Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Issue: IPN 997-00012-49F Issue Date: November 2012 Refer to the separate SC200 or SC100 system controller handbook for full details of the system controller operation dcpower.eaton.com/Manuals.asp Eaton Corporation Telecommunications Power Solutions dcpower.eaton.com DCinfo@eaton.
The product discussed in this literature is subject to terms and conditions outlined in Eaton selling policies. The sole source governing the rights and remedies of any purchaser of this equipment is the relevant Eaton selling policy. No warranties, express or implied, including warranties of fitness for a particular purpose or merchantability, or warranties arising from course of dealing or usage of trade, are made regarding the information, recommendations and descriptions contained herein.
About This Guide About T his Gui de Scope This guide covers installation, operation and maintenance of Access Power Solutions (APS6-300/500 and APS12-300 Series) dc power systems (APS), controlled by the SC200 or SC100 system controller. Refer to the separate SC200 or SC100 system controller handbook for full details of the system controller operation - dcpower.eaton.com/Manuals.asp.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) ii Copyright © 2007-2012 Eaton Corporation. All Rights Reserved.
Table of Contents Tabl e of C ontents About This Guide Scope ........................................................................................................................................... i Audience ..................................................................................................................................... i Related Information ..................................................................................................................
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Chapter 4 Start-Up Overview .................................................................................................................................. 35 Start-Up Tasks ......................................................................................................................... 36 Task 1 - Inserting the Rectifiers ..................................................................................
Table of Contents Appendix A Equipment and Tools Safety Equipment .......................................................................................................................... 69 Essential Tools................................................................................................................................ 69 Recommended Tools ..................................................................................................................... 69 Spare Parts ...................
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) vi Copyright © 2007-2012 Eaton Corporation. All Rights Reserved.
Chapter 1 General Description C h a Gener al D escription p t e r 1 Overview Topic Page Model Numbers 2 Access Power Solutions DC Power Systems 3 Rectifiers 7 System Controller 8 Input/Output Board 10 Other Features 12 Copyright © 2007-2012 Eaton Corporation. All Rights Reserved.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Model Numbers Model Number DC Output Power (max.) System Controller LVDs 24V nominal 48V nominal APS6-310 - 12.0kW SC100 - APS6-311 - 8.6kW (Note 1) SC100 1 APS6-312 - 8.6kW (Note 1) SC100 2 APS6-320 - 12.0kW 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.
General Description Access Power Solutions DC Power Systems APS6 Models Front View System labels Rectifier 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 terminals Load and battery cable tie rod DC distribution with: Up to 16 Load Miniature Circuit Breakers (MCBs). See Note 1.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) APS6 Models Rear View AC cable entry gland Optional (low priority) load disconnect Low Voltage Disconnect (LVD) (behind side panel) (see details on AC earth conductor connection point (see connection page 12) details on page 26) Up to 16 Load Miniature Circuit Breakers (MCBs). I/O Board (see details on page 10) Voltage Feed Module with connector for optional See Note 1.
General Description APS12 Models Front View System labels Rectifier modules, 48V only (see details on page 7) SC200 or SC100 system controller (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 DC common bus battery terminals DC common bus load terminals Load and battery cable tie rod DC distribution with: Up to 16 Load Miniature Circuit Breakers (MCBs). See Note 1.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) APS12 Models Rear View AC earth conductor connection point for top and Optional battery disconnect Low Voltage Disconnect bottom rectifier shelf (see connection details on page 26) AC cable entry glands for top and bottom rectifier shelves I/O Board (see details on page 10) Voltage Feed Module with connector for optional (LVD) (see details on page 12) Optional (low priority) load disconnect Low Vo
General Description Rectifiers Access Power Solutions APS6-500 models can be fitted with either 24V or 48V Access Power Rectifiers (APR24-3G/APR48-3G/APR48-ES). Access Power 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 further information.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) System Controller The SC200 or SC100 system controller provides control, communications and alarm functions. The system controller is supplied pre-configured. Configuration changes can be made with the keypad, or via a PC connected to the USB connector (SC200) or RS232 (SC100) connector. Or changes can be made remotely (see External Communications on page 12).
General Description SC100 System Controller The SC100 system controller is a full-featured control and monitoring solution which provides alarm notifications via dial-out modem to PowerManagerII remote monitoring software, SMS text messaging, or by relay contact closures.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) 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 includes a range of sense inputs for dc power system control and monitoring. It also allows real time data collection from building services and other external devices, and relay outputs for alarm signals or control of external devices.
General Description Connections The following diagram shows the connections between the SC200 or SC100, the I/O board, the other dc power system components and external devices.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Other Features External communications Refer to the system controller handbook for information on these communications options.
General Description Battery Mid-point Monitoring Description (SC200 only) Battery Mid-point Monitoring provides a cost-effective method for the early detection of internal battery faults. The voltages of the two halves of a battery string are measured and the system controller generates an alarm signal if a voltage imbalance is detected. A voltage imbalance is an indication that one or more cells has an internal fault.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) 14 Copyright © 2007-2012 Eaton Corporation. All Rights Reserved.
Chapter 2 Preparation C h Prepar ation a p t e r 2 Overview Topic Page Warnings 16 Inspecting the Equipment and Reporting Damage 18 Copyright © 2007-2012 Eaton Corporation. All Rights Reserved.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Warnings This section contains important warnings. Read these warnings before installing or operating an Eaton Access Power Solutions dc power system. Electrical Safety Access Power Solutions (APS6-300/500 and APS12-300 Series) dc power systems must be mounted in an enclosed cabinet that meets safety and fire enclosure requirements as specified in AS/NZS 60950.1 and EN 60950-1.
Preparation Batteries The plastic cases of batteries installed in Eaton dc power system racks must have a flammability rating of UL 94-V2 or better. Flooded cell and VRLA lead acid batteries can emit explosive gases and must be installed with adequate ventilation. Refer to the battery manufacturer or supplier for advice on minimum ventilation levels. Do not wear a synthetic dust-coat or overalls. Synthetic fabrics can hold static electric charges that create sparks during discharge.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Servicing and Maintenance The APS contains hazardous voltages and hazardous energy levels. Before undertaking any maintenance task refer to the Warnings on page 16. If a maintenance task must be performed on a "live" system then take all necessary precautions to avoid short-circuits or disconnection of the load equipment, and follow any "live-working" instructions applicable to the site.
Chapter 3 Installation C h Installation a p t e r 3 Overview Topic Page Installation Tasks 20 Task 1 - Check the AC Supply and Earthing 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 Battery Temperature Sensor 31 Task 8 - Connect External Input/Output Cabling (if required) 32 Task 9 - Connect Additional Input/Output (
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Installation Tasks Before starting the installation, review the following information: Required Equipment and Tools on page 69 Warnings and Cautions on page 16 Inspecting the Equipment and Reporting Damage on page 18 Complete the Installation tasks in the following order: Task Description Reference 1 Check the AC Supply and Earthing See details on page 20 2 Prepare the APS See details on page 23 3 Connect
Installation Step 2 - Check high ac voltage protection at the site 1 Check if the ac voltage is expected to exceed 275V (L-N). 2 If so, then it is strongly recommended that an external high voltage protection unit (HVPU) be installed. This will automatically disconnect the ac at high voltage and reconnect it at normal voltage. 3 Install the HVPU as in the following diagram. 4 Connect the High VAC alarm output to one of the Digital Inputs on the I/O board (see the diagram on page 10 for location).
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Step 4 - Check ac discrimination Each rectifier has two internal fast-acting fuses. Under certain internal fault conditions these fuses will blow. If there is insufficient discrimination between these fuses and any upstream ac supply-disconnect device then the upstream ac supply-disconnect device will operate before a rectifier fuse blows. This will disconnect the ac supply to all rectifiers.
Installation Step 5 - Check the earthing arrangements at the site Confirm that all earths are brought together at one "star" point so that surge currents cannot flow in "earth loops" and create large voltages. For more information see Transient Protection on page 87. Procedure complete Task 2 - Prepare APS Step 1 - Fit the system controller (if required) Ignore this Step if the system controller is already fitted.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Rack-mounting bracket (available for 19-inch Alternative bracket mounting positions and 23-inch wide racks) Step 4 - Install Load circuit breakers (if required) Ignore this Step if the load MCBs are already fitted. The current rating of the MCBs must be derated to 75%. The APS can use either Chint or Schneider circuit breakers. However, Chint and Schneider circuit breakers are not interchangeable.
Installation Step 5 - Install Battery MCBs (if required) Ignore this Step if the Battery MCBs are already fitted. The current rating of the MCBs must be derated to 75%. The APS can use either 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 in use (see Spare Parts on page 70 for ordering details).
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Busbar chassis screw Busbar Busbar nut DC common bar Procedure complete Task 3 - Connect the AC Supply Cable(s) Ignore this task if the APS has pre-fitted ac cord(s). For APS12 models only, repeat the following steps for the second rectifier shelf.
Installation Step 3 - Prepare the ac supply cable 1 Select ac supply cable to suit the ac supply source, the maximum ac current (as noted in the Specifications on page 73) and in accordance with the local wiring regulations. 2 Route the ac supply cable from the ac supply point through to the front of the rack to the APS. Do not terminate at the ac supply point at this stage. 3 At the APS end, cut the conductors to suit the positions of the terminals and/or ac MCB(s).
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Step 7 - Check terminations, secure cables and test insulation 1 Check all terminations are correct and are tightened. 2 Tighten the ac cable entry gland to ensure there is no strain on the terminals. Secure the cable with cable ties. 3 Replace the ac MCB cover or ac terminal cover. 4 Test the insulation resistance of the conductors according to local ac wiring regulations.
Installation Step 3 - Mount the APS 1 Carefully feed the ac supply cable or cord(s) into the rack. 2 Lift the APS to the correct position in the rack. 3 A suitable mechanical support or a second person must support the weight of the APS. Attach the APS using four rack mounting screws. Tighten the screws.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Step 4 - Connect load cables 1 Select load cable to suit the dc load currents and voltage drop requirements. Also refer to the table of minimum cable sizes for specific MCBs on page 79. 2 Route the load cables to the APS. If the optional top cover is used then route the cables under the cable tie rod. 3 Terminate the load common cable(s) with an M6 crimp lug.
Installation Step 2 - Connect Mid-point Monitoring sense wires (SC200 only) 1 The Mid-point Monitoring sense wires must have short-circuit protection fitted close to the battery terminals. Use the Battery Mid-point Monitoring kits from Eaton (see Spare Parts on page 70) or equivalent. Connect a Mid-point Monitoring sense wire to the middle interconnecting link on each string of batteries (see following diagram). Connect the wire from XH12A pin 1 to string 1, and so on.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Step 2 - Fix sensor Fix the sensor above the batteries. To avoid false readings: Do not attach the sensor to a battery case, battery cables, terminals or interconnecting bars. Do not expose the sensor to direct sunlight, or air movements from air-conditioning systems or open windows.
Installation Step 3 - Set up SC200 or SC100 Configure the inputs and outputs after completing the installation and all the Startup Tasks on page 36. For configuration details refer to Digital Inputs and Digital Outputs in the System Controller Operation Handbook (see Related Information on page i). Step 4 - Refit top cover (if removed) Replace the top cover (if fitted and all installation tasks are completed).
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Step 2 - Connect at the ac supply point 1 Check the ac supply point is isolated. 2 Connect the cord(s) or cable to the ac supply point, or fit plug(s) to the cord(s) to match the wall receptacle/socket(s), as required. 3 Follow the manufacturer's instructions and local wiring regulations. Label the connection at the ac supply point.
Chapter 4 Start-Up C h Start-Up a p t e r 4 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 DC Power System 38 Task 5 - Applying DC Power to Battery and Load 39 Start-Up Completed 40 Copyright © 2007-2012 Eaton Corporation. All Rights Reserved.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Start-Up Tasks Complete all the Installation tasks (see details on page 20) before starting these Start-Up tasks.
Start-Up Step 3 - Repeat for other rectifiers or fit blank panels 1 Fit the remaining rectifiers. 2 Fit rectifier blank panels in any vacant rectifier positions. Procedure complete Task 2 - Pre-Power-Up Checklist Complete the checklist to confirm initial work is complete before progressing further.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) 2 After start-up of the system controller: Press any key on the system controller to silence the alarm. Depending on the configuration file settings, one or both alarm LED(s) may be on and the system controller may display some system alarm messages. This is normal. For an explanation of alarm messages see Alarm Descriptions in the System Controller Operation Handbook. The LCD module shows the summary screen.
Start-Up Parameter Action Where to find Temperature Compensation Enable (if battery and battery temperature sensor connected) and check the settings. SC100: Menu > Configuration > Temp Compensation > Edit SC200: Control Processes > Temp. Compensation > Enable DCTools: Control Processes > Temperature Compensation Low Voltage Disconnect (LVD) Enable (if LVD(s) installed SC100: and battery connected) SC200: and check the settings.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Step 4 - Check the rectifier currents 1 Check the rectifier currents. 2 Verify the load current is as expected for the load and battery size and does not exceed the maximum load rating (see details on page 74). Step 5 - Charge the batteries 1 Charge the batteries according to the battery manufacturer’s recommendations.
Chapter 5 System Controller C h System C ontroller a p t e r 5 Topic Page Configuration File 42 Starting the SC200 or SC100 43 SC200 or SC100 Operation using the Keypad and Screen 44 SC200 or SC100 Operation Using a PC/Laptop 46 SC200 or SC100 Identity Information 48 Copyright © 2007-2012 Eaton Corporation. All Rights Reserved.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Configuration File The operational settings of the dc power system are stored in a configuration file loaded into the SC200 or SC100 system controller. The SC200 or SC100 is supplied pre-loaded with a configuration file. If this configuration file has been customized for the site then no further configuration changes will be necessary.
System Controller ► To use a web browser for Restore (SC200 only) 1 Connect to the SC200 via a web browser. For details see Ethernet Communications in the System Controller Operation Handbook. 2 Go to Tools. 3 Select Restore Tool. 4 Select the file type: System Snapshot (*.dcs): Configuration file including site specific settings. Configuration (*.dcc): Configuration file without site specific settings - Site Identity, IP Address, S3P Address, battery characterization data). Fragment (*.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) SC200 or SC100 Operation using the Keypad and Screen LCD Soft key 1 label (SC200 only) Soft key 1 (SC200 only) Navigation keys (Up - Down Left - Right) Soft key 2 (SC200 only) Soft key 2 label (SC200 only) Keypad Access Security SC200 System Controller This feature prevents accidental or unauthorized changes to settings from the SC200 keypad.
System Controller SC100 System Controller This feature prevents accidental or unauthorized changes to settings from the SC100 keypad. ► To use DCTools/Web to enable/disable keypad access In DCTools/Web go to Communications. Set UI Access to: Unprotected - keypad access is allowed, or Protected - keypad access is denied (can be temporarily over-ridden, see below). ► To temporarily enable keypad access at the SC100 when access is set to Protected Press Up and Down keys together for 5 seconds.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) ► To enable/disable the audible alarm indicator Either: On SC200 go to: Alarms > Alarm Settings > Audible Alarms > Edit. or on SC100 go to: Menu > Configuration > Audible Alarm. Or: In DCTools/Web go to: Alarms > Alarm Configuration. When Disabled, the audible indicator will still indicate an invalid key press.
System Controller ► To connect a PC/laptop to the SC200 or SC100: 1 Download the latest version of DCTools from: dcpower.eaton.com/downloads. 2 Install DCTools on the PC/laptop. 3 Connect a null-modem cable from the COM1 RS232 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.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) SC200 or SC100 Identity Information The following identity information is stored in the SC200 or SC100. Parameter Description Where to find: Serial Number The SC200 or SC100 serial number (factory set). SC100: Menu > Identity >SC100 Identity Software Version The version of the embedded (App Version) software in the SC200 or SC100 (factory set).
Chapter 6 Maintenance C h Maintenanc e a p t e r 6 Overview The APS contains hazardous voltages and hazardous energy levels. Before undertaking any maintenance task refer to the Warnings on page 16. If a maintenance task must be performed on a "live" system then take all necessary precautions to avoid short-circuits or disconnection of the load equipment, and follow any "live-working" instructions applicable to the site. Only perform the maintenance tasks described in the Maintenance chapter.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Troubleshooting Use the table to troubleshoot minor installation and operational problems. For additional assistance see contact details on page 107. Return items for replacement or repair with a completed Equipment Incident Report on page 105. System Problems Problem Possible Cause Required Action All rectifiers are off (no LEDs on) and system controller display is blank.
Maintenance Problem Possible Cause Required Action Rectifier yellow LED on. Rectifier power limit or current limit is active. Power system is charging the batteries. Load current exceeds the total rectifier capacity. Install additional rectifiers. Rectifier temperature turndown is active due to low ac supply voltage or high ambient temperature. Power system will return to normal operation when the ac supply voltage and/or ambient temperature are within the specified ranges.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Problem Possible Cause Required Action High system output voltage. Temperature Compensation is active and the battery temperature is below the reference temperature. None. This is normal operation (if batteries are connected). Disable Temperature Compensation if no batteries connected. Equalize or Fast Charge is active. None. Output voltage will return to normal when Equalize or Fast Charge is completed.
Maintenance Problem Possible Cause Required Action String Fail Alarm (SC200 only) The Battery Mid-point See Battery Mid-point Monitoring on Monitoring system has detected page 68. a voltage imbalance in one of the battery strings. A Battery Mid-point Monitoring Check the sense wires. sense wire is disconnected. System Controller Problems Problem Possible Cause Required Action SC200 or SC100 displays a dc power system alarm message. SC200 or SC100 LCD is blank and green Power On LED is off.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Problem Possible Cause Required Action Incorrect battery or load current readings. Bus voltage sense polarity is incorrect. Check the bus voltage sense polarity and correct if necessary. Incorrectly configured shunt inputs. Check shunt mapping and gain is correct. Current is within the Battery None, normal operation. State Threshold. See details in the System Controller Operation Handbook.
Maintenance Problem Possible Cause Required Action Modem/RS232 communications problem. Incorrect, disconnected or faulty Check an RS232 straight-thru cable is cable. plugged into XS1 and the modem. Replace faulty cable. Access to RS232 connector XS1 is restricted. Use a DB9 ribbon cable extension (Farnell part number 869-6411). Incorrect communications settings. See PSTN Modem Communications or GSM Modem Communications in the System Controller Operation Handbook. Incorrect modem setup string.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Problem Possible Cause Required Action Web communications problem (SC200 only) Ethernet communications problem. See previous entry. Cannot connect to web server. Check IP address and other settings in SC200 are correct. Check correct IP address is used in web browser address bar. See Ethernet Communications in the System Controller Operation Handbook. Check HTTP Access or HTTPS Access is enabled.
Maintenance Problem Possible Cause Required Action LVD Status LED(s) (on I/O board) are on. LVD contactor is energized. None, this is normal operation. LVD Status LED(s) are off LVD contactor is de-energized. (I/O board Power On LED is on). None, this is normal operation. LVD Status LED(s) flashing. The contactor is in the wrong state (SC200 or SC100 internal state does not match signal from contactor auxiliary switch).
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Replacing or Adding a Rectifier Rectifiers can be replaced without switching off the dc power system and disconnecting the equipment it powers. To reduce the risk of electric shock and maintain optimum system cooling, always cover empty rectifier slots with blanking panels. To avoid electric shock do not place hands inside the rectifier shelf. Do not attempt to disassemble faulty rectifiers.
Maintenance 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 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 locate the rectifier in its rear connector.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Replacing or Adding a Load MCB Step 1 - Remove covers 1 Remove the top cover, if fitted. 2 Remove the DC Distribution front cover. Step 2 - Remove existing MCB (if required) 1 Disconnect the load cable and the fuse fail detect wire from the MCB top terminal. Insulate the ends of both the cable and the wire. 2 Undo the bottom MCB terminal. 3 Unclip the MCB from the DIN rail and remove the MCB.
Maintenance Replacing the System Controller The SC200 or SC100 system controller can 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 (SC200 only) a web browser* connected to the system controller via an IP network. *See Communications Options in the System Controller Operation Handbook. A replacement SC200 or SC100 system controller.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Step 4 - Download the configuration file 1 Connect to the system controller with DCTools/Web. See details on page 46 in the System Controller Operation Handbook. 2 If a copy of the old configuration file, or a master configuration file is available, then use DCTools to restore (download) it to the new system controller. 3 See Backup and Restore on page 42 in the System Controller Operation Handbook.
Maintenance Step 6 - 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 > LVDs > LVD x > Not Characterized > Edit, or on the SC100 go to: Menu > Configuration > LVD1/LVD2 2 If available, select Characterize With IOB Values. Press Enter. Repeat for other LVD(s) if fitted. No further action is required.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Replacing the Input/Output Board When the I/O board is removed any LVD fitted will disconnect: If a battery disconnect LVD is fitted the battery will be disconnected when the I/O board is removed (the load equipment will continue to operate from the rectifiers). If a load disconnect LVD is fitted then this LVD must be bridged so that the loads are not disconnected when the I/O board is removed.
Maintenance Load disconnect LVD M6 (APS6) or M10 (APS12) bolt to low priority load comb bus. 450mm (18") long LVD bridge cable M8 (APS6) or M10 (APS12) bolt to high priority load comb bus. Step 3 - Remove one rectifier and system controller to access I/O board 1 Check that the load current can be supplied 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.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Step 4 - Remove the I/O board 1 See the diagram on page 4 or the diagram on page 6 for location of I/O board. 2 Label then disconnect all I/O board cable plugs. Do not disconnect the input/output wires connected to the push-connect terminals (XH15 - XH21). Any LVDs fitted will disconnect. 3 Lift the I/O board up and off the support posts and partly remove it from the APS.
Maintenance Step 8 - Characterize LVD(s) (if required) Ignore this step if there is no LVD Characterization Error alarm. If the SC200 or SC100 indicates an LVD Characterization Error alarm then the LVD(s) must be characterized. This will cause the LVD 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.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Battery Mid-point Monitoring (String Fail) Alarm (SC200 only) Use the following procedure if a String Fail alarm is generated. Step 1 - Identify the faulty battery string 1 Press any button on the SC200 to silence the alarm. 2 Connect to the SC200 using DCTools/Web. Go to Batteries > Mid-point Monitoring. 3 Click + to expand the Mid-point Monitoring table to identify which battery string has failed.
Appendix A Equipment and Tools A p p Equipment and T ools e n d i x A 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 f
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Spare Parts Item Description Part Number 1 Rectifier See replacement procedure on page 58. 48V, 2000W: 48V, 1800W: 24V, 1440W: 2 Rectifier blank panel (to cover un-used rectifier positions) Eaton RMB1U-00 3 System controller See replacement procedure on page 61. Eaton SC100-00 or SC200-00 4 Input/Output Board. See replacement procedure on page 64.
Equipment and Tools Standard Torque Settings Use the following torque settings unless specific values are stated on the fastener or elsewhere. For battery terminals use 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-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.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) 72 Copyright © 2007-2012 Eaton Corporation. All Rights Reserved.
Appendix B Specifications A p Specific ati ons x p e n d i x B Environment Ambient Temperature Range (operating) -40°C to 70°C [ -40°F to 158°F] Note: Rectifier output derates above 50°C and below -10°C [14°F]. The maximum output current of APS12 models with the LVD option is limited to 400A (or less depending on ambient temperature). See System Output. Relative Humidity (operating and storage) <95% (non condensing) Dimensions H, W, D APS6-300/APS6-500 6U, 19” mounting, 335 mm [13.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) System Output Output Voltage (nominal) Dependent on rectifier model. 24V or 48V Output Voltage Range 21.5 - 32V / 43 - 57.5V Output Power (maximum) APS6-300 models: No LVD: With LVD: 8.9kW* @ 48V 8.6kW* @ 48V APS6-500 models: 8.64kW* @ 28.8V or 12.0kW* @ 48V APS12-300 models: No LVD: 17.2kW* @ 48V With LVD: 17.2kW* @ 48V up to 40°C [104°F] ambient 16.1kW* @ 48V up to 45°C [113°F] ambient 15.
Specifications Rectifiers Operating Ranges APR24-3G/APR48-3G: Rated: 175 – 275V Full output up to 50°C [122°F] Extended: 90 – 300V Reduced output power below 175V APR48-ES: Rated: 185 – 275V Full output up to 50°C [122°F] Extended: 90 – 300V Reduced output power below 185V Input Current (maximum) 20°C [68°F] APR24-3G: APR48-3G: APR48-ES: 9.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Digital Inputs (IOBGP) Number of Digital Inputs 6 Connectors Screwless terminal blocks Wire Size 0.5 - 2.
Specifications Battery Mid-point Monitoring (SC200 only) Number of Strings Standard: Maximum: 4 24 (with additional IOBGP-01 I/O boards) Range –35V to +35V Resolution <30mV Accuracy ±0.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) 78 Copyright © 2007-2012 Eaton Corporation. All Rights Reserved.
Appendix C Cable Ratings A p Cabl e R ati ngs p e n d i x C 18 mm DIN rail MCB's Eaton Part Number* Chint NB1 Series Minimum cable size 307-900600-61 Chint, NB1-63 UL Series, 6A, Curve 1mm2 / 16AWG 307-901000-61 Chint, NB1-63 UL Series, 10A, Curve 1.25mm2 / 16AWG 307-901600-61 Chint, NB1-63 UL Series, 16A, Curve 2.
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Appendix D Controller Menus A p Controller M enus p e n d i x D SC200 Menu At each menu screen press Enter to access the associated configuration menu screen(s). These menus have multiple configuration menu screens. See details in the System Controller Operation Handbook. Copyright © 2007-2012 Eaton Corporation. All Rights Reserved.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) 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 any other rectifiers. List of any active alarms. 82 Operate control processes. SC100, I/O board and rectifier identity information. Configure control processes.
Appendix E Connector Pin-outs A p p Connector Pi n-outs e n d i x E System Controller Connector Pin-outs Connector Type Purpose XS1 DB9M RS232 Serial Interface XS31 RJ45 (SC200 only) YS11 RJ45 USB USB B (SC200 only) Ethernet Interface RXP System Communications USB Serial Interface 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 - 9 - 1 Rx 2 Rx 3 Tx 4 - 5 - 6 Tx 7 -
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) 1 1 8 RS232 D9M and RJ45 connector pin-outs RJ45 plug pin-outs I/O Board (IOBGP-00, -01) Connector Pin-outs See input and output specifications on page 73.
Connector Pin-outs Connector Type Purpose XH8 MTA 156 LVD Power MTA 156 Bus Voltage Sense Input MTA 156 Battery Mid-point Monitoring sense inputs (SC200 only) XH9 XH12A XH15A XH15B XH16/XH17 XH18/XH19 XH20/XH21 Pin Digital inputs D1-D3 Digital inputs D4-D6 Digital relay outputs 1-2 Digital relay outputs 3-4 Digital relay outputs 5-6* Description 1 Bus live 2 Common 1 Controller reference (Live) 2 Controller sense (Com) 1 String 1 Mid-point 2 String 2 Mid-point 3 String
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Connector YH3 YH11 Type RJ45 RJ45 Purpose Pin DC power system digital inputs RXP System Communications Description 6 Relay 6 Common (COM) 1 Load Fuse 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 1 +24/48V (System bus voltage) 2 +24/48V (System bus voltage) 3 - 4 RS485
Appendix F Transient Protection A p p Transi ent Protecti on e n d i x F To prevent damage to Eaton Access Power Solutions from lightning and transient over-voltages, structural lightning protection and transient protection must be installed at each site.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Primary Transient Protection Primary transient protection must be considered at all sites. Eaton recommends primary transient protection on the incoming ac supply either at the main ac switchboard or sub-switchboard. In the absence of sufficient information, primary transient protective devices with a minimum repeat strike rating of 100kA (8/20μs wave shape) are recommended.
Transient Protection Transient protective devices are fitted with alarm contacts and visual indicators. Monitor the status of all externally installed transient protective devices. Either: Regularly inspect the visual indicators Connect the alarm contacts to the MOV Fail termination on the I/O board (preferred option) or to the building management system. See the Connections diagram on page 11 for location of MOV Fail termination (YH3) and connector pin-outs on page 84.
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Appendix G Earth Bonding A p Earth Bonding p e n d i x G The earthing arrangement of your communications equipment determines how the dc common bus of the dc power system is referenced to earth. There are two options: ac and dc earths bonded, or ac and dc earths separated. AC-DC Earth Linked (recommended) During a lightning surge, very large voltages can develop between ac earth and dc common bus as the surge current flows through the earth cables to earth.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Step 2 - Remove or replace the ac-dc Earth Link Ignore this Step if the factory fitted ac-dc earth link is used. There are two options if the ac-dc earth link cannot be retained. Either: If the site surge protection is designed to limit transient ac earth - dc earth voltages to less than 1500V at the dc power system, then remove the ac-dc earth link as in Step 1. No further action is required.
Appendix H Commissioning A p Commissioning p e n d i x H Complete the tasks in this appendix only if a formal commissioning test is required. Before starting these Commissioning tasks: Complete all the Installation 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, note any changes to the configuration file that are incorrect.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Analog Inputs Equipment required: Digital Voltmeter DC Load bank DC Current Clamp meter Trim pot adjustment tool Thermometer Test Test procedure Adjustment DC Voltage Measure the dc voltage across the dc bus. Ensure the bus voltage on the SC200 or SC100 display and in DCTools/Web is within specifications. Battery Current Conduct the load test and turn off the rectifiers.
Commissioning Notes 1 When the rectifiers are turned off, the battery current will supply all the current to the load. At this time the battery current will equal the load current. This test assumes there is a current sensor on the dc Load 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 test.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) System Controls Equipment Required: DC Load bank Test Test procedure Adjustment Apply a load to the power system. With DCTools, ensure the bus voltage matches the Target Voltage as shown on the Voltage Control Summary of DCTools. None None Note 2 Heat the battery temperature sensor. Ensure the system voltage changes in accordance with the configured slope. Equalize Set the Equalize Duration to 1 minute.
Commissioning Test Current Share Note 6 Test procedure Adjustment View the individual rectifier currents with the SC200 or SC100 or DCTools/Web. None Ensure the currents are all at 0 amps. Connect load to the system. Ensure that all rectifiers share the load evenly and any variation is within specification. Battery Test Set the Battery Test Interval to 0 days.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Test Test procedure Adjustment Automatic Operation Reduce the system voltage below the LVD Disconnect Voltage Threshold. Note 7 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 voltage above the configured Reconnect Voltage. Wait for the configured Recognition Period.
Commissioning System Alarms Equipment Required: dc load bank dc power supply Test General notes about alarm testing Test procedure Adjustment For all alarms check the following where applicable: SC200 or SC100 LED status. SC200 or SC100 display indication. DCTools/Web alarm indication Remote alarm indication (PowerManagerII, SNMP traps, and so on) Digital outputs (relays). Reducing the alarm recognition time will reduce the alarm testing time.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Test Test procedure Adjustment Multiple Rectifier comms lost Remove 2 rectifiers from the system. Partial AC Fail Turn off the ac to more than 20% of the rectifiers in the system. Ensure alarm operates. Ensure alarm operates. AC Fail Turn off all ac to the system. Ensure alarm operates. System Overload Reduce the System Overload Recognition Period to 0 minutes. Apply load to the system.
Commissioning Test Test procedure Adjustment Fast Charge For details see Fast Charge test in System Controls on page 96. Battery Test For details see Battery Test in System Controls on page 96. In Discharge Connect load to the system. Note 3 Turn off the ac supply to the rectifiers. Allow the battery to start discharging. Ensure alarm operates. Config Error Note 4 Load incorrect configuration file. - or Remove all rectifiers from the system.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Notes 1 Ensure Alarm Tracking is disabled. Ensure Temperature Compensation is enabled. 2 If the load is not connected to the load MCBs and if an electronic Fuse Fail detect circuits is installed, this test can also be performed as follows: Turn off the load MCB Connect a high impedance path >100k ) between the end load side of the MCB and the Common Bus.
Commissioning Digital Outputs (Relays) Test Test procedure Adjustment Refer to Digital Outputs in the SC200 or SC100 handbook. Follow the instructions to manually change the state of the digital output. When the digital output is Active, check any remote alarms are extended. Digital Output 1 Note 1 When the digital output is Inactive, check any remote alarms are return to their original state. Digital Output 2 As for Digital Output 1. Digital Output 3 As for Digital Output 1.
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Equipment Inci dent Report EQUIPMENT INCIDENT REPORT Please enter as much information as you can. Send the completed form, together with the item for repair to your nearest authorized service agent. NOTE: Only one fault to be recorded per form. For further information contact your local Eaton dc product supplier or Eaton (see contact details on page 107). Or email: CustomerServiceNZ@eaton.
INFORMATION continued (fault details, circumstances, consequences, actions) ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ _
Worldwide Support Worldwide Support For product information and a complete listing of worldwide sales offices, visit Eaton's website at: dcpower.eaton.com or email: DCinfo@eaton.com For technical support contact either your local Eaton dc product representative, the closest office from the following list, telephone (+64) 3-343-7448, or email CustomerServiceNZ@eaton.
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) 108 Copyright © 2007-2012 Eaton Corporation. All Rights Reserved.
Index Index Battery Installation • 30 Disposal and Recycling • 68 ? Mid-Point Monitoring (MPM) • 13, 30, 77 ??? on SC200 or SC100 Display • 45, 54 Reverse Polarity • 39 String Fail Alarm • 13, 53, 68 A Temperature Sensor • 10, 11, 31, 76 AC Earth Time Remaining • 13 AC-DC Earth Connection • 23, 91 Battery Circuit Breakers • 52 Connection Point • 3, 6 Connecting to MCBs • 29 Site Earth • 20 Fitting MCBs • 23 AC phase/neutral terminals • 4 Location • 3, 5 AC Supply Browsers (recommended) •
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) Battery Current • 54 H Load Current • 54 High AC Voltage Protection • 20 Rectifier Current • 43 Current Sense • 10, 11, 76 I Identity Information • 48 D Input/Output (I/O) Board Damage (transport) • 18, 36 Connections to other system components • 11 DC Common Connector Pin-outs • 84 AC-DC Earth Connection • 23, 91 Description • 10 Location • 3, 5 Digital Inputs • 76 Polarity • 23 I/O Board Mapping •
Index Problems • 57 Rectifier Current • 43 LVD • See Low Voltage Disconnect (LVD) Rectifier Fuses • See AC Discrimination Rectifier LEDs • 7 M Rectifier Replacement • 58 Main Screen • 43 Registration • 37 Mid-Point Monitoring (MPM) • 13, 30, 77 Repair and Return • 105 Startup • 37 String Fail Alarm • 13, 53, 68 Relays • See Digital Outputs (Relays) Model numbers • 2 Monitor OK Alarm • 10, 53 Modem (PSTN, GSM) • See Communications Monitor OK Alarm • 10, 53 Repair and Return • 105 MOVs • See T
Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series) SMS Text Messaging • See GSM Modem Communications SNMP • 12 Web Access Security • 56 Web Server • 12, 56 Write Access Password • 55 SNTP • See Internal Clock Software Versions • 9 Sound • See Audible Alarm Indication Spares • 70 Specifications • 73 String Fail Alarm • 13, 53, 68 T Target Failed to Respond Error • 54 Technical Assistance • 107 Temperature Temperature Sensor • 10, 11, 31, 76 Text Messaging (SMS) • S
