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Appendix A

Equipment and Tools

IPN 997-00012-49G May 2013

Equipment and T ools

Safety Equipment

Use approved safety equipment as required by local health and safety regulations including
(but not restricted to):



Safety glasses



Safety gloves



Safety footwear



Appropriate handling equipment for batteries and other heavy items



Appropriate 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 connectors used



Torque wrench with pivot head and insulated handle



Heatshrink tubing and heat gun



Digital multimeter



Insulation tester



Non-static clothing

Recommended Tools



Laptop with:



USB port (for use with SC200) or RS232 port (for use with SC100)



DCTools software (download from dcpower.eaton.com/downloads).



Test load (to suit maximum output of dc power system)



Labeling tool and labels



Clamp-on ammeter

Содержание APS12-300 Series

Страница 1: ...eries Issue IPN 997 00012 49G Issue Date May 2013 Refer to the separate SC200 or SC100 system controller handbook for full details of the system controller operation dcpower eaton com Manuals asp Eato...

Страница 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...

Страница 3: ...quipment the relevant local 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 e...

Страница 5: ...rd 10 Connections 11 Other Features 12 External communications 12 Low Voltage Disconnect Options 12 Battery Mid point Monitoring Description SC200 only 13 Battery Time Remaining 13 Chapter 2 Preparati...

Страница 6: ...ation File 42 Backup and Restore 42 Starting the SC200 or SC100 43 SC200 43 SC100 43 SC200 or SC100 Operation using the Keypad and Screen 44 Keypad Access Security 44 Alarm Indicators 45 SC200 or SC10...

Страница 7: ...tions Appendix C Cable Ratings Appendix D Controller Menus SC200 Menu 81 SC100 Menu 82 Appendix E Connector Pin outs System Controller Connector Pin outs 83 I O Board IOBGP 00 01 Connector Pin outs 84...

Страница 9: ...on Corporation All Rights Reserved IPN 997 00012 49G May 2013 1 C h a p t e r 1 Gener al D escription Overview Topic Page Model Numbers 2 Access Power Solutions DC Power Systems 3 Rectifiers 7 System...

Страница 10: ...SC200 APS6 321 8 6kW Note 1 SC200 1 APS6 322 8 6kW Note 1 SC200 2 APS6 510 8 64kW 12 0kW SC100 APS6 511 8 64kW 12 0kW SC100 1 APS6 512 8 64kW 12 0kW SC100 2 APS6 520 8 64kW 12 0kW SC200 APS6 521 8 64...

Страница 11: ...ifier modules see details on page 7 SC200 or SC100 system controller see details on page 8 AC Miniature Circuit Breakers MCBs if fitted AC MCB cover DC common bus battery terminals DC common bus load...

Страница 12: ...nal low priority load disconnect Low Voltage Disconnect LVD behind side panel see details on page 12 Up to 16 Load Miniature Circuit Breakers MCBs See Note 1 Up to 4 Battery Miniature Circuit Breakers...

Страница 13: ...ller see details on page 8 AC Miniature Circuit Breakers MCBs if fitted for bottom rectifier shelf AC MCB covers AC Miniature Circuit Breakers MCBs if fitted for top rectifier shelf DC common bus batt...

Страница 14: ...al battery disconnect Low Voltage Disconnect LVD see details on page 12 Optional low priority load disconnect Low Voltage Disconnect LVD see details on page 12 Up to 4 Battery Miniature Circuit Breake...

Страница 15: ...er Solutions APS6 300 and APS12 300 models can be fitted with 48V Access Power Rectifiers APR48 3G or APR48 ES only All rectifiers are fan cooled and hot pluggable See Specifications on page 73 for fu...

Страница 16: ...e 41 For further details refer to the System Controller Operation Handbook see Related Information on page i See Troubleshooting on page 50 for details of system controller alarms SC200 System Control...

Страница 17: ...alarm LED red LCD Navigation keys 4 RS232 D9M connector Retaining screw Power and system communications connector Compatible Software The following software is compatible with the SC200 or SC100 syst...

Страница 18: ...inputs 4 pre defined system functions 6 user defined Relay outputs 6 one also used as Monitor OK alarm LVD contactor outputs 2 For input and output specifications see details on page 75 For connector...

Страница 19: ...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 power...

Страница 20: ...n with a Network Management System NMS using SNMP Communication with a Building Management System BMS using Modbus Alarm and status messages to GSM Short Messaging Service SMS text capable cell phones...

Страница 21: ...loat charge and after a configurable lockout period since the last battery discharge Fast Charge Equalize or Battery Test Battery Time Remaining The SC200 or SC100 obtains characterization data from e...

Страница 23: ...Preparation Copyright 2007 2013 Eaton Corporation All Rights Reserved IPN 997 00012 49G May 2013 15 C h a p t e r 2 Prepar ation Overview Topic Page Warnings 16 Inspecting the Equipment and Reporting...

Страница 24: ...dwide Support on page 107 A registered electrician or suitably qualified person must check the integrity of the installed cabling BEFORE the dc power system is powered up Tasks must be performed in th...

Страница 25: ...to the instructions on page 68 Rectifiers Only operate the rectifiers when the surrounding area is clean and dust free To reduce the risk of electric shock and maintain optimum system cooling always c...

Страница 26: ...ower system will not respond to electromagnetic disturbances or will not cause interference to other equipment in a particular installation In a domestic environment this product may cause radio inter...

Страница 27: ...20 Task 2 Prepare APS 23 Task 3 Connect the AC Supply Cable s 26 Task 4 Mount the APS in the Rack 28 Task 5 Connect the DC Load and Battery Cables 29 Task 6 Install the Batteries 30 Task 7 Mount the B...

Страница 28: ...and Battery Cables See details on page 29 6 Install the Batteries See details on page 30 7 Mount the Battery Temperature Sensor See details on page 31 8 Connect External Input Output Cabling if requi...

Страница 29: ...Vs dc power system I O board SC200 or SC100 system controller Rectifiers Step 3 Check the type of ac supply disconnect device and RCDs 1 Check the type of ac supply Only the types of ac supply listed...

Страница 30: ...rent tripping curve s of all ac supply disconnect device s upstream of the APS with the following curve for the rectifier fuses Refer to the manufacturer s data for tripping curves Time Current Curve...

Страница 31: ...eck polarity The APS can be configured for either positive earth or negative earth operation 1 Remove top cover if fitted 2 Check the polarity label on the dc common bus bar s on the common bar s indi...

Страница 32: ...cuit breakers or fitting new ones use the type that is already in use see Spare Parts on page 70 for ordering details 1 Remove the dc distribution front cover and top cover if fitted 2 Fit the load MC...

Страница 33: ...ht hand end and clip onto the DIN rail 4 Tighten the bottom MCB terminals 5 Connect the battery fuse fail detect wires to the MCB auxiliary switches see following diagram Tighten the terminals 6 Fit M...

Страница 34: ...then 105 C rated cable rated cable must be used for the ac connections Step 1 Check ac rating of the APS See the diagram on page 3 or the diagram on page 5 for location of ac rating label AC source V...

Страница 35: ...1 Position the APS in front of the rack 2 Pass the ac supply cable through the ac cable entry gland 3 Terminate the earth conductor with an M6 crimp lug Ensure the ferrule of the crimp lug covers all...

Страница 36: ...rminal cover 4 Test the insulation resistance of the conductors according to local ac wiring regulations Procedure complete Task 4 Mount the APS in the Rack Step 1 Check clearances APSs require the fo...

Страница 37: ...ttery strings If this conductor is not installed then battery fault current will be carried by the ac dc earth link and the ac earth conductor which are typically too small for such currents Step 3 Co...

Страница 38: ...must be derated to 75 Ensure that the fuse fail detection wires are properly terminated as shown in the following diagram 6 Tighten the MCB terminal s 7 Switch OFF all MCBs Load MCB Load live cable F...

Страница 39: ...n 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 input output board Middle inte...

Страница 40: ...d can control and monitor external devices If no external devices are to be connected then ignore this task Step 1 Route cable to the I O board See the diagram for the location of the I O board Route...

Страница 41: ...n SiteSure 3G modules can be connected to the APS SC200 only A SiteSure 3G input output module has the following features SiteSure 3G Digital Inputs 10 Digital Outputs relays 6 Analog Inputs 0 to 10V...

Страница 42: ...the manufacturer s instructions and local wiring regulations 3 Label the connection at the ac supply point Step 3 Check terminations secure cable and test insulation 1 Check all terminations are corr...

Страница 43: ...2 49G May 2013 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 the...

Страница 44: ...ls on page 39 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 U...

Страница 45: ...he installed cabling All panels are in place and all empty rectifier slots are covered with blanking panels AC isolator and all ac MCBs if fitted are switched off All dc distribution MCBs are switched...

Страница 46: ...he SC200 or SC100 system controller See details on page 42 The system controller is supplied pre loaded with a configuration file If this configuration file has been customized for the site then no fu...

Страница 47: ...ation 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 closing...

Страница 48: ...hen follow the instructions 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...

Страница 49: ...eserved IPN 997 00012 49G May 2013 41 C h a p t e r 5 System C ontroller Topic Page Configuration File 42 Starting the SC200 or SC100 43 SC200 or SC100 Operation using the Keypad and Screen 44 SC200 o...

Страница 50: ...ook Backup and 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 standa...

Страница 51: ...erization 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 SC100 W...

Страница 52: ...nfiguration changes can be made Contact your Eaton dc product supplier or Eaton for advice see Worldwide Support on page 107 To use DCTools Web to enable disable keypad access In DCTools Web go to Com...

Страница 53: ...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 LED...

Страница 54: ...troller Operation Handbook Before you start you will need The latest version of DCTools available from dcpower eaton com downloads A PC laptop with USB port and USB A B cable RadioShack 55010997 Jayca...

Страница 55: ...no force is applied to the RS232 connector as this may damage the connector If COM1 port is not available or for more details see Direct RS232 Communications in the System Controller Operation Handboo...

Страница 56: ...rsion The version of the 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...

Страница 57: ...le 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 a...

Страница 58: ...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 start then there is a fault with the re...

Страница 59: ...c supply failed Power system will return to normal operation when the ac supply voltage is within the specified range See Specifications on page 73 DC overvoltage Remove and re insert rectifier s or s...

Страница 60: ...tage 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 MCB ope...

Страница 61: ...e 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 Replace...

Страница 62: ...Handbook SC200 or 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 m...

Страница 63: ...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...

Страница 64: ...ew Logon ID and 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 Def...

Страница 65: ...k the electrical and mechanical operation of the contactor and auxiliary switch Check all wiring and connectors See Connections on page 11 LVD Type setting is incorrect Check LVD Type setting LVD cont...

Страница 66: ...th 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 Equipm...

Страница 67: ...screw contacts the shelf 2 Check the rectifier s rear connector is correctly aligned with the shelf connector or damage may occur 3 Tighten the retaining screw to 1 5Nm 13 3 inch pounds This will loc...

Страница 68: ...ther Chint or Schneider circuit breakers However Chint and Schneider circuit breakers are not interchangeable When replacing existing circuit breakers or fitting new ones use the type that is already...

Страница 69: ...nfiguration 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 This file will have to be cu...

Страница 70: ...hange the configuration settings to the correct values provided the system controller is set for the correct nominal system voltage Step 5 Check the system controller operation 1 Map the I O board SC2...

Страница 71: ...erized This will cause the LVD s contactor s to disconnect for a few seconds If a battery disconnect LVD is fitted then the load equipment will continue to be powered by the rectifiers If a load disco...

Страница 72: ...A replacement input output board An anti static wrist strap to prevent damage to the static sensitive components on the input output board If a load disconnect LVD is fitted APS6 models A 450mm 18 lo...

Страница 73: ...ied by the remaining rectifier s when one rectifier is removed 2 Remove the rectifier next to the system controller See Replacing a Rectifier on page 58 Push any system controller key to silence the R...

Страница 74: ...H21 2 Fit the I O board on to the support posts in the APS 3 Reconnect all I O board cable plugs 4 Check the I O board Power On LED is on If not see Troubleshooting on page 50 Step 6 Replace rectifier...

Страница 75: ...then the low priority load equipment will continue to be powered via the LVD bridge cable 1 On the SC200 go to Battery LVDs LVD x Not Characterized Edit or on the SC100 go to Menu Configuration LVD1 L...

Страница 76: ...tion from the 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...

Страница 77: ...ropriate 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 a...

Страница 78: ...00 4 Input Output Board See replacement procedure on page 64 Eaton IOBGP 00 5 USB A B cable for use with SC200 system controller RadioShack 55010997 Jaycar WC7700 or equivalent 6 RS232 DB9 F F Null mo...

Страница 79: ...m 9 8 11 5 inch pounds M5 2 3 2 7Nm 20 5 23 9 inch pounds M6 3 9 4 5Nm 35 39 inch pounds M8 9 5 11 1Nm 85 98 inch pounds M10 18 7 21 9Nm 166 194 inch pounds M12 32 8 38 4Nm 292 340 inch pounds M16 81...

Страница 81: ...APS12 300 9U 19 mounting 335 mm 13 2 Additional clear air space is required at rear for rectifier exhaust air venting See details on page 28 Weight APS6 300 APS6 500 12kg 26 4 lb APS12 300 18kg 40 lb...

Страница 82: ...LVD 17 2kW 48V up to 40 C 104 F ambient 16 1kW 48V up to 45 C 113 F ambient 15 0kW 48V up to 50 C 122 F ambient Load Current maximum APS6 300 models Total Load Essential Priority Load Non essential N...

Страница 83: ...APR24 3G 50A 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 Digital Outputs Alarm Relays...

Страница 84: ...s standard Input Protection Protected against damage from short circuit to live or common bus Temperature Sense Inputs IOBGP Number of Temperature Sense Inputs 2 One only connected as standard Second...

Страница 85: ...attery side of the LVD Contactor Coil Voltage nominal With auxiliary contacts 12V 24V or 48V Without auxiliary contacts Equal to nominal system voltage Maximum Hold in Current 1 2A per contactor Maxim...

Страница 87: ...es 20A Curve 4mm2 10AWG 307 902500 61 Chint NB1 63 UL Series 25A Curve 4mm2 10AWG 307 903200 61 Chint NB1 63 UL Series 32A Curve 6mm2 8AWG 307 904000 61 Chint NB1 63 UL Series 40A Curve 10mm2 6AWG 307...

Страница 89: ...eserved IPN 997 00012 49G May 2013 81 A p p e n d i x D Controller M enus SC200 Menu At each menu screen press Enter to access the associated configuration menu screen s These menus have multiple conf...

Страница 90: ...49G May 2013 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 Scr...

Страница 91: ...scription 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 Rx...

Страница 92: ...s on page 73 Connector Type Purpose Pin Description XH4 MTA 156 LVD 1 Interface 1 Coil 2 Coil 3 LVD 1 auxiliary switch 4 Auxiliary switch common XH5 MTA 156 LVD 2 Interface 1 Coil 2 Coil 3 LVD 2 auxil...

Страница 93: ...t 2 0V 3 D2 input 4 0V 5 D3 input 6 0V XH15B Digital inputs D4 D6 1 D4 input 2 0V 3 D5 input 4 0V 5 D6 input 6 0V XH16 XH17 Digital relay outputs 1 2 1 Relay 1 normally closed NC 2 Relay 1 normally op...

Страница 94: ...use Fail 2 Battery Fuse Fail 3 12V out 4 AC Distribution Fan Fail 5 AC Distribution MOV Fail 6 0V out system live protected 7 8 System common protected YH11 RJ45 RXP System Communications 1 24 48V Sys...

Страница 95: ...urge 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 contro...

Страница 96: ...wnstream secondary transient protection via suitably rated surge decoupling coils These should have been specified as part of the transient protection plan for the site If no surge decoupling coils we...

Страница 97: ...odels of Access Power Solutions are factory fitted with secondary transient protection to protect the power system from a limited number of repeated 15kA transients 8 20 s wave shape Factory fitted se...

Страница 99: ...see the diagram on page 25 This link prevents these very large voltages from developing and protects the rectifiers from surge related damage If your installation uses a mesh earth then Eaton recommen...

Страница 100: ...n 1500V at the dc power system then replace the ac dc earth link with a surge protection device The surge protection device bonds the ac and dc earths during transient activity to prevent damage to th...

Страница 101: ...on tasks see details on page 20 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 testing...

Страница 102: ...current is the 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...

Страница 103: ...s 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 tes...

Страница 104: ...ow 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 ac Ensure the system performs...

Страница 105: ...Test Duration to 1 minute Set the Battery Test Termination Voltage to a value approximately 10 volts below the float voltage Connect load to the system Start the Battery Test Ensure the SC200 or SC10...

Страница 106: ...rd LVD LED is on None Notes 1 AVC must be enabled Allow up to 1 minute for the system to stabilize after load or voltage changes 2 Breathing on the sensor can increase the temperature 3 Battery Curren...

Страница 107: ...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 Float threshold Ensure al...

Страница 108: ...tes 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 ACD Fan Fail Stop th...

Страница 109: ...s on page 96 Rectifier No Load Ensure the dc load and batteries are isolated from the system Ensure alarm operates Rectifier Current Limit Apply a dc load to the system Turn off rectifiers until the r...

Страница 110: ...ly for an incorrect 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 Thes...

Страница 111: ...igital 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 As for Digital Output 1...

Страница 112: ...Access Power Solutions Installation and Operation Guide APS6 300 500 and APS12 300 Series 104 Copyright 2007 2013 Eaton Corporation All Rights Reserved IPN 997 00012 49G May 2013...

Страница 113: ..._______________________________________________________________ Location of Failure Product code ___________ Serial number __________ Document number _____________ System type installed in ___________...

Страница 114: ...___________________________________________ ______________________________________________________________________________________ _____________________________________________________________________...

Страница 115: ...ffice 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 86 755 2757 2666 extension...

Страница 116: ...Access Power Solutions Installation and Operation Guide APS6 300 500 and APS12 300 Series 108 Copyright 2007 2013 Eaton Corporation All Rights Reserved IPN 997 00012 49G May 2013...

Страница 117: ...iers See Rectifiers Audible Alarm Indication 45 B Battery Battery Charging 39 Battery Current 54 Battery Fuses 52 Battery Installation 30 Disposal and Recycling 68 Mid Point Monitoring MPM 13 30 77 Re...

Страница 118: ...ernet Communications 12 55 Problems See Troubleshooting F Fuse Battery Fuses 52 Load Fuses 52 Rectifier Fuses See AC Discrimination G GSM Modem Communications 12 55 H High AC Voltage Protection 20 I I...

Страница 119: ...shooting Rectifier Alarms 7 37 Rectifier blank panel 58 Rectifier Current 43 Rectifier Fuses See AC Discrimination Rectifier LEDs 7 Rectifier Replacement 58 Registration 37 Repair and Return 105 Start...

Страница 120: ...cal Assistance 107 Temperature Temperature Sensor 10 11 31 76 Text Messaging SMS See GSM Modem Communications Time See Internal Clock Time Remaining 13 Tools 69 Top Cover 4 Torque Settings 71 Transien...

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