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Eaton DV2-C16-3 Series, Installation And Operation Manual

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Eaton DV2-C16-3 Series Installation And Operation Manual Download Page 57

Maintenance 

 

 

Copyright © 2008-2009 Eaton Corporation.  All Rights Reserved. 

IPN 997-00012-71B    July 2009 

51

 

Installing a Replacement Rectifier 

Step 1 - Remove rectifier blank panel (if fitted) 

 

 

 

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 

Tighten the retaining screw to 1.5Nm (13.3 inch-pounds). This will locate the 
rectifier in its rear connector. 

3 

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 

its operating parameters. No adjustments are required. 

 

 

 

Procedure complete 

 

 

Summary of Contents for DV2-C16-3 Series

Page 1: ...Power Solutions Installation and Operation Guide DV2 C16 Models Issue IPN 997 00012 71B Issue Date July 2009 Eaton Corporation Telecommunications Power Solutions www eaton com telecompower DCinfo eato...

Page 2: ...ontained in this document is subject to change without further notice Subject to the right to use its equipment Eaton Corporation does not convey any right title or interest in its intellectual proper...

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

Page 4: ...Models ii Copyright 2008 2009 Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009 For Further Information and Technical Assistance For further information and technical assistance see W...

Page 5: ...ttery Detect Option 8 External current shunts sensors option 8 Chapter 2 Preparation Overview 9 Warnings 10 Inspecting the Equipment and Reporting Damage 12 Chapter 3 Positioning Cabinets Overview 13...

Page 6: ...the Input Output Board 62 Monitoring and Replacing Transient Protective Devices 63 Battery Mid point Monitoring String Fail Alarm 64 Battery Disposal and Recycling 65 Appendix A Equipment and Tools Sa...

Page 7: ...09 Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009 1 C h a p t e r 1 General Description Overview Topic Page Typical Core Power Solutions CPS 2 Rectifiers CR48 3G 3 SC200 System Cont...

Page 8: ...on page i Rectifier magazine s for up to 16 rectifier modules CR48 3G See details of rectifiers on page 3 Optional plinth for use with raised floors See details on page 68 3 An optional security door...

Page 9: ...Disconnect see details on page 7 LVD1201 00 single 1200A contactor LVD1202 00 dual 1200A contactors LVD2001 00 single 2000A contactor LVD2002 00 dual 2000A contactors Rectifiers CR48 3G Core Power So...

Page 10: ...andbook see Related Information on page i See Troubleshooting on page 46 for details of SC200 alarms For connector pin outs refer to the SC200 Operation Handbook see Related Information on page i Comp...

Page 11: ...77 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: ...nnection 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 digi...

Page 13: ...battery under discharge so that high priority equipment operates for a longer time after an ac supply failure The system controller has two LVD control channels LVD1 and LVD2 These can be set to disc...

Page 14: ...ted with the incorrect polarity External current shunts sensors option Various models of external current shunts sensors are available for use with the Core Power Solutions to measure battery and or l...

Page 15: ...Preparation Copyright 2008 2009 Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009 9 C h a p t e r 2 Preparation Overview Topic Page Warnings 10 Inspecting the Equipment and Reporting...

Page 16: ...equipment closets or similar in accordance with the U S National Electric Code NEC ANSI NFPA No 70 and according to the applicable local codes For ease of access and to maintain optimum system cooling...

Page 17: ...e battery and or personal injury There is a risk of electric shock if a battery is replaced by an incorrect type Dispose of batteries according to the instructions on page 65 Rectifiers Do not install...

Page 18: ...uit 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 dispositif de c...

Page 19: ...er 3 Positioning Cabinets Copyright 2008 2009 Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009 13 C h a p t e r 3 Positioning Cabinets Overview Topic Page Preparation 14 Fixing Cabine...

Page 20: ...ront of the system and for opening the optional 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 syst...

Page 21: ...Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009 15 Cabinet footprint Recommended fixing holes Remove cabinet side panels to access Alternate fixing holes Bottom rectifier magazine m...

Page 22: ...Core Power Solutions DV2 C16 Models 16 Copyright 2008 2009 Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009...

Page 23: ...abling Copyright 2008 2009 Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009 17 C h a p t e r 4 DC Cabling Overview Topic Page DC Installation Practices 18 Connecting the Load and Batt...

Page 24: ...e coupling separate the dc load battery and control cabling from the ac supply cables If the cables have to cross run them at right angles to the ac supply cables In order to minimize parasitic cable...

Page 25: ...e cabinet side panels for rear top access Step 2 Install and terminate cables 1 Select cable sizes to suit the fuse link ratings refer to following table 2 Route the cables to the CPS 3 Terminate the...

Page 26: ...nce of the cables Step 5 Refit cabinet panels and push in the fuse fail detect circuit breaker Procedure complete DCB1000 10 Way circuit breaker distribution Front cover hinged screw fixed Circuit bre...

Page 27: ...ghten the saddle clip screws to 2 3 2 7Nm 20 5 23 9 inch pounds 4 Fit a live cable connection plate to the top terminal of each circuit breaker Use a 1 pole 2 pole or 3 pole plate to suit the circuit...

Page 28: ...In US Canada use these parts or equivalent UL listed crimp lugs Step 4 Connect cables 1 Connect the live negative cables to the circuit breaker terminals 2 Connect the common positive cables to the c...

Page 29: ...cal cable access when multiple DCM2000 modules are mounted in the same cabinet Step 1 Access circuit breakers 1 Open the hinged front cover 2 Switch off all circuit breakers 3 Undo and remove the circ...

Page 30: ...C 194 F rated 2 Route the cables to the CPS 3 Terminate the cables with the required crimp lugs refer to the following table CB Rating Note 1 Cable Size AWG Note 2 2 hole Crimp Lug Note 3 Crimping To...

Page 31: ...e correct and tighten to 1 4 studs 3 9 4 5Nm 35 39 inch pounds 3 8 studs 18 7 21 9Nm 166 194 inch pounds 2 Secure the cables with cable ties to ensure there will be no strain on the terminals 3 Test t...

Page 32: ...Core Power Solutions DV2 C16 Models 26 Copyright 2008 2009 Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009...

Page 33: ...ight 2008 2009 Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009 27 C h a p t e r 5 AC Cables Overview Topic Page Input Transient Protection 28 Connecting to the AC Supply 31 Connectin...

Page 34: ...uppression plan that includes Primary surge protection Secondary surge protection Primary secondary surge decoupling coils Secondary tertiary surge decoupling coils 6 Protect the data and control line...

Page 35: ...m from the primary transient protection must be present at all sites to protect the dc power system from transients This will protect the power system from a limited number of repeated 15kA transients...

Page 36: ...h Switchboard earth ground busbar Rectifiers Transient protective devices are fitted with alarm contacts and visual indicators Monitor the status of all externally installed transient protective devic...

Page 37: ...ber and size of conductors according to the type of ac distribution fitted ac supply voltage and maximum ac input current see Specifications on page 71 208 240V ac 3W PE 220 277 380 480V ac 3W N PE AC...

Page 38: ...manufacturer s instructions and local wiring regulations 3 Label the connection at the ac supply point Step 4 Check terminations secure cables and test insulation 1 Check all terminations are correct...

Page 39: ...he site surge protection is designed to limit transient ac earth dc earth voltages to less than 1500V at the dc power system AC earth ground dc earth ground communications earth dc common bus 3 Replac...

Page 40: ...Core Power Solutions DV2 C16 Models 34 Copyright 2008 2009 Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009...

Page 41: ...lation Copyright 2008 2009 Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009 35 C h a p t e r 6 Battery Installation Overview Topic Page Installing the Batteries 36 Mounting the Batter...

Page 42: ...lled with adequate ventilation Refer to the battery manufacturer or supplier for advice on minimum ventilation levels Switch off all battery circuit breakers and or remove all battery fuses Unpacking...

Page 43: ...manufacturer s installation instructions 3 Insulate any un connected sense wires 4 Secure all sense wires to avoid any strain on the terminations Mid point Monitoring sense wire from XH12A on the inpu...

Page 44: ...the temperature sensor connected to the supervisory module in the master dc power cabinet 2 Mount this sensor centrally above the batteries on the third shelf from the floor in the master battery rac...

Page 45: ...012 71B July 2009 39 C h a p t e r 7 Start Up Overview Topic Page Start Up Tasks 40 Task 1 Inserting the Rectifiers 40 Task 2 Pre Power Up Checklist 41 Task 3 Applying AC Power 41 Task 4 Configure the...

Page 46: ...ry and Load See details on page 43 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 Un...

Page 47: ...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 removed AC supply is isolated at each poin...

Page 48: ...reen Power On LED s are on no alarm LEDs On the SC200 keypad select Menu Rectifiers See details in the System Controller Operation Handbook Check that all rectifiers are registered 6 If any problems s...

Page 49: ...on 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 are complete Refer to...

Page 50: ...ons in the 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...

Page 51: ...described in the Maintenance chapter All other tasks are classified as Servicing Servicing must only be performed according to specific instructions and only by personnel authorized by Eaton This inc...

Page 52: ...tifier and tighten retaining screw Green LED of 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 t...

Page 53: ...System Controller Operation Handbook If required restart the rectifier Very high or low ac voltage or ac supply failed Power system will return to normal operation when the ac supply voltage is withi...

Page 54: ...ier with one that is working Return the faulty rectifier for service Load circuit breaker open Check the load circuit breakers System has no dc output rectifiers are on LVD contactor has disconnected...

Page 55: ...e does not match signal from contactor auxiliary switch Check the electrical and mechanical operation of the contactor and auxiliary switch Check all wiring and connectors See Connections on page 6 LV...

Page 56: ...s with blanking panels To avoid electric shock do not place hands inside the rectifier shelf Do not attempt to disassemble faulty rectifiers Return them in their original packaging with a completed Eq...

Page 57: ...rectifier 1 Push in the rectifier until the retaining screw contacts the shelf 2 Tighten the retaining screw to 1 5Nm 13 3 inch pounds This will locate the rectifier in its rear connector 3 Check that...

Page 58: ...g Step 1 Remove fuse links and access cable connection points 1 Pull out fuse link carrier s and remove the fuse link s if fitted 2 If connecting new load cables to a fuse then remove cabinet side pan...

Page 59: ...listed crimp lugs Step 3 Connect cables 1 Connect the live negative cables to the live cable connection plates 2 Connect the common positive cables to the system common bar Step 4 Check terminations...

Page 60: ...able 1 pole 2 pole or 3 pole to suit circuit breakers 3 8 studs 1 spacing Common bar horizontal or vertical mounting holes suit 3 8 M10 bolts 1 spacing Step 1 Access circuit breakers 1 Open the hinged...

Page 61: ...ghten the saddle clip screws to 2 3 2 7Nm 20 5 23 9 inch pounds 4 Fit a live cable connection plate to the top terminal of each circuit breaker Use a 1 pole 2 pole or 3 pole plate to suit the circuit...

Page 62: ...tep 4 Connect cables 1 Connect the live negative cables to the circuit breaker terminals 2 Connect the common positive cables to the common bar Step 5 Check terminations secure cables and test insulat...

Page 63: ...n multiple DCM2000 modules are mounted in the same cabinet Step 1 Access circuit breakers 1 Open the hinged front cover 2 Undo and remove the circuit breaker cover 3 If necessary remove cabinet side p...

Page 64: ...C 194 F rated 2 Route the cables to the CPS 3 Terminate the cables with the required crimp lugs refer to the following table CB Rating Note 1 Cable Size AWG Note 2 2 hole Crimp Lug Note 3 Crimping To...

Page 65: ...quipment manufacturer s instructions before applying dc power to any equipment 2 To apply dc power to the equipment switch on the circuit breaker 3 Close the hinged front cover Procedure complete Repl...

Page 66: ...ble 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 alarm 2 Ins...

Page 67: ...peration Handbook Step 6 LVD Characterization Alarm If LVD s fitted the SC200 may indicate an LVD Characterization alarm If there is no alarm then no further action is required 1 On the SC200 go to Ba...

Page 68: ...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 cable s...

Page 69: ...isconnect LVD then the low priority load equipment will continue to be powered via the LVD bridge cable On the SC200 go to Battery LVDs LVD x Not Characterized Edit The LVD1 contactor will disconnect...

Page 70: ...systems and the maintenance plan at that site must be reviewed Battery Mid point Monitoring String Fail Alarm Use the following procedure if a String Fail alarm is generated Step 1 Identify the fault...

Page 71: ...onobloc 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 guideline...

Page 72: ...Core Power Solutions DV2 C16 Models 66 Copyright 2008 2009 Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009...

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: ...ycar WC7700 or equivalent 6 SiteSure 3G Input Output Module optional Eaton IOBSS 00 7 Dual temperature sensors 2m leads Eaton TS2 200 8 Battery Mid point Monitoring connection kit for two battery stri...

Page 75: ...t breaker 15A derates to 12A Heinemann AMA1R B2 AA 20 D DU 52 15 1 4 Circuit breaker 20A derates to 16A Heinemann AMA1R B2 AA 20 D DU 52 20 1 5 Circuit breaker 25A derates to 20A Heinemann AMA1R B2 AA...

Page 76: ...orque 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 pounds M...

Page 77: ...ectifier System Output Output Voltage Nominal Range 48V dc 43 58V dc Output Current 48V 1936A max 16 rectifiers Output Power 92 8kW max 16 rectifiers Output Characteristic Constant power DC Distributi...

Page 78: ...C 23 F to 104 F Relative Humidity operating and storage 95 non condensing Dimensions H W D Cabinets 43U racks 47U racks 78 7 23 6 23 6 2000mm 600mm 600mm 85 7 23 6 23 6 2176mm 600mm 600mm Rectifiers...

Page 79: ...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 Accuracy 1...

Page 80: ...ernet Interface Connector Protocols 10baseT RJ45 TCP IP SNMP S3P over IP http Web https secure Web SNTP Modbus TCP Serial Server MAC Address See details in the System Controller Operation Handbook Web...

Page 81: ...pose Pin Description 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 RJ45 Et...

Page 82: ...Core Power Solutions DV2 C16 Models 76 Copyright 2008 2009 Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009 8 1 1 8 RS232 D9M and RJ45 connector pin outs RJ45 plug pin outs...

Page 83: ...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 Sense 1 5 Temp Sens...

Page 84: ...ormally 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 normally cl...

Page 85: ...ts Copyright 2008 2009 Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009 79 Connector Type Purpose Pin Description 3 4 RS485 A 5 RS485 B 6 7 0V 8 0V 8 1 1 8 RJ45 connector pin outs RJ4...

Page 86: ...Core Power Solutions DV2 C16 Models 80 Copyright 2008 2009 Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009...

Page 87: ...ing Diagrams Copyright 2008 2009 Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009 81 A p p e n d i x D System Wiring Diagrams Drawing Number Issue Title 3705372 A Wiring Diagram DV2 C...

Page 88: ...Core Power Solutions DV2 C16 Models 82 Copyright 2008 2009 Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009...

Page 89: ...d 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 your Pow...

Page 90: ...pacity check Supervisory Module Configuration as in Configuration Printout or as modified at customer s request see Note below Check password access as specified Compare supervisory module current vol...

Page 91: ...dule Supervisors to obtain further training for reconfiguring they can do using supervisory module Operators and supervisors to obtain overview of documentation Decide location of documentation logboo...

Page 92: ...Core Power Solutions DV2 C16 Models 86 Copyright 2008 2009 Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009...

Page 93: ...urrent Sense Signal Output XU1 to supervisory module via intermediate current sensor if fitted RJ45 Current Sense Signal Input XU2 from other current sensor if fitted 3 Using the CS04 Current Sensor E...

Page 94: ...CS04 current sensor extension PCB Step 3 Resistance measurement Measure the resistance of the inductor located at the back of the CS04 current sensor PCB as shown Step 4 Set the gain range of the CS0...

Page 95: ...current sensor PCB To obtain the required jumper configuration you might have to break the track between connection points 1 and 3 and solder additional jumpers between connection points Step 5 Apply...

Page 96: ...nt sensor closer than 150mm 6 from A bus bar joint Termination bolts Bolts joining laminated bus bars Ensure correct orientation of the CS04 A11 current sensor before drilling the mounting holes into...

Page 97: ...sensor as shown in the following diagrams Ensure correct orientation of the CS04 A11 see Step 1 for details Without Extension PCB With Extension PCB Step 3B Mounting a CS04 A11 threaded hole mounting...

Page 98: ...ns and configuration 2 Configure the current sense input s The current sense input s must be Enabled and configured Refer to Enable and Configure I O in the SiteSure 3G Installation and Operation Guid...

Page 99: ...te Customer Information Company Postal Address Return Address Not PO Box Telephone Fax Email Contact Name Location of Failure Product code Serial number Document number System type installed in Serial...

Page 100: ...94 Copyright 2008 2009 Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009 INFORMATION continued fault details circumstances consequences actions SG 03 ISS06...

Page 101: ...resentative the closest 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 8...

Page 102: ...Core Power Solutions DV2 C16 Models 96 Copyright 2008 2009 Eaton Corporation All Rights Reserved IPN 997 00012 71B July 2009...

Page 103: ...munications Options 7 Connector 3 6 DCTools 4 7 67 GSM Modem Communications 7 Problems See Troubleshooting PSTN Modem Communications 7 SNMP 7 Web Browsers recommended 4 Web Server 7 Configuration File...

Page 104: ...hooting Rectifier Alarms 3 41 Rectifier blank panel 50 Rectifier LEDs 3 Rectifier Replacement 50 Registration 41 Repair and Return 93 Startup 41 Relays See Digital Outputs Relays Monitor OK Alarm 4 Re...

Page 105: ...997 00012 71B July 2009 99 Technical Assistance 95 U USB Connector 3 6 Problems See Troubleshooting V Voltage Bus See Bus Voltage Sense Voltage Control Bus Voltage Sense 4 Voltage Feed Module 6 W Web...

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