Eaton DV2-A10B Installation And Operation Manual Download Page 23

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Chapter 4

DC Cabling



IPN 997-00012-82B May 2011

DC Cabling

Overview

Topic

Page

DC Installation Practices

Connecting the Telecom Earth Cable

Fit or Remove Low Voltage Disconnects

Load Cables and Circuit Breakers

Fit DCM2000 in Battery Cabinet (if required)

Summary of Contents for DV2-A10B

Page 1: ...deo 3G Power Solutions Installation and Operation Guide UL Listed Models Issue IPN 997 00012 82B Issue Date May 2011 Eaton Corporation Telecommunications Power Solutions www eaton com telecompower DCi...

Page 2: ...the 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 informatio...

Page 3: ...n and maintenance of Eaton Data Voice Video 3G Power Solutions It does not cover System controller operations installation of external alarm and user digital inputs cabling or setup of communications...

Page 4: ...ns UL Listed Models ii Copyright 2011 Eaton Corporation All Rights Reserved IPN 997 00012 82B May 2011 For Further Information and Technical Assistance For further information and technical assistance...

Page 5: ...nt Monitoring Description 8 Reverse Battery Detect Option 8 Bottom Cable Entry Option 8 Chapter 2 Preparation Overview 9 Warnings 10 Inspecting the Equipment and Reporting Damage 12 Chapter 3 Position...

Page 6: ...iew 49 Troubleshooting 50 Replacing or Adding a Rectifier 54 Replacing or Adding a Circuit Breaker 55 Replacing the System Controller 55 Replacing the Input Output Board 58 Battery Mid point Monitorin...

Page 7: ...pyright 2011 Eaton Corporation All Rights Reserved IPN 997 00012 82B May 2011 1 C h a p t e r 1 General Description Overview Topic Page DC Power Systems 2 Rectifiers 3 SC200 System Controller 3 Input...

Page 8: ...200 system controller see details on page 3 Also refer to the system controller handbook listed in Related Information on page i 3U space for other equipment DV2 A10B models only Rectifier magazine fo...

Page 9: ...n page 50 for details of rectifier alarms Left APR24 3G and APR48 3G Right APR48 ES Power On LED Green Minor Alarm LED Yellow Major Alarm LED Red Serial Number Retaining Screw Tighten to 1 5Nm 13 3 in...

Page 10: ...0 for details of SC200 alarms For connector pin outs refer to the SC200 Operation Handbook see Related Information on page i Compatible Software The following software is compatible with the SC200 sys...

Page 11: ...71 Bus voltage sense input XH9 Power Comms OK LED green Digital inputs D1 D6 6 user defined XH15A XH15B Digital relay outputs RY1 RY6 6 XH16 XH21 LVD contactor 2 status LED green LVD contactor 2 conn...

Page 12: ...ts Connection to additional I O board s and or SiteSure 3G I O module s via RJ45 splitter see details Connection to dc common bus Connection to dc live bus Communications to rectifiers DC power system...

Page 13: ...cts LVDs The LVD s are connected to disconnect the low priority loads LVD 1 and to disconnect the battery LVD 2 LVDs have two purposes to protect a VRLA battery from deep discharge and premature failu...

Page 14: ...cell s and action can be taken to correct the problem and prevent a total battery failure To connect Battery Mid point Monitoring see details on page 29 If a String Fail alarm is generated see Troubl...

Page 15: ...r 2 Preparation Copyright 2011 Eaton Corporation All Rights Reserved IPN 997 00012 82B May 2011 9 C h a p t e r 2 Preparation Overview Topic Page Warnings 10 Inspecting the Equipment and Reporting Dam...

Page 16: ...ording to the applicable local codes For ease of access and to maintain optimum system cooling observe the clearances stated on page 14 Ensure the ambient temperature and humidity are within the range...

Page 17: ...injury There is a risk of electric shock or explosion if a battery is replaced by an incorrect type Dispose of batteries according to the instructions on page 60 Rectifiers Do not install the rectifi...

Page 18: ...onducteur 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 alimentation c c...

Page 19: ...inets Copyright 2011 Eaton Corporation All Rights Reserved IPN 997 00012 82B May 2011 13 C h a p t e r 3 Positioning Cabinets Overview Topic Page Preparation 14 Fixing Cabinets 14 Fit the Rear Extensi...

Page 20: ...t of the system and for opening the security door minimum 24 610mm Allow for working space behind the system minimum 24 600mm Allow space at one end for access to the space behind the system Allow dis...

Page 21: ...ccess holes Area covered by rear extension cabinet if fitted see details on page 15 Fit the Rear Extension Cabinet if required Ignore this task if only top cable entry is used The optional rear extens...

Page 22: ...012 82B May 2011 Step 2 Replace the rear panel of the DV2 3G Remove rear panel Fit the 30U high panel supplied with the rear extension cabinet kit Step 3 Fit the rear extension cabinet Assemble the re...

Page 23: ...ved IPN 997 00012 82B May 2011 17 C h a p t e r 4 DC Cabling Overview Topic Page DC Installation Practices 18 Connecting the Telecom Earth Cable 18 Fit or Remove Low Voltage Disconnects 19 Load Cables...

Page 24: ...inside the Data Voice Video 3G Power Solutions especially at their connection points to prevent excessive strain on these cables To reduce inductive coupling separate the dc load battery and control c...

Page 25: ...8L BOX Crimping tool MY29 11 dieless Part numbers are for FCI BURNDY products In US Canada use these parts or equivalent UL Listed crimp lugs In other countries use equivalent parts Fit or Remove Low...

Page 26: ...s to 1 1 1 3Nm 9 8 11 5 inch pounds Fit the two pieces of bus work to the contactor Tighten the four M12 nuts to 32 8 38 4Nm 292 340 inch pounds Tighten the two M10 bolts and two M10 nuts to 18 7 21 9...

Page 27: ...Undo the two M10 bolts and remove the link bar Fit the two pieces of bus work to the contactor Tighten the two M10 nuts to 18 7 21 9Nm 166 194 inch pounds Fit the contactor assembly Ensure the contact...

Page 28: ...ity will void all warranty claims Refer to the Specifications on page 65 for the maximum load currents Front cover hinged screw fixed Circuit breaker cover Up to 20 circuit breakers dependent on ratin...

Page 29: ...ole or 3 pole insulator as required Fit a 2 pole or 3 pole cable connection plate to the circuit breaker terminals and common bar For circuit breakers rated 100A or greater leave an empty position eit...

Page 30: ...r 2 Connect the live negative cables to the circuit breaker terminals Step 5 Check terminations secure cables and test insulation 1 Check all terminations are correct and tighten to 1 4 studs 3 9 4 5N...

Page 31: ...on battery cabinet Remove 4U blank panel Mount DCM2000 using four mounting screws Step 2 Connect DCM2000 common bar 1 Use the two common link bar assemblies to connect the common bar in the DCM2000 an...

Page 32: ...dc power system cabinet to the extension battery cabinet 3 If the second DCM2000 is to have two feeds separate priority and non priority distributions then remove the link bar 4 Terminate the live cab...

Page 33: ...5 Battery Installation Copyright 2011 Eaton Corporation All Rights Reserved IPN 997 00012 82B May 2011 27 C h a p t e r 5 Battery Installation Overview Topic Page Battery Types 28 Installing the Batte...

Page 34: ...g are recommended Battery Installation Practices These supplement any specific installation instructions from the battery manufacturer General Do not wear a synthetic dust coat or overalls Synthetic f...

Page 35: ...tal objects onto intercell connections or terminals of opposite polarity Check that loose cables cannot make contact with other cables or terminals which may be live Install the Batteries Installation...

Page 36: ...ositive terminal of the string for 48V positive earth dc systems or the negative terminal of the string for 24V negative earth dc systems 5 Check the cables are close to the sides of monoblocs so they...

Page 37: ...ing cable and crimp lugs Conductor Copper stranded single core Temperature rating 194 F 90 C minimum Cable size minimum 2 300 kcmil for each pole Metric cable size equivalent min 2 150mm2 for each pol...

Page 38: ...live negative cables 1 Run a live negative battery cable link internally from the first battery rack to the rectifier rack 2 Bolt the ring crimp lugs to the live negative busbar in the battery rack a...

Page 39: ...pyright 2011 Eaton Corporation All Rights Reserved IPN 997 00012 82B May 2011 33 C h a p t e r 6 AC Cables Overview Topic Page Input Transient Protection 34 Connecting to the AC Supply 37 Connecting t...

Page 40: ...ltage surge suppression plan that includes Primary surge protection Secondary surge protection Primary secondary surge decoupling coils Secondary tertiary surge decoupling coils 6 Protect the data and...

Page 41: ...es to protect the dc power system from transients Secondary transient protection for 3P N PE system Phase to neutral metal oxide varistors MOVs with a voltage rating to suit the supply voltage capable...

Page 42: ...wing diagrams 3P N PE Systems Supply transformer Building entrance Main switchboard Fuses Primary transient protection refer to text for rating Building earth ground busbar Primary secondary surge dec...

Page 43: ...Inputs on the supervisory module preferred option or to the building management system See Installing External Alarm and User Digital Inputs Cabling for details of Digital Inputs Regular inspection o...

Page 44: ...p 3 Connect the protective earth conductor Ensure that the ac supply earth conductor is 30 50mm 1 2 inches longer than the live conductors L1 L2 and L3 1 A Service Person shall check whether or not th...

Page 45: ...11 39 3W N PE 3W PE 2W PE or 1W N PE Ferrite toroids Protective earth bonding connections to cabinet frame dc common bar and rectifier magazine chassis RM1 Rectifier Magazine 1 RM2 Rectifier Magazine...

Page 46: ...necting the Output to Earth Step 1 Connect dc common busbar to earth Install a separate conductor from the dc common busbar to earth This conductor must be rated to carry the combined fault current of...

Page 47: ...with a surge protection device The surge protection device bonds the ac and communications earths during transient activity to prevent damage to the rectifiers The preferred surge protection device i...

Page 49: ...2 82B May 2011 43 C h a p t e r 7 Start Up Overview Topic Page Start Up Tasks 44 Task 1 Inserting the Rectifiers 44 Task 2 Pre Power Up Checklist 45 Task 3 Applying AC Power 45 Task 4 Configure the dc...

Page 50: ...ting 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 rectifiers and i...

Page 51: ...place and all empty rectifier slots are covered with blanking panels AC isolator and all ac circuit breakers are switched off All dc distribution circuit breakers are switched off and or fuses remove...

Page 52: ...On LED s are on no alarm LEDs Use the SC200 keypad to check that all rectifiers are registered See details in the System Controller Operation Handbook 6 If any problems see Troubleshooting on page 50...

Page 53: ...ty Time Synchronization Refer to the System Controller Operation Handbook for navigation details see Related Information on page i Other configuration settings can be changed after all Start Up tasks...

Page 54: ...e System Controller Operation Handbook for details see Related Information on page i Equalize increases the system voltage to the Equalize voltage for the Equalize duration After the Equalize duration...

Page 55: ...ble to 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...

Page 56: ...pply Rectifier s not fully inserted Insert rectifier and tighten retaining screw Internal rectifier fault Remove the rectifier and insert another one in the same slot If second rectifier fails to star...

Page 57: ...upply failed Power system will return to normal operation when the ac supply voltage is within the specified range See Specifications on page 65 DC overvoltage Remove and re insert rectifier s or shut...

Page 58: ...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 breaker...

Page 59: ...ion LVD Status LED s are off I O board Power On LED is on LVD contactor is de energized None this is normal operation LVD Status LED s flashing The contactor is in the wrong state SC200 internal state...

Page 60: ...shelf Do not attempt to disassemble faulty rectifiers Return them in their original packaging with a completed Equipment Incident Report on page 83 Removing a Rectifier Step 1 Undo the rectifier reta...

Page 61: ...be replaced without switching off the dc power system and disconnecting the equipment it powers Before you start you will require A PC Laptop with DCTools connected to the system controller or a web b...

Page 62: ...t the cable s to the rear connectors The system controller will start See Starting the SC200 Various alarms may appear because of incorrect configuration file settings Press any key to silence the ala...

Page 63: ...LVD Characterization Alarm If LVD s are fitted the system controller may indicate an LVD Characterization alarm If there is no alarm then no further action is required 1 On the SC200 go to Battery LV...

Page 64: ...input output board An LVD bridge cable if a load disconnect LVD is fitted Step 1 Bridge load disconnect LVD s if fitted Ignore this Step if there is no load disconnect LVD fitted 1 Connect suitable c...

Page 65: ...ontactor s to disconnect for a few seconds If LVD is a battery disconnect LVD then the load equipment will continue to be powered by the rectifiers If LVD is a load disconnect LVD then the low priorit...

Page 66: ...nal torque settings 2 In DCTools Web go to Batteries Mid point Monitoring Click Clear String Fail 3 If the alarm clears then the fault is fixed No further action is required Step 4 Service or replace...

Page 67: ...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 connectors used Torq...

Page 68: ...sensors 2m 78 leads Eaton TS2 200 7 Battery Mid point Monitoring connection kit for use with SC200 for four battery strings Eaton MPTLOOM 2222 4 sense wires 8 Rear extension cabinet for bottom cable...

Page 69: ...A1R B2 AI 20 D DU 52 70 1 307 907056 81 11 Circuit breaker 80A derates to 64A AMA1R B2 AI 20 D DU 52 80 1 307 908056 81 12 Circuit breaker 100A derates to 70A AMA1R B2 AI 20 D DU 52 100 1 307 910056 8...

Page 70: ...the torque values specified by the battery manufacturer Thread Size ISO Coarse Minimum Maximum Torque M2 5 0 3 0 4Nm 2 7 3 5 inch pounds M3 0 5 0 6Nm 4 5 5 3 inch pounds M4 1 1 1 3Nm 9 8 11 5 inch pou...

Page 71: ...81A 2AWG 25mm2 38A 6AWG 10mm2 220 240 1 46A 6AWG 10mm2 81A 2AWG 25mm2 38A 6AWG 10mm2 277 480 1 46A 6AWG 10mm2 81A 2AWG 25mm2 38A 6AWG 10mm2 AC Cable Temperature Rating minimum 90 C 194 F Disconnect de...

Page 72: ...0A 28 8V APR48 3G 37 5A 48V APR48 ES 41 7A 48V Preset Voltage APR24 3G 27V 0 1V APR48 3G 54 5V 0 1V APR48 ES 54 5V 0 1V Rectifier Input Fuses internal 16A 250V Environment Ambient Temperature Range op...

Page 73: ...ors Screwless terminal blocks Wire Size 0 5 2 0mm2 20 14 AWG Input 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...

Page 74: ...auxiliary contacts only Contactor Coil Voltage nominal 12V 24V or 48V Maximum Hold in Current 1 2A per contactor Connector MTA156 4 way Communications USB Version Connector 1 1 12Mbits s USB B female...

Page 75: ...e Pin 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 RJ45 Ethernet Interface 1 Rx 2 Rx 3...

Page 76: ...Data Voice Video 3G Power Solutions UL Listed Models 70 Copyright 2011 Eaton Corporation All Rights Reserved IPN 997 00012 82B May 2011 8 1 1 8 RS232 D9M and RJ45 connector pin outs RJ45 plug pin outs...

Page 77: ...itch 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 T...

Page 78: ...Relay 2 normally open NO 6 Relay 2 Common COM 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 no...

Page 79: ...ription YH11 RJ45 RXP System Communications 1 24 48V System bus voltage 2 24 48V System bus voltage 3 4 RS485 A 5 RS485 B 6 7 0V 8 0V Digital Output 6 is also used as the Monitor Fail alarm relay It w...

Page 81: ...ht 2011 Eaton Corporation All Rights Reserved IPN 997 00012 82B May 2011 75 A p p e n d i x D System Wiring Diagrams Drawing Number Issue Title 3709087 A Battery Cabinet DV2 EBC4 00101 3709088 A Wirin...

Page 85: ...handed to Customer Customer keeps copy of completed handover acceptance checklist Copy of acceptance checklist retained at site in the Configuration Printout folder Formal acceptance in writing to you...

Page 86: ...ry capacity check Supervisory Module Configuration as in Configuration Printout or as modified at customer s request see Note below Check password access as specified Compare system controller current...

Page 87: ...r Supervisors to obtain further training for reconfiguring they can do using system controller Operators and supervisors to obtain overview of documentation Decide location of documentation logbook Co...

Page 89: ..._________________________________________________________ Location of Failure Product code ___________ Serial number __________ Document number _____________ System type installed in _________________...

Page 90: ...________________________________________ ______________________________________________________________________________________ ________________________________________________________________________...

Page 91: ...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 86 571...

Page 93: ...7 58 Circuit Breakers Battery Circuit Breakers 52 Load Circuit Breakers 52 Location 2 Communications 68 Browsers recommended 4 Communications Options 7 Connector 3 6 DCTools 4 7 61 GSM Modem Communica...

Page 94: ...verse Polarity 47 PowerManagerII 4 Problems See Troubleshooting PSTN Modem Communications 7 R Raised Floor Plinth See Plinth for raised floors Rectifiers 66 Description 3 Inserting the Rectifiers 44 L...

Page 95: ...67 Text Messaging SMS See GSM Modem Communications Tools 61 Torque Settings 64 Troubleshooting 50 Damage transport 12 28 44 Repair and Return 83 Servicing 11 83 85 Technical Assistance 85 U USB Connec...

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