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Appendix A

Equipment and Tools



IPN 997-00012-53B December 2010

Equipment and Tools

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 and USB A/B cable (RadioShack 55010997, Jaycar WC7700 or similar)



DCTools software (download from www.powerquality.eaton.com/downloads).



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



Labeling tool and labels



Clamp-on ammeter

Содержание APS6-400 Series

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 108: ..._____________________________________________ ______________________________________________________________________________________ ___________________________________________________________________...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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