...

Page 113: ...fier Current 43 Rectifier Fuses See AC Discrimination Rectifier LEDs 4 Rectifier Replacement 58 Registration 37 Repair and Return 100 Startup 37 Relays See Digital Outputs Relays Monitor OK Alarm 53 R...

Page 114: ...hnical Assistance 103 Temperature 72 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 Da...

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