aps6-300_+_aps12-300_installation_guide_b_a4 recti impreso

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Access Power Solut ions

Ins tal lat ion and Operat ion Gu ide

(APS6-300 and APS12-300 Series )

Issue: IPN 997-00012-49B

Issue Date: November 2007

Eaton Corporation

Telecommunications Solutions Division

www.powerware.com

[email protected]


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Eaton Corporation disclaims any liability for direct, indirect, incidental, special orconsequential damages arising out of the application or use of any informationcontained in this document. The foregoing disclaimer applies to damages or personalinjury, property damage, loss of operation, loss of profits, loss of product or loss of time,whether incurred by the purchaser, the purchaser’s employees or third party.

Information in this document does not constitute a warranty, representation orguarantee concerning the suitability or performance of Eaton products. No such

warranty, representation or guarantee is expressed or implied.

Information contained in this document is subject to change without further notice.

Subject to the right to use its equipment, Eaton Corporation does not convey any right,title or interest in its intellectual property, including, without limitation, its patents,copyrights and know-how.

No part of this document may be reproduced or transmitted in any form, by any meansor for any purpose other than the Purchaser’s personal use, without the express writtenpermission of Eaton Corporation.

Eaton®, Powerware

®, Intergy

TM, CellSure

TM, SiteSure

TM, PowerManagerII

TM and

DCToolsTM

are trade names, trademarks, and/or service marks of Eaton Corporation orits subsidiaries and affiliates. Unless otherwise noted, brands, product names,trademarks or registered trademarks are the property of their respective holders.

Copyright © 2007 Eaton Corporation. All Rights Reserved.


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Abou t This Guide


IPN 997-00012-49B November 2007i

AboutThisGuide

ScopeThis guide covers installation, operation and maintenance of Access Power Solutions (APS6-300 and APS12-300 Series) DC power systems (APS), controlled by the SC200 systemcontroller.

Audience

This guide is intended for use by:

• DC power system installers competent in:

• installing and commissioning DC Power Systems• safe working practices for AC and DC powered equipment

• the relevant local electrical safety regulations and wiring standards

• DC power system operators and maintenance staff competent in:

• operation of DC Power Systems

• safe working practices for AC and DC powered equipment

Related Information

• PowerManagerII Online Help• DCTools Online Help

• SiteSure-3G Installation and Operation Guide – IPN 997-00012-51

Repor t ing Problems with th is Guide

Please use this email address to report any problems you find in this guide:

Powerware DC Product Marketing Communications

EMAIL: [email protected]

For Fur ther Inform at ion and Technica l Ass istance

For further information and technical assistance see Worldwide Support on page 153.


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Ac cess Pow er Solut ion s Instal lat ion and Op eration Guide (APS6-300 and APS12-300 Series)

i iCopyright © 2007 Eaton Corporation. All Rights Reserved.

IPN 997-00012-49B November 2007


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Table of Con tents


IPN 997-00012-49B November 2007i i i

Tableof Contents

About This Guide Scope .................................................................. .................................................................. ....... i Audience..................................................................................................................................... i Related Information ............................................................ ...................................................... i Reporting Problems with this Guide...................................................................................... i For Further Information and Technical Assistance .............................................................. i

Chapter 1 General Description Overview ................................................................. .................................................................. 1 Access Power Solutions DC Power Systems ................................................................ ........ 2

APS6 Models Front View................................................................................................................2 APS6 Models Rear View................................................................................................................. 3 APS12 Models Front View..............................................................................................................4 APS12 Models Rear View............................................................................................................... 5

Access Power Rectifiers (APR24-3G/APR48-3G)................................................................ 6 SC200 System Controller ....................................................................... .................................. 6

Input/Output Board ..................... ....................... ...................... ....................... ...................... ........ 7 Low Voltage Disconnect Options........................................................................................... 8 Connections............................................................................................................................... 9 Compatible Software .............................................................. ............................................... 10

Chapter 2 Preparation Overview ................................................................. ................................................................ 11 Warnings .......................................................... ................................................................... .... 12 Inspecting the Equipment and Reporting Damage ........................................................... 14

Chapter 3 Installation Overview ................................................................. ................................................................ 15 Installation Tasks.................................................................................................................... 16 Task 1 - Check the AC Supply and Earthing...................................................................... 16 Task 2 - Customize APS......................................................................................................... 19 Task 3 - Connect the AC Supply Cable(s) ....................................................................... .... 22 Task 4 - Mount the APS in the Rack..................................................................................... 24 Task 5 - Connect the DC Load and Battery Cables............................................................ 25 Task 6 - Install the Batteries .................................................................... .............................. 27 Task 7 - Mount the Battery Temperature Sensor ............................................................... 27 Task 8 - Connect External Input/Output Cabling (if required)....................................... 28

Task 9 - Connect Additional Input/Output (if required) ................................................. 30 Task 10 - Connect to the AC Supply Point.......................................................................... 30 Installation Completed ............................................................... ........................................... 31

Chapter 4 Start-Up Overview ................................................................. ................................................................ 33 Start-Up Tasks......................................................................................................................... 34 Task 1 - Inserting the Rectifiers .............................................................................. .............. 34 Task 2 - Pre-Power-Up Checklist ........................................................... .............................. 35 Task 3 - Applying AC Power................................................................................................ 36 Task 4 - Configuring the DC Power System....................................................................... 36 Task 5 - Applying DC Power to Battery and Load............................................................ 37 Start-Up Completed ...................................................................... ......................................... 38


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ivCopyright © 2007 Eaton Corporation. All Rights Reserved.

IPN 997-00012-49B November 2007

Chapter 5 SC200 Operation Overview ................................................................. ................................................................ 39 Configuration File ................................................................ .................................................. 40

Backup and Restore....................................................................................................................... 40

Starting the SC200 ..................................................................... ............................................. 41 SC200 Operation using the Keypad and Screen................................................................. 41

Soft Keys ...................... ....................... ...................... ....................... ....................... ...................... .. 42 Navigation Keys .................... ....................... ....................... ...................... ....................... ............. 42 Main Menu Navigation................................................................................................................. 43 Changing a Configuration Setting using the Keypad............................................................... 44 Keypad Access Security................................................................................................................ 44 Display Settings .................... ...................... ....................... ...................... ...................... ................ 45 Display Time-out ...................... ...................... ...................... ...................... ....................... ............ 45 Alarm Indicators............................................................................................................................ 45

SC200 Operation Using a PC/Laptop ................................................................. ................ 46 SC200 Identity Information................................................................................................... 48 SC200 Internal Clock.............................................................................................................. 48

SC200 Firmware Upgrade..................................................................................................... 49 Chapter 6 System Operation

Overview ................................................................. ................................................................ 51 Voltage Control....................................................................................................................... 52

Float Voltage ..................... ...................... ....................... ....................... ...................... ................... 53 Active Voltage Control (AVC) ................... ....................... ....................... ...................... .............. 53 Battery Current Limit (BCL)......................................................................................................... 54 Battery Test..................................................................................................................................... 55 Equalize........................................................................................................................................... 57 Fast Charge..................................................................................................................................... 58 Temperature Compensation .................... ....................... ....................... ...................... ................ 59

Rectifiers ............................................................ .................................................................. .... 60

Identify............................................................................................................................................ 62 Rectifier Shutdown........................................................................................................................ 62 Low Voltage Disconnect (LVD)............................................................................................ 63 System Alarms........................................................................................................................ 66

System Overload Alarm ...................... ....................... ...................... ....................... ..................... 68 Generator Start Option ....................................................................... ................................... 69 Input/Output (I/O) ............................................................... ................................................ 70

Identify an I/O Board .................... ...................... ....................... ....................... ..................... ...... 70 Analog System Values ................... ....................... ....................... ...................... ..................... ...... 71 Analog Inputs................................................................................................................................. 71 System States.................................................................................................................................. 72 Digital Inputs ....................... ....................... ...................... ....................... ...................... ................ 72 Digital Outputs .................... ....................... ....................... ...................... ....................... ............... 73

Data Logging........................................................................................................................... 74 Chapter 7 Communications

Overview ................................................................. ................................................................ 77 Communications Options ..................................................................... ................................ 78 Direct (USB) Communications ........................................................................... .................. 78 Ethernet Communications ................................................................. ................................... 78 PSTN Modem Communications ......................................................................... ................. 82 GSM Modem Communications............................................................................................ 85 Communications Security..................................................................................................... 87

Serial Communications (USB/RS232/Ethernet) Security ........................ ....................... ......... 88 Web Access Security...................................................................................................................... 89


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Table of Contents


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Chapter 8 Maintenance Overview ................................................................. ................................................................ 91 Troubleshooting...................................................................................................................... 92 Replacing a Rectifier ..................................................................... ......................................... 99

Replacing or Adding a Load MCB..................................................................................... 100 Replacing the System Controller........................................................................................ 101 Replacing the Input/Output Board .................................................................... ............... 104 Battery Disposal and Recycling.......................................................................................... 108

Appendix A Equipment and Tools Safety Equipment .................... ....................... ...................... ....................... ...................... .......... 109 Essential Tools.............................................................................................................................. 109 Recommended Tools................................................................................................................... 109

Spare Parts............................................................................................................................. 110 Standard Torque Settings.................................................................................................... 111

Appendix B Specifications

Appendix C Connector Pin-outs Connector Pin-outs............................................................................................................... 117 I/O Board Connector Pin-outs ................................................................. .......................... 119

Appendix D SC200 Mappings I/O Board Mapping............................................................................................................. 123 Digital Output (Relay) Activation...................................................................................... 125

Appendix E Alarm Descriptions

Appendix F System Event Types

Appendix G Transient Protection

Appendix H Earth Bonding

Appendix I Commissioning Analog Inputs ............................................................. .......................................................... 138 System Controls.................................................................................................................... 140 System Alarms...................................................................................................................... 145 Digital Inputs ............................................................ ............................................................ 149 Digital Outputs (Relays)...................................................................................................... 149 Commissioning Completed ...................................................................... .......................... 150

Equipment Incident Report

Worldwide Support

Index


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v iCopyright © 2007 Eaton Corporation. All Rights Reserved.

IPN 997-00012-49B November 2007


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Chapter 1

General Desc ript ion


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C h a p t e r 1GeneralDescription

Overview

Topic Page

Access Power Solutions DC Power Systems 2

Access Power Rectifiers (APR24-3G/APR48-3G) 6

SC200 System Controller 6

Low Voltage Disconnect Options 8

Connections 9

Compatible Software 10


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2Copyright © 2007 Eaton Corporation. All Rights Reserved.

IPN 997-00012-49B November 2007

Acc ess Power Solut ions DC Power Systems

APS6 Models Front View

AC Rating Label

APR-3G Series rectifier (see details on page 6)

SC200 system controller (see details on page 6)

AC Miniature Circuit Breakers (MCBs) (if fitted)

AC MCB cover

AC earth conductor connection point (seeconnection details on page 22)

DC Common battery terminals

DC Common load terminals

Voltage Feed Module with connector foroptional SiteSure-3G I/O module

Load and battery cable tie rod

DC Distribution with:Up to 16 Load Miniature Circuit Breakers(MCBs). See Note 1.Up to 4 Battery Miniature Circuit Breakers(MCBs)

DC Distribution cover


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General Descript io n


IPN 997-00012-49B November 20073

APS6 Models Rear View

AC cable entry gland

I/O Board (see details on page 7)

Optional battery disconnect Low VoltageDisconnect (LVD) (see details on page 8)

Optional (low priority) load disconnect LowVoltage Disconnect (LVD) (see details on page8)

Up to 16 Load Miniature Circuit Breakers(MCBs). See Note 1.

Up to 4 Battery Miniature Circuit Breakers(MCBs)

Notes:

1If a load disconnect LVD is fitted then load MCB positions 1-8 are for low priority loadsand MCB positions 9-16 are for high priority loads. For more details see Low VoltageDisconnect Option on page 8.

2 Optional 19" rack mount top cover (IPN 621-08917-15) not shown.

3 AC supply cord(s) may be pre-fitted.


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IPN 997-00012-49B November 2007

APS12 Models Front View

AC Rating Label

APR-3G Series rectifier, 48V only (see detailson page 6)

SC200 system controller (see details on page 6)

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

AC earth conductor connection point for toprectifier shelf (see connection details on page22)

DC Common battery terminals

DC Common load terminals

Load and battery cable tie rod

DC Distribution with:Up to 16 Load Miniature Circuit Breakers(MCBs). See Note 1.Up to 4 Battery Miniature Circuit Breakers(MCBs)

DC Distribution cover


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IPN 997-00012-49B November 20075

APS12 Models Rear View

AC cable entry glands for top and bottomrectifier shelves

I/O Board (see details on page 7)

Voltage Feed Module with connector foroptional SiteSure-3G I/O module

Optional battery disconnect Low VoltageDisconnect (LVD) (see details on page 8)

Optional (low priority) load disconnect LowVoltage Disconnect (LVD) (see details on page8)

Up to 4 Battery Miniature Circuit Breakers(MCBs)

Up to 16 Load Miniature Circuit Breakers(MCBs). See Note 1.

Notes:

1 If a load disconnect LVD is fitted then load MCB positions 1-8 are for low priority loadsand MCB positions 9-16 are for high priority loads. For more details see Low VoltageDisconnect Option on page 8.

2 Optional 19" rack mount top cover (IPN 621-08917-15) not shown.

3 AC supply cord(s) may be pre-fitted.

4 DC inter-shelf connection cables (from rectifier shelves to DC distribution) not shown forclarity.


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IPN 997-00012-49B November 2007

Acc ess Pow er Rectif iers (APR24-3G/APR48-3G)

Powerware Access Power Solutions APS6 models can be fitted with either 24V or 48V AccessPower Rectifiers (APR24-3G/APR48-3G).

Powerware Access Power Solutions APS12 models can be fitted with 48V Access PowerRectifiers (APR48-3G) only.

All rectifiers are fan-cooled and hot-pluggable.

See Specifications on page 113 for further information.

Power On LED (Green)

Minor Alarm LED (Yellow)

Major Alarm LED (Red)

Serial Number label

Retaining Screw. Tighten to 1.5Nm (13.3inch-pounds).

See Troubleshooting on page 92 for details of rectifier alarms.

SC200 System Contro l ler

The SC200 system controller is an advanced control and monitoring solution which providesa full suite of advanced communications options, including built-in Ethernet interface, Webserver, and SNMP agent.

Alarm notifications may be by SNMP traps, SMS text messaging, dial-out to PowerManagerIIremote monitoring software, or relay contact closures.


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IPN 997-00012-49B November 20077

RXP

YS11

RS232

XS1

XS31

Power on LED (green)

Minor alarm LED (yellow)

Critical/Major alarm LED(red)

Color LCD display

Soft keys (2)

Navigation keys (4)

USB 1.1 connector (12Mb/s)

Retaining screw (undercover)

Ethernet connector andstatus LEDs

RS232 connector

Power and systemcommunications connector

The SC200 is supplied pre-configured with either a default configuration file, or with onefactory customized for a particular application. Some configuration file changes can be madewith the keypad, or all settings can be changed via a PC connected to the USB interface (seedetails on page 40).

For connector pin-outs see details on page 117. See Troubleshooting on page 92 for details of

SC200 alarms.

Input/Output Board

The input/output (I/O) board provides the I/O interfaces and connections for the SC200system controller.

The I/O board includes a range of sense inputs for DC power system control andmonitoring. It also allows real time data collection from building services and other externaldevices, and relay outputs for alarm signals or control of external devices.

The I/O functions are:

Sensors: Current - 3, Bus voltage - 1, Temperature - 2

Input/Output: Digital inputs: 4 pre-defined system functions, 6 user-definedRelay outputs: 6 (one also used as Monitor OK alarm)LVD contactor outputs: 2

For input and output specifications see details on page 114 . For connector pin-outs see detailson page 119 .


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IPN 997-00012-49B November 2007

YH11XH6XH7

XH12

YH3

XH4

XH5

1

1 1 1

8

8 8 8

1 2

4 1

XH9

RY1XH16

RYXH18

3RYXH20

5 RYXH17

2RYXH19

4RYXH21

6XH15AXH15B

N O

N O

N O

N O

N O

N O

N C

N C

N C

N C

N C

N C

C O M

C O M

C O M

C O M

C O M

C O M D

1 D 4

D 6

D 3

D 5

D 2

0 V

0 V

0 V

0 V

0 V

0 V

1

1

4

4

1

2

6 1 6 6 6 61 1 1 1

Bus voltage sense input - XH9

Power/Comms OK LED (green)

Digital inputs D1-D6 (6 user defined) - XH15A,XH15B

Digital (relay) outputs RY1-RY6 (6) - XH16-

XH21

LVD2 status LED (green)

LVD2 control connector - XH5

LVD1 status LED (green)

LVD1 control connector - XH4

LVD power input connector - XH8

Power and RXP comms input - YH11

Current sense inputs (3) - XH6

Temperature sense inputs (2) - XH7

Battery mid-point monitoring sense inputs - XH12(future option)

DC power system digital inputs (4 pre-defined:Load Fuse Fail, Battery Fuse Fail, AC DistributionFan Fail, AC Distribution MOV Fail) - YH3

See Troubleshooting on page 92 for details of I/O board LED signals.

Low Vol tage Disco nnect Opt ions

Single or dual optional Low Voltage Disconnects (LVD) are available for the Access PowerSolutions (APS6-300 and APS12-300 Series). See diagram on page 3 (APS6 models) ordiagram on page 5 (APS12 models) for location. These are connected as a battery disconnect(single LVD) or low priority load/battery disconnect (dual LVD).

For information on operation refer to Low Voltage Disconnect (LVD) on page 63.


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IPN 997-00012-49B November 20079

Connect ions

The following diagram shows the connections between the SC200, the I/O board, the otherDC power system components and external devices.

SC200 system controller

I/O board

Voltage feed module

USB communications to local PC or laptop

Ethernet communications via an IP network

RS232 communications via an externalmodem

Digital relay outputs (6) to external devicesand/or alarm indication system

Digital inputs (6) from external switches orrelay contacts

Connection to additional I/O board(s) and/orSiteSure-3G I/O module(s)

Connection to DC common bus

Connection to DC live bus

Communications to rectifiers

DC power system digital inputs (Load Fuse Fail,Battery Fuse Fail, AC Distribution Fan Fail, ACDistribution MOV Fail)

Connections to battery mid-points (4) - futureoption

Connection to temperature sensors (2)

Connection to current sensors (3)

Optional LVD1 contactor and auxiliary switch

Optional LVD2 contactor and auxiliary switch

For connector pin-outs see details on page 119 . For input and output specifications see detailson page 113 .


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IPN 997-00012-49B November 2007

Comp at ib le Softw are

The following software is compatible with the SC200 system controller:

•

DCTools Configuration Software. Latest version is available free fromwww.powerware.com/downloads.

• PowerManagerII Remote Control and Monitoring Software. Contact your PowerwareDC product supplier or Eaton for further information (refer to Worldwide Support onpage 153).


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Chapter 2

Preparat ion


IPN 997-00012-49B November 200711

C h a p t e r 2Preparation

Overview

Topic Page

Warnings 12

Inspecting the Equipment and Reporting Damage 14


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IPN 997-00012-49B November 2007

Warnings

This section contains important warnings. Read these warnings before installing or operatinga Powerware Access Power Solutions DC power system.

Electrical Safety• Powerware Access Power Solutions (APS6-300 and APS12-300 Series) DC power systems mustbe mounted in an enclosed cabinet that meets safety and fire enclosure requirements as specifiedin AS/NZS 60950.1 and EN 60950-1.

• The DC power system may be powered from multiple AC sources. All AC power sources mustbe isolated before internally servicing the equipment.

• The DC power system MCBs are not a disconnect device. The APS DC power system must beconnected to a suitable upstream AC supply disconnect device such as Miniature CircuitBreaker(s) (MCB) or fuses. This device must isolate both the phase and neutral conductors in

single-phase and three-phase connections, unless the neutral conductor is clearly identified.• If the DC power system is to be installed in a location where the ambient temperature may rise

above 50ºC (122ºF), then V105 rated cable must be used for all connections.

• The DC power system is not compatible with IT (Impedance Terra) AC power distributiontopologies. For advice refer to Worldwide Support on page 153.

• A registered electrician (or suitably qualified person) must check the integrity of the installedcabling, BEFORE the DC power system is powered up.

• Tasks must be performed in the sequence documented in this guide.

Location and Environment• An APS DC power system must be installed in a restricted access location.• For ease of access and to maintain optimum system cooling observe the clearances stated onpage 24.

• Dust build-up within the DC power system may cause premature failure. In dusty environmentsfilter the ventilation air entering the equipment room. Ensure regular cleaning of the air filters.

• Do not allow water or any foreign object to enter the DC power system. Do not place objectscontaining liquid on top of or near the unit.

• Flooded cell and VRLA lead acid batteries can emit explosive gases and must be installed withadequate ventilation. Refer to the battery manufacturer or supplier for advice on minimumventilation levels.

Reverse Polarity• Always check that the battery cables have been terminated to the correct system polarityBEFORE connecting the batteries or closing the battery disconnect device. Connecting batteriesto the DC power system with incorrect system polarity will damage the rectifiers and void allwarranty claims.

Hazardous Energy Levels• Rectifiers and batteries contain hazardous energy levels. Only personnel trained andexperienced in DC power systems are to service this equipment.

• Always use insulated tools.

• Do not short-circuit the live and common bus bars or cables.


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Preparation


IPN 997-00012-49B November 200713

Batteries• The plastic cases of batteries installed in Powerware DC power system racks must have aflammability rating of UL 94-V2 or better.

• Flooded cell lead acid batteries must be installed in a battery room. Do not install flooded leadacid batteries in a Powerware DC power system rack.

• Flooded cell and VRLA lead acid batteries can emit explosive gases and must be installed withadequate ventilation. Refer to the battery manufacturer or supplier for advice on minimumventilation levels.

• Do not wear a synthetic dust-coat or overalls. Synthetic fabrics can hold static electric charge thatcreate sparks during discharge.

• Remove rings, wristwatch and other metal jewelry that might be exposed to battery terminals,before installing batteries.

• Batteries are powerful sources of energy and present a potential electrical shock and energyhazard. The energy hazard is always present, even if the batteries are not connected. Avoid shortcircuiting terminals of opposite polarity.

• Always use insulated tools.• Do not place tools, loose cables or metal objects (such as interconnecting bars) on top of batteries.

• Do not drop tools, loose cables or metal objects onto intercell connections or terminals ofopposite polarity.

• Only terminate cables and interconnecting bars after confirming that the termination will notcreate a short circuit.

• Always tighten battery terminal bolts according to the battery manufacturer’s specification.Failing to do so can cause erratic battery performance, possible damage to the battery, and/orpersonal injury.

• There is a risk of electric shock if a battery is replaced by an incorrect type.

• Dispose of batteries according to the instructions on page 108.

Rectifiers

• Do not install the rectifiers until the room has been cleaned and is dust free.

• To reduce the risk of electric shock and maintain optimum system cooling, always cover emptyrectifier slots with blanking panels.

• To avoid electrical shock, do not place hands inside the rectifier magazine.

• Rectifier cases may exceed 100ºC (212ºF), especially after prolonged operation. Use suitablegloves when removing a rectifier from the magazine.

• Do not attempt to disassemble faulty rectifiers. Return them (in their original packaging) with acopy of the Equipment Incident Report on page 151.

• Ensure that any upstream Residual Current Devices (RCDs) are appropriately rated for therectifiers' maximum earth leakage current (see Specifications on page 113 for value).

DC Distribution(s)

• The DC Common of the DC power system can be connected to earth (ground). If this connectionis made all of the following conditions must be met:

• Your equipment and the DC power system must be located within the same premises.

• No switching or disconnecting devices are allowed in the conductor between the DCcommon line and the point of connection to the earth electrode conductor.Refer to Connecting the DC Output to Earth on page 19 for further information.

• For installations in the United States, Listed compression connectors must be used to terminateListed field-wired conductors where required. For all installations, use the appropriateconnector for the conductor size as specified by the connector manufacturer. And use only theconnector manufacturer's recommended tooling or tooling approved for that connector.

• Follow all applicable local and national rules and regulations when making field connections.• Tighten all electrical connections to the torques stated in this guide or on the manufacturer's

label.


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IPN 997-00012-49B November 2007

Servicing• The DC power system contains hazardous voltages and hazardous energy levels. Do notattempt to disassemble or service the unit if you are not qualified.

EMC Compliance

• This Powerware product ("the equipment") has been tested and found to comply with the limitsfor a Class B digital device, pursuant to part 15 of the Federal Communications Commission(FCC) Rules. These limits are designed to provide reasonable protection against harmfulinterference in a residential installation.

• The equipment generates, uses, and can radiate radio frequency energy and, if not installed andused in accordance with the instructions in this installation guide, may cause harmfulinterference to radio communications. However, there is no guarantee that the interference willnot occur in a particular installation.

• If the equipment does cause harmful interference to radio or television reception, which can bedetermined by turning the equipment off and on, the user is encouraged to try to correct the

interference by one or more of the following measures:• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.

• Connect the equipment into an outlet on a circuit different from that to which the receiver isconnected.

• Consult the dealer or an experienced radio/TV technician for help.

• Changes or modifications to the equipment not approved by Eaton Corporation could void theFCC authority to operate the equipment.

Insp ect ing the Equipm ent and Repor t ing Damage

Unpack the equipment and inspect it carefully for possible damage that may have occurredwhile in transit.

Report any damage immediately, using a copy of the Equipment Incident Report on page151.

Keep the original packaging and use it if any equipment needs to be returned for replacement orrepair.


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Chapter 3

Instal lat ion


IPN 997-00012-49B November 200715

C h a p t e r 3Installation

Overview

Topic Page

Installation Tasks 16

Task 1 - Check the AC Supply and Earthing 16

Task 2 - Customize APS 19

Task 3 - Connect the AC Supply Cable(s) 22

Task 4 - Mount the APS in the Rack 24

Task 5 - Connect the DC Load and Battery Cables 25

Task 6 - Install the Batteries 27

Task 7 - Mount the Battery Temperature Sensor 27

Task 8 - Connect External Input/Output Cabling (if required) 28

Task 9 - Connect Additional Input/Output (if required) 30

Task 10 - Connect to the AC Supply Point 30

Installation Completed 31


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IPN 997-00012-49B November 2007

Ins tal lat ion Tasks

Before starting the installation, review the following information:

• Required Equipment and Tools on page 109 • Warnings and Cautions on page 12

• Inspecting the Equipment and Reporting Damage on page 14

Complete the Installation tasks in the following order:

Task Description Reference

1 Check the AC Supply and Earthing See details on page 16

2 Customize the APS See details on page 19

3 Connect the AC Supply Cable See details on page 22

4 Mount the APS in the Rack See details on page 24

5 Connect the DC Load and Battery Cables See details on page 25

6 Install the Batteries See details on page 27

7 Mount the Battery Temperature Sensor See details on page 27

8 Connect External Input/Output Cabling (if required) See details on page 28

9 Connect Additional Input/Output (if required) See details

10 Connect to the AC Supply Point See details on page 30

For installation of external communications refer to Communications Options on page 78.

Task 1 - Check th e AC Supp ly and Ear th ing

It is important that the AC supply for the Access Power Solutions DC power system includesthe correct levels of protection.

Step 1 - Check transient voltage protection at the site

1 Confirm that there is a transient protection plan (compliant with IEC61643-12) for the site.

For more information refer to Transient Protection on page 131 .2 If necessary, install suitable transient protection.


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Instal lat ion


IPN 997-00012-49B November 200717

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 disconnectthe 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 theI/O board (see diagram on page 7 for location).

The High VAC alarm signal lines must be isolated from the AC supplyby a voltage-free relay contact.

YH3

AC supply

Primary transient protection devices

High voltage protection unit with alarmoutput

Secondary transient protection devices(MOVs)

DC power system

I/O board

SC200 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 inTask 3 on page 22 are suitable for the APS.

Only use a two-phase or three-phase (L-L) AC supply if referenced toearth, or a protection system is in place so that the phase-earth voltagecannot exceed the rating of the rectifier.

2 Check that the APS will be connected to a suitable upstream ACdisconnect device such as Miniature Circuit Breaker(s) (MCB) or fuses.

3 Check the disconnect device will isolate both the phase and neutralconductors in single-phase and three-phase connections, unless theneutral conductor is clearly identified.

4 Check that any Residual Current Devices (RCD) upstream of the APSare rated for the maximum earth leakage current of the rectifiers. Ifnecessary, install higher rated RCD(s).

The maximum earth leakage current of Access Power Rectifiers is givenin the Specifications on page 113 .


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Step 4 - Check AC Discrimination

Each rectifier has two internal fast-acting fuses. Under certain internal faultconditions these fuses will blow.

If there is insufficient discrimination between these fuses and any upstreamAC supply-disconnect device then the upstream AC supply-disconnectdevice will operate before a rectifier fuse blows. This will disconnect theAC supply to all rectifiers.

1 Check the time-current (tripping) curve(s) of all AC supply-disconnectdevice(s) upstream of the APS with the following curve for the rectifierfuses.

Refer to the manufacturer's data for tripping curves.

Time-CurrentCurve (minimumand maximum) forAPR-3G internalfuses (IEC 60127-2).

Source: Schurter SP5x20 Pigtail datasheet.

2 No action is required if the time-current curves of the upstream ACsupply-disconnect devices are entirely to the right of the curves for therectifier fuses.

3 If the curve of an upstream AC supply-disconnect device crosses thecurve for the rectifier fuse there may not be adequate discrimination.

If necessary, replace the upstream AC supply-disconnect device toachieve adequate discrimination. Or, contact your Powerware DCproduct supplier for advice (refer to Worldwide Support on page 153).


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Step 5 - Check the earthing arrangements at the site

Confirm that all earths are brought together at one "star" point so that surgecurrents cannot flow in "earth loops" and create large voltages.

For more information refer to Transient Protection on page 131 .

Procedure complete

Task 2 - Cus tom ize APS

Step 1 - Check polarity

The APS can be configured for either positive earth or negative earthoperation.

1 Remove top cover if fitted.

2 Check the polarity label on the DC Common bus bar(s).

(+) on the common bar(s) indicates positive earth. (-) indicates negativeearth.

3 If the polarity of the APS matches the equipment at the site then nofurther action is required.

4 If the polarity of the APS is not correct for the equipment to be powered

then contact your Powerware DC product supplier for advice (refer toWorldwide Support on page 153).

Step 2 - Check position of mounting brackets

APSs are pre-assembled with 19-inch rack-mounting brackets as shown inthe following diagram. If required, the brackets can be moved to alternativepositions to reduce the effective depth of the unit.

Rack-mounting brackets are also available for use in 23-inch wide racks.1 Remove top cover if fitted.

2 Undo the two screws holding each bracket.

3 Refit the brackets at the required location. Tighten the screws.


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Rack-mounting bracket (available for 19-inch and 23-inch wide racks)

Alternative bracket mounting positions

Step 3 - Install Load circuit breakers (if required)

If the Load circuit breakers are already fitted then ignore this task.

The current rating of the MCBs must be derated to 80%.1 Remove the DC Distribution front cover and top cover (if fitted).

2 Fit the load MCBs onto the load tooth-comb bus (start at the right-handend) and clip onto the DIN rail. Tighten the bottom MCB terminals.

3 Cut the load fuse fail detect wires (from thefuse fail alarm board on the APS) to thecorrect length to reach the MCBs.

There is one load fuse fail detect wire foreach load MCB. These wires are thinnerthan the battery fuse fail detect wires.

4 Connect the wires to the top terminals of theMCBs and tighten terminal to hold the wirein place.

5 Fit MCB blanks to cover any unusedpositions.

6 Switch OFF all MCBs.

Load MCB

Load fuse fail detectwire from fuse failalarm board.


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Step 4 - Install Battery circuit breakers (if required)

If the Battery circuit breakers are already fitted then ignore this task.

The current rating of the MCBs must be derated to 80%.1 Place the battery MCBs side-by-side (see following diagram).2 Use the battery fuse fail detect loop wire to connect the auxiliary

switches in series.

Use the auxiliary switch terminals that will be closed when the MCB isON.

3 Fit the MCBs onto the battery tooth-comb bus (at the right 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 MCB blanks to cover any unused positions.


Battery MCBs (front view)

Auxiliary switches

Fuse fail detect loop wire

Battery fuse fail detectwires

Step 5 - Check if the APS AC and DC earths are bonded

There are two options: AC and DC earths bonded or separated.

1 Check if the APS AC and DC earths are bonded:

• Remove top cover (if fitted).

• If the AC-DC earth link screw (at one end of the DC common bar) isvisible (see following diagram) then the AC and DC earths arebonded. This is the recommended, factory standard arrangement.

• If the screw is not visible then the AC and DC earths are separated.

2 If the arrangement of the AC and DC earths is as required, no furtheraction is required.

3 If the arrangement of the AC and DC earths is not as required, followthe procedure in Earth Bonding on page 135.


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AC-DC earth link screw

Stand-off

DC common bar

Common bus

Procedure complete

Task 3 - Connect th e AC Sup ply 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.

• If the APS DC power system is to be installed in a location where the ambienttemperature may rise above 50ºC (122ºF), then V105 rated cable must be used for

the AC connections.

Step 1 - Check AC rating of the APS

Refer to the diagram on page 2 or the diagram on page 4 for location of ACRating label.

AC source Voltage (nominal)* AC MCB(if fitted)

1-phase (L), neutral (N) and Protective Earth(PE) 220-240V phase-neutral 1-pole

2-phase (L1/L2) and Protective Earth (PE) 208V phase-phase 2-pole(linked)

3-phase (L1/L2/L3), neutral (N) andProtective Earth (PE)

220-240V phase-neutral 3-pole

3-phase (L1/L2/L3) and Protective Earth(PE)

208V phase-phase 3-pole(linked)

*Refer to the Specifications on page 113 for the AC voltage range and ACinput current.


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Step 2 - Remove AC MCB cover to access AC MCBs and/or terminals

See diagram on page 2 or the diagram on page 4 for cover location.

Step 3 - Prepare the AC supply cable

1 Select AC supply cable to suit the ACsupply source, the maximum AC current(as noted in the Specifications on page 113)and in accordance with the local wiringregulations.

2 Route the AC supply cable from the ACsupply point through to the front of therack to the APS.

Do not terminate at the AC supply pointat this stage.

3 At the APS end, cut the conductors to suitthe positions of the terminals and/or ACMCB(s).

Ensure the earth conductor is 30-50mm(1¼ - 2 inches) longer than the longest phase or neutral conductor.

Rack cabinet

Proposed position of APS

AC cable from supplypoint (top or bottomentry into rack asrequired).

Step 4 - Terminate the earth conductor at APS

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 strands of wire.4 Connect the earth conductor to the earth termination point next to the

AC cable entry gland (see diagram on page 2 or diagram on page 4).

Step 5 - Terminate the conductor(s) at MCBs (if fitted)

Ignore this step if AC MCB(s) are not fitted.Connect the phase conductor(s) to the MCB(s) and the neutral conductor (iffitted) to the adjacent terminal block.

Connect according to the labels fitted to the MCBs and neutral terminalblock.


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Step 6 - Terminate the conductor(s) at terminal blocks (no MCBs fitted)

Ignore this step if AC MCB(s) are fitted.

1 If the AC supply is 1-phase or 2-phase (L1/L2) then loop together thethree live (L) terminal blocks.

2 Connect the phase conductor(s) and the neutral conductor (if fitted) tothe terminal block.

Connect according to the labels fitted to the terminal blocks.

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 theterminals. 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 ACwiring regulations.

Procedure complete

Task 4 - Moun t the APS in th e Rack

Step 1 - Check clearances

APSs require the following minimum clearances:

• Front Clearance - 600mm (24") for access and unrestricted air intake.

• Rear Clearance - 50mm (2”) from back of rack, other equipment andcables to allow air escape route for optimum system cooling.

• Top Clearance - 1U (44.45mm / 1¾") minimum from other equipmentin the rack. Recommended for access to cable terminations.


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Step 2 - Fit cage nuts

Fit cage nuts in the correct positions to match the screw holes in the APSrack mounting brackets.

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.

A suitable mechanical support or a second person must support theweight of the APS.

3 Attach the APS using four rack mounting screws. Tighten the screws.

Procedure complete

Task 5 - Conn ect the DC Load and B attery Cables

• If the APS DC power system is to be installed in a location where the ambienttemperature may rise above 50ºC (122ºF), then V105 rated cable must be used for

the DC load and battery connections.

Step 1 - Remove covers

1 Remove the distribution front cover.

2 Remove the top cover (if fitted).


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Step 2 - Connect battery cables

• Always check that the battery cables have been terminated to the correct systempolarity BEFORE connecting the batteries or closing the battery disconnect device.

•Connecting batteries to the system with incorrect system polarity will void allwarranty claims.

1 Select battery cable to suit the maximum battery current and voltagedrop requirements.

2 Route the battery cables to the APS.

If the optional top cover is used then route the cables under the cable tierod.

3 Terminate the battery common cable(s) with an M8 crimp lug.

4 Connect the battery common cable(s) on the common bar at the batterytermination points. Tighten according to the Standard Torque Settingson page 111.

5 Terminate the battery live cable(s) at the battery MCB(s). Tighten theterminals.

The current rating of the MCBs must be derated to 80%.6 Switch OFF all MCBs.

Step 3 - Connect load cables

1 Select load cable to suit the DC load currents and voltage droprequirements.

2 Route the load cables to the APS.

If the optional top cover is used then route the cables under the cable tierod.

3 Terminate the load common cable(s) with an M6 crimp lug.

4 Connect the load common cable(s) on the common bar at the loadtermination points. Tighten according to the Standard Torque Settingson page 111.

5 Terminate the load live cable(s) at the load MCB(s).

The current rating of the MCBs must be derated to 80%.

Ensure that the fuse fail detection wires are properly terminated asshown in the following diagram.


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6 Tighten the MCB terminal(s).


Load MCB

Load live cable

Fuse fail detection wire (connected tofuse fail alarm board)

Step 4 - Check terminations, secure cables and test insulation


2 Secure the cables with cable ties to the cable tie rod to ensure there willbe no strain on the terminals.

3 Test the insulation resistance of the cables.

Procedure complete

Task 6 - Ins tal l the Batter ies

• Always check that the battery cables have been terminated to the correct system

polarity BEFORE connecting the batteries or closing the battery disconnect device.

• Connecting batteries to the system with incorrect system polarity will void allwarranty claims.

Because of the wide range of battery types and sizes available, battery installation in notincluded in this guide. Always install batteries according to the battery manufacturer'sand/or supplier's instructions.

Task 7 - Moun t the Battery Temperature Sensor

The DC power system is supplied with a battery temperature sensor and standard 2m (6.5feet) long cable, already connected to the IOBGP input/output (I/O) board.

If required, longer cables are available (refer to Worldwide Support on page 153) or you canmake up your own. We recommend a maximum cable length of 20m (65 feet) because ofnoise considerations.

The battery temperature sensor measures the ambient temperature around the batteries andis required for the temperature compensation control function (see details on page 59).


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The best location for the battery temperature sensor is in the middle of the battery standabove the batteries.

To avoid false readings do not:

•

Place the sensor on a battery case.• Attach the sensor to battery cables, terminals or interconnecting bars.

• Expose the sensor to direct sunlight or air movements from air-conditioning systems oropen windows.

• Run the sensor cable along AC power cables.

Task 8 - Connect External Input/Outpu t Cabl ing ( i f required)

The APS is fitted with an input/output (I/O) board. This provides a number of digital inputsand digital outputs (relays). Refer to Input/Output Board on page 7 for details of how theI/O board can control and monitor external devices.

If no external devices are to be connected then ignore this task.

Step 1 - Access the I/O board

Remove the top cover (if fitted).

Step 2 - Terminate the cabling

1 Route the cabling through the access hole to the terminal blocks on the I/Oboard.

Leave a loop of at least 300mm (12") of cable to allow the I/O board to bewithdrawn with the wires attached.

2 Visually check the cable for damage.

3 Test the insulation and continuity of the cabling.

4 Terminate the cabling as in the following diagrams.

For alarm relay and digital input specifications see Specifications on page 113 .

5 Use cable ties to secure the cable and prevent strain on the connector.


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Externalinput/outputconnectors on I/Oboard

Externalinput/output cable

Minimum 300mm(12") loop

XH1XH6XH7

XH12

YH3

XH4

XH5

1

1 1 1

8

8 8 8

1 2

4 1

XH9

RY1

XH16

RY

XH18

3RY

XH20

5 RY

XH17

2RY

XH19

4RY

XH21

6XH15AXH15B

N O

N O

N O

N O

N O

N O

N C

N C

N C

N C

N C

N C

C O M

C O M

C O M

C O M

C O M

C O M D

1 D 4

D 6

D 3

D 5

D 2

0 V

0 V

0 V

0 V

0 V

0 V

1

1

4

4

1

2

6 1 6 6 6 61 1 1 1

Digital input terminals (push-connecttype).

Alarm relay (digital output) terminals (push-connecttype).

Step 3 - Refit top cover (if removed)

Replace the top cover (if fitted and all installation tasks are completed).


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Step 4 - Set up SC200

Configure the inputs and outputs after completing the installation and all theStartup Tasks on page 34.

For configuration details refer to Digital Inputs on page 72 and Digital Outputs on page 73 .

Procedure complete

For details about setting up and testing refer to Input/Output (I/O) on page 70.

Task 9 - Connect Addit io nal Inpu t/Output ( i f requ ired)

If additional input/outputs are required then SiteSure-3G modules can be connected to the

DC power system. A SiteSure-3G input/output module has the following features.

SiteSure-3G

Digital Inputs 10

Digital Outputs (relays) 6

Analog Inputs (0 to 10V) 4

Current Sense Inputs 3

Temperature Sense Inputs 2

Bus Voltage Input (0-60V) 1

Enclosure Wall or panel mounting plastic case

For further information refer to the SiteSure-3G Installation and Operation Guide (seeRelated information on page i).

Connect the SiteSure-3G cable to a spare RJ45 socket (S1, S2 or S3) on the Voltage Feed Module board. See the diagram on page 2 (APS6 models) or the diagram on page 5 (APS12models) for socket location.

Task 10 - Connect to the AC Supp ly Point

• A suitably qualified electrician familiar with local wiring regulations must carry

out the AC connection.

Step 1 - Replace all covers on the APS


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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.

Follow 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


2 Secure the cord(s) or cable to ensure there is no strain on the terminals.

3 Test the insulation resistance of the conductors according to local AC

wiring regulations.

Procedure complete

Do not switch on the AC supply at this stage.

Ins tal lat ion Completed

Installation of the APS is now complete. Follow the instructions in Start-Up on page 34 tomake the system operational.


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Chapter 4

Start-Up


IPN 997-00012-49B November 200733

C h a p t e r 4Start-Up

Overview

Topic Page

Start-Up Tasks 34

Task 1 - Inserting the Rectifiers 34

Task 2 - Pre-Power-Up Checklist 35

Task 3 - Applying AC Power 36

Task 4 - Configuring the DC Power System 36

Task 5 - Applying DC Power to Battery and Load 37

Start-Up Completed 38


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Start-Up Tasks

Complete all the Installation tasks (see details on page 16) before starting these Start-Uptasks.

Complete the Start-Up tasks in the following order:

Task Description Reference

1 Insert the Rectifiers See details on page 34

2 Complete the Pre-Power-Up Checklist See details on page 35

3 Apply AC Power See details on page 36

4 Configure the DC Power System See details on page 36

5 Apply DC Power to Battery and Load See details on page 37

Task 1 - Insert ing th e Recti f iers

• Do NOT install the rectifiers until the room has been cleaned and is dust free.

• Do NOT switch on the AC supply at this stage.

Step 1 - Unpack the rectifiers

Unpack the rectifiers and inspect them carefully for possible transport damage.Report any damage immediately using a copy of the Equipment Incident Reporton page 151.

Keep the original packaging to return a rectifier for replacement or repair, ifrequired.

Step 2 - Fit first rectifier

1 Align the rectifier with the left side of the shelf.

2 Push in the rectifier until the retaining screw contacts the shelf.

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


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Step 3 - Repeat for other rectifiers or fit blank panels

If not already fitted, fit rectifier blank panels in any vacant rectifier positions.

Procedure complete

Task 2 - Pre-Power-Up Ch eckl ist

Complete the checklist to confirm initial work is complete before progressing further.

All cabling is installed, securely tied and correctly insulated

Upstream surge protection is fitted (see Input Transient Protection on page 131)

Earth bonding is correct (see details on page 19)

DC battery and load cabling has the correct polarity

A registered electrician or other suitable approved person has checked the integrity of theinstalled 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 off and/or fuses removed

AC supply is isolated at each point of isolation leading back to the AC supply point

Batteries are electrically isolated from the DC power system

The site is clean


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Task 3 - Ap ply ing AC Power

• A registered electrician (or suitably qualified person) must check the integrity ofthe installed cabling, BEFORE the DC power system is powered up.

1 Switch on the AC supply.

• All rectifiers start up (after the startup delay).

• The rectifier alarm LEDs will turn on for a short time.

• The SC200 system controller will turn on (green Power On LED is on) when therectifiers start.

• During bootup of the SC200 system controller the rectifier yellow alarm LEDs willflash until the rectifiers are registered.

2 After bootup of the SC200:

• Press any SC200 key to silence the alarm.

Depending on the configuration file settings, the alarm LED(s) may be on and the SC200may display some system alarm messages. This is normal. For an explanation of alarmmessages refer to Alarm Descriptions on page 127 .

• The LCD display module shows the summary screen. See details on page 41.

If no load or battery is connected the current will be 0A.• If fitted and enabled, the LVD(s) operate.

3 Check all rectifiers are running and only the rectifier green Power On LEDs are on (noalarm LEDs).

• On the SC200 keypad select Menu > Rectifiers. See details on page 41. Check that allrectifiers are registered.

If any problems see Troubleshooting on page 92 .

Task 4 - Conf igur ing the DC Power System

The operational settings of the DC power system are stored in a configuration file loaded intothe SC200 system controller (see details on page 40).

The SC200 is supplied pre-loaded with a configuration file. If this configuration file has beencustomized for the site then no further configuration changes will be necessary.


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If the configuration file is not fully customized for the site then check the following settingsand change if necessary. It is important that these settings are correct before progressingfurther.

Parameter Action SC200 NavigationSee details on page 41

Float Voltage Set to the value recommended bythe battery manufacturer.

Menu > Voltage Controls >Voltage Control

See Float Voltage on page 53.

Battery Capacity Set to the rated 10 hour capacity ofthe installed battery strings. Zeromeans no battery is installed.

Menu > Settings > Battery

See Fast Charge on page 58.

Cells Per String Set to the number of cells in eachbattery string.

Menu > Settings > Battery

See Temperature Compensationon page 59.

TemperatureCompensation

Enable (if required) and check thesettings.

Menu > Voltage Controls >Temperature Compensation

See Temperature Compensationon page 59.

Low VoltageDisconnect (LVD)

Enable (if LVD installed) and checkthe settings.

Menu > LVD > LVD

See Low Voltage Disconnect onpage 63.

Other configuration settings can be changed after all Start-Up tasks are complete. Refer toSystem Operation on page 51 for details on how to customize the system's configuration.

Task 5 - Apply ing DC Power to Battery and Load

Reverse Polarity• Always check that the battery cables have been terminated to the correct system polarityBEFORE connecting the batteries or closing the battery disconnect device. Connecting batteriesto the DC power system with incorrect system polarity will damage the rectifiers and void allwarranty claims.

Step 1 - Check DC voltage and polarity

Check the DC output voltage and polarity of the power system and thebattery string(s).


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Step 2 - Connect batteries

1 If connecting multiple battery strings then check the individual stringsare of similar voltage.

2 Switch on all Battery MCB(s) and/or fit the battery fuses.

3 Check the Battery Fuse Fail alarm clears.

All Battery MCBs (including any unused MCBs) must be switched onto clear the alarm.

4 Check the battery current. The actual value depends on the state ofcharge of the batteries.

Step 3 - Connect load

1 Switch on the Load MCB(s) and/or fit the Load fuses.2 Check the equipment powers up and the Load Fuse Fail alarm clears.

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.

Step 5 - Charge the batteries

1 Charge the batteries according to the battery manufacturer’srecommendations.

2 If an Equalize charge is recommended by the battery manufacturerthen follow the instructions on page 57.

Equalize increases the system voltage to the Equalize voltage for theEqualize duration. After the Equalize duration has expired, the DC power system voltage reverts to float voltage automatically.

Procedure complete

Start-Up Com pleted

Start-Up of the APS is now complete and the system is operational.

A Commissioning Procedure is available on page 137 if a formal commissioning or hand-over test is required.

The following chapters of this guide describe how to use the SC200 system controller (seeSC200 Operation on page 39), how to customize the system configuration settings (seeSystem Operation on page 51), and how to setup the remote communications options (seeCommunications on page 77).

For information on alarms, or operation problems see Maintenance on page 91.


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Chapter 5

SC200 Operation


IPN 997-00012-49B November 200739

C h a p t e r 5SC200Operati on

Overview

Topic Page

Configuration File 40

Starting the SC200 41

SC200 Operation using the Keypad and Screen 41

SC200 Operation Using a PC/Laptop 46

SC200 Identity Information 48

SC200 Internal Clock 48

SC200 Firmware Upgrade 49


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Config urat ion Fi le

The operational settings of the DC power system are stored in a configuration file loaded intothe SC200 system controller.

The SC200 is supplied pre-loaded with a configuration file. If this configuration file has beencustomized for the site then no further configuration changes will be necessary.

Otherwise, it is important that the settings of this configuration file are checked/verified andchanged as required for site-specific conditions. In particular, settings that may affect theperformance and life expectancy of the battery must be checked and set according to thebattery manufacturer’s recommendations.

Some settings in the configuration file can be edited using the system controller's keypad (seedetails on page 41), or all settings can be edited using a PC/laptop with the DCToolssoftware (see details on page 46) or a web browser (if the SC200 is connected to an IPnetwork).

Backup and Restore

The configuration file settings in the SC200 can be saved to (Backup) or loaded from(Restore) a PC/laptop using DCTools or a web browser.

Backup and Restore can be used to:

• Load a standard (master) configuration file into an SC200 for customization.

• Copy a customized configuration file from one SC200 to others (at similar sites).

•

Save a copy of a customized configuration file. This is recommended in case the SC200has to be replaced.

► To use DCTools for Backup and Restore

1 Connect to the SC200 with DCTools. (For details refer to Communications Options onpage 78.)

2 In DCTools go to File > ICE Backup/Restore and follow the prompts.

The saved file does not include site specific settings including Site Identity, IP Address andS3P Address.

► To use a web browser for Backup and Restore

1 Connect to the SC200 via a web browser. (For details refer to Ethernet Communicationson page 78.)

2 Go to Tools.

3 Select Backup Tool or Restore Tool.

4 Select Configuration (does not include site specific settings including Site Identity, IPAddress and S3P Address) or System Snapshot (includes site specific settings).

5Click Proceed.


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Startin g the SC200

When DC power is applied to the SC200 (via the RXP connector YS11) the bootup sequencebegins.

Approx.

60s

Bus Voltage

Rectifier Current

Battery Fuse Fail

Bootup screen Summary screen Main menu

All active alarms aredisplayed.

See details on page 43 .

SC200 Operat ion u sing the Keypad and Screen

LCD display

Soft key 1 label

Soft key 1

Navigation keys (Up - Down -Left - Right)

Soft key 2

Soft key 2 label


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Soft Keys

The function of the soft keys is indicated by the corresponding labels on the LCD screen.

Label Key function

No function

Go to main menu screen. See details on page 43.

Go back to parent menu screen.

Go to sub-menu or configuration screen*.

Save a new configuration setting*.

Ignore a new configuration setting*.

* See Changing a Configuration Setting on page 44.

Navigation Keys

Key Function

• Move up/down in the main menu screen. See details on page 43.• Move up/down in a list (hold to go to the top or bottom of the

list).

• Select options in a configuration screen.

• Increase/decrease a value in a configuration screen.

• Move left/right in the main menu screen. See details on page 43.

• Move left/right between tabs in Settings menu.

• Move left/right between segments of a multiple segment value ina configuration screen.


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Main Menu Navigation


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Changing a Configuration Setting using the Keypad

For the configuration settings that can be changed using the keypad, the keys have thefollowing functions.

Indicates the value cannot be changed (usually indicates a status value).

Press to change the setting or activate a control function.

Not available when another change is still being updated. Wait a short timeand try again. See "Save" below.

Press to change the value. Hold key to change at a faster rate.

Use these keys for values with multiple segments (e.g. IP address).

Or

Press to save the new value.

There will be a short delay before another change can be made.Press to leave the value unchanged.

Keypad Access Security

This feature prevents accidental or unauthorized changes to settings from the SC200 keypad.

All access to change SC200 settings will be lost if:

• All communications are disabled (see S3P Access on page 88 and HTTP/HTTPSAccess on page 89), and

• Keypad access is PIN Protected, and

• The keypad access PIN is lost.

The SC200 will continue to function, but no configuration changes can be made.Contact your Powerware DC product supplier or Eaton for advice (refer to WorldwideSupport on page 153).

► 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), or

• PIN Protected - keypad access is allowed when a 4-digit Product IdentificationNumber (PIN) is entered

Enter the selected 4-digit number in the PIN field.

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