Eaton APS3-330 Series, Installation And Operation Manual

Page 1: ...and Operation Guide APS3 330 Series with SC300 Issue IPN 997 00012 07A1 Issue Date July 2018 Refer also to the separate system controller handbook Eaton Corporation Telecommunications Power Solutions...

Page 2: ...the use of existing power facilities or claims against the purchaser or user by its customers resulting from the use of the information recommendations and descriptions contained herein The informatio...

Page 3: ...powered equipment the relevant local electrical safety regulations and wiring standards Operators and maintenance staff competent in operation of dc power systems safe working practices for ac and dc...

Page 4: ...int Monitoring Description 9 Battery Time Remaining 10 Preparation 11 Overview 11 Warnings 12 Inspecting the Equipment and Reporting Damage 14 Installation 15 Overview 15 Installation Tasks 16 Task 1...

Page 5: ...Adding a Load MCB 59 Replacing the System Controller 60 Replacing the Input Output Board 63 Battery Mid point Quarter point Monitoring String Fail Alarm 65 Battery Disposal and Recycling 65 Equipment...

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Page 7: ...2018 Eaton Corporation All Rights Reserved IPN 997 00012 07A1 July 2018 1 C h a p t e r 1 Gener al D escription Overview Topic Page Access Power Solutions DC Power Systems 2 Rectifiers 4 System Contro...

Page 8: ...s Front View System labels Rectifier modules see details on page 4 system controller see details on page 5 Integrated dc distribution with up to 10 Load and 2 Battery Miniature Circuit Breakers MCBs D...

Page 9: ...cover AC phase neutral terminals see connection details on page 22 AC earth conductor connection point see connection details on page 22 AC cable entry gland Cable tie points Optional Low Voltage Disc...

Page 10: ...V 2000W APR48 ES 48V 1800W APR48 3G 48V 900W EPR48 3G or 24V 1440W APR24 3G rectifiers The rectifiers are fan cooled and hot pluggable See Specifications on page 71 for further information See Trouble...

Page 11: ...basic operating information see System Controller on page 39 For further details refer to the System Controller Operation Handbook see Related Information on page i See Troubleshooting on page 50 for...

Page 12: ...and relay outputs for alarm signals or control of external devices The I O functions are Sensors Current 3 Bus voltage 1 Temperature 2 Battery Mid point 4 Input Output Digital inputs 4 pre defined sys...

Page 13: ...l AC Distribution MOV Fail YH3 7 Bus voltage sense input XH9 8 Power Comms OK LED green 9 Digital inputs D11 D13 3 user defined XH15D IOBGP 10 11 20 21 only 10 Digital inputs D1 D6 6 user defined XH15...

Page 14: ...ts 6 to external devices and or alarm indication system Digital inputs 6 from external voltage free switches or relay contacts Connection to additional I O board s and or SiteSure 3G I O module s Conn...

Page 15: ...nect LVD is available for the Access Power Solutions APS3 330 Series See the diagram on page 3 for location This is connected as a battery disconnect For information on operation see Low Voltage Disco...

Page 16: ...the specified end voltage If a battery disconnect LVD is fitted then the end voltage will usually be the voltage at which the LVD disconnects the battery Battery Time Remaining is designed for a cons...

Page 17: ...reparation Copyright 2007 2018 Eaton Corporation All Rights Reserved IPN 997 00012 07A1 July 2018 11 C h a p t e r 2 Prepar ation Overview Topic Page Warnings 12 Inspecting the Equipment and Reporting...

Page 18: ...age 103 A registered electrician or suitably qualified person must check the integrity of the installed cabling BEFORE the dc power system is powered up Tasks must be performed in the sequence documen...

Page 19: ...g to the instructions on page 65 Rectifiers Only operate the rectifiers when the surrounding area is clean and dust free To reduce the risk of electric shock and maintain optimum system cooling always...

Page 20: ...tem will not respond to electromagnetic disturbances or will not cause interference to other equipment in a particular installation In a domestic environment this product may cause radio interference...

Page 21: ...g 16 Task 2 Prepare APS 19 Task 3 Connect the AC Supply Cable 22 Task 4 Mount the APS in the Rack 25 Task 5 Connect the DC Load and Battery Cables 26 Task 6 Install the Batteries 28 Task 7 Mount the B...

Page 22: ...tery Cables See details on page 26 6 Install the Batteries See details on page 28 7 Mount the Battery Temperature Sensor See details on page 29 8 Connect External Input Output Cabling if required See...

Page 23: ...es MOVs dc power system I O board SC300 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 in T...

Page 24: ...pping curve s of all ac supply disconnect device s upstream of the APS with the following curve for the rectifier fuses Refer to the manufacturer s data for tripping curves Time Current Curve minimum...

Page 25: ...heck polarity The APS can be configured for either positive earth or negative earth operation 1 Remove top cover if fitted 2 Check the polarity label on the dc common bus bar s on the common bar s ind...

Page 26: ...r fitting new ones use the type that is already in use see Spare Parts on page 68 for ordering details 1 Remove the dc distribution front cover and top cover if fitted 2 Fit the load MCBs onto the loa...

Page 27: ...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...

Page 28: ...APS has pre fitted ac cord s then ignore this task If the APS dc power system is to be installed in a location where the ambient temperature may rise above 50 122 F then 90 C rated cable rated cable...

Page 29: ...to suit the ac supply source the maximum ac current see Specifications on page 71 and in accordance with the local wiring regulations 2 Route the ac supply cable from the ac supply point into the rack...

Page 30: ...to the ac terminal s according to the following diagram that corresponds to the ac supply source Ensure the ferrules of the crimp lugs cover all strands of wire 3 If fitted terminate the neutral condu...

Page 31: ...he ac cable entry gland 4 Test the insulation resistance of the conductors according to local ac wiring regulations Procedure complete Task 4 Mount the APS in the Rack Step 1 Check clearances APSs req...

Page 32: ...mbined fault current of all battery strings If this conductor is not installed then battery fault current will be carried by the ac dc earth link and the ac earth conductor which are typically too sma...

Page 33: ...load termination points Tighten according to the Standard Torque Settings on page 68 5 Terminate the load live cable s at the load MCB s The current rating of the MCBs must be derated to 75 Ensure th...

Page 34: ...es 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 68 or equivalent 1 Connect a Mid point Monitori...

Page 35: ...supplied to socket XH7 on the I O board If required extend the cable using an RJ45 patch cable and in line joiner Recommended maximum cable length is 20m 65 feet because of noise considerations 2 Rout...

Page 36: ...External input output connectors on I O board External input output cable Minimum 300mm 12 loop Step 2 Terminate the cabling Connect only voltage free switch or relay contacts to Digital Inputs Do not...

Page 37: ...S 10 SiteSure 3G IOBSS 00 Digital Inputs 13 10 Digital Outputs relays 10 6 Analog Inputs 0 to 10V 4 4 Current Sense Inputs 3 3 Temperature Sense Inputs 2 2 Bus Voltage Input 0 60V 1 1 Enclosure Wall o...

Page 38: ...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 Che...

Page 39: ...07A1 July 2018 33 C h a p t e r 4 Start 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 35 Task 4 Configuring the...

Page 40: ...ge 37 Task 1 Inserting the Rectifiers Do NOT install the rectifiers until the room has been cleaned and is dust free Do NOT switch on the ac supply at this stage Step 1 Unpack the rectifiers Unpack th...

Page 41: ...of the installed cabling All panels are in place and all empty rectifier slots are covered with blanking panels AC isolator and all ac MCBs if fitted are switched off All dc distribution MCBs are swi...

Page 42: ...ith a configuration file If this configuration file has been customized for the site then no further configuration changes will be necessary If the configuration file has not been customized for the s...

Page 43: ...rs and void all warranty claims Step 1 Check dc voltage and polarity Check the dc output voltage and polarity of the power system and the battery string s Step 2 Connect batteries 1 If connecting mult...

Page 44: ...duration After the Equalize duration has expired the dc power system voltage reverts to float voltage automatically Procedure complete Start Up Completed Start Up of the APS is now complete and the s...

Page 45: ...tion All Rights Reserved IPN 997 00012 07A1 July 2018 39 C h a p t e r 5 System C ontroller Topic Page Configuration File 40 Starting the SC300 41 SC300 Operation using the Keypad and Screen 41 SC300...

Page 46: ...ation Handbook Backup and Restore The configuration file settings in the SC300 can be saved to Backup or loaded from Restore a PC laptop using DCTools Web Backup and Restore can be used to Load a stan...

Page 47: ...zation data Fragment dcf Restore part of a configuration file such as battery characterization data 5 Click Next and then select a file name to Restore a configuration Starting the SC300 When dc power...

Page 48: ...nt Panel Set Access to Unprotected keypad access is allowed to view and change parameters or Read Only keypad access is allowed to view parameters only or PIN Protected keypad access is allowed to vie...

Page 49: ...dcpower eaton com downloads Using DCTools via USB DCTools can be run on a PC laptop connected to the SC300 s USB port DCTools can also be run on a remote PC laptop connected to the SC300 s RS232 seri...

Page 50: ...7A1 July 2018 SC300 Identity Information The following identity information is stored in the SC300 Parameter Description Where to find Serial Number The SC300 serial number factory set SC300 Info Web...

Page 51: ...tem at the site Map Coordinates Longitude and latitude When these values are entered a web browser will show these coordinates on a map using Google Maps Site Name Name of the site Site Address Addres...

Page 52: ...e configuration file that was last loaded into the SC300 by web interface or DCTools A version number such as 87668 is attached to assist tracking of changes Web Identity DCTools Configuration Identit...

Page 53: ...em type Other settings are left unchanged The settings loaded using Generic System Type may not be suitable for all systems Where possible obtain the appropriate configuration file After selecting a G...

Page 54: ...A1 July 2018 Configuration item Parameter Description Where to find Generic System Type If a suitable configuration file is not available select the appropriate system type here This will load suitabl...

Page 55: ...plicable to the site Only perform the maintenance tasks described in the Maintenance chapter All other tasks are classified as Servicing Servicing must only be performed according to specific instruct...

Page 56: ...rectifier and tighten retaining screw Internal rectifier fault Remove the rectifier and insert another one in the same slot If second rectifier fails to start then there is a fault with the rectifier...

Page 57: ...ac supply failed Power system will return to normal operation when the ac supply voltage is within the specified range See Specifications on page 71 DC overvoltage Remove and re insert rectifier s or...

Page 58: ...e faulty rectifier is found The output voltage returns to normal when faulty rectifier is removed Replace faulty rectifier with one that is working Return the faulty rectifier for service System has n...

Page 59: ...to complete See Starting the SC300 on page 41 Faulty SC300 Replace faulty SC300 SC300 Red LED or Yellow LED is on An alarm is active Check the type of alarm on the LCD or with DCTools Web or PowerMana...

Page 60: ...ckup and Restore on page 40 or Change one or more configuration settings using the SC300 keypad or DCTools Incorrect rectifier voltage because installed rectifiers have different output voltages Check...

Page 61: ...d required to change settings See Write Access Password in the System Controller Operation Handbook Serial communications are disabled S3P Access is disabled Set S3P Access to Enabled See details in t...

Page 62: ...et communications connections See previous entry Check web browser type and version See Compatible Software on page 5 Lost Logon ID and or Password Use DCTools to set up a new Logon ID and or Password...

Page 63: ...rgized None this is normal operation LVD Status LED s flashing The contactor is in the wrong state SC300 internal state does not match signal from contactor auxiliary switch Check the electrical and m...

Page 64: ...t place hands inside the rectifier shelf Do not attempt to disassemble faulty rectifiers Return them in their original packaging with a completed Equipment Incident Report on page 100 Removing a Recti...

Page 65: ...onnector 4 Check that the rectifier s Power On LED turns on after the startup delay and the alarm LEDs turn off The rectifier will automatically register with the system controller and download its op...

Page 66: ...2 Replace the DC Distribution front cover Procedure complete Replacing the System Controller See also Application Note AN0145 The SC300 system controller can be replaced without switching off the dc p...

Page 67: ...r will start See Starting the SC300 on page 41 Various alarms may appear because of incorrect configuration file settings Press any key to silence the alarm 2 Insert the system controller and tighten...

Page 68: ...identification parameters and communications settings 5 Change the configuration file as required to ensure that the system controller operates as intended 6 Check the system controller time See detai...

Page 69: ...e 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 Push any key to silence the Rectifier Co...

Page 70: ...fiers IOB Missing New Hardware and other alarms will appear because of the I O board mapping change Press any key to silence the alarm Step 6 Update I O board mapping 1 In DCTools go to I O Board I O...

Page 71: ...ell monobloc terminals 1 Check the terminal connections of the cell monobloc are correctly tightened and clean Refer to the battery manufacturer s instructions for correct terminal torque settings 2 I...

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Page 73: ...latform s and access for working at height if required Essential Tools Standard electrical toolkit with insulated tools plus Cable crimping tool and crimp lugs suitable for all cable sizes and connect...

Page 74: ...put Module optional Eaton IOBSS 00 or IOBSS 10 See details on page 31 9 Dual temperature sensors 2m leads Eaton TS2 200 10 Battery Mid point Monitoring connection kit for use with SC300 for two batter...

Page 75: ...and stainless steel 2 Torque is based on 60 of yield stress of the material Yield for the purposes of this chart is 240MPa 3 Tolerance range is 60 70 of yield 4 When a bolt and nut is torqued use a sp...

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Page 77: ...ifier module 1 7kg 3 7 lb weight of a typical configuration excluding rectifiers System Input Input Voltage Refer to the rectifier specifications for range 220 240V nominal L N 208V nominal L L Maximu...

Page 78: ...ut Current APR24 3G 50A 28 8V EPR48 3G 18 75A 48V APR48 3G 37 5A 48V APR48 ES 41 7A 48V Preset Voltage APR24 3G 27V 0 1V Other models 54 5V 0 1V Rectifier Input Fuses internal EPR48 3G 8A 250V Other m...

Page 79: ...f Temperature Sense Inputs 2 One only connected as standard Second input available requires additional temperature sensor Range 2 53V to 3 43V 20 to 70 C 4 to 158 F Resolution 0 01V 1 C 1 8 F Accuracy...

Page 80: ...2V 24V or 48V Maximum Hold in Current 1 2A per contactor Maximum Cable Length 3m 10 feet Connector MTA156 4 way Communications USB Version Connector 2 USB micro type AB RS232 Interface Connector RS232...

Page 81: ...ies 20A Curve 4mm2 10AWG 307 902500 61 Chint NB1 63 UL Series 25A Curve 4mm2 10AWG 307 903200 61 Chint NB1 63 UL Series 32A Curve 6mm2 8AWG 307 904000 61 Chint NB1 63 UL Series 40A Curve 10mm2 6AWG 30...

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Page 83: ...served IPN 997 00012 07A1 July 2018 77 A p p e n d i x D Controller M enus SC300 Menu At each menu screen press Enter to access the associated configuration menu screen s These menus have multiple con...

Page 84: ...2 RD Receive Data 3 TD Transmit Data 4 DTR Data Terminal Ready 5 Common Ground 6 7 RTS Request to Send 8 RS 485A 9 RS 485 B XS31 RJ45 Ethernet Interface 1 Rx 2 Rx 3 Tx 4 5 6 Tx 7 8 YS11 RJ45 RXP Syste...

Page 85: ...iption XH4 MTA 156 LVD 1 Interface 1 Coil 2 Coil 3 LVD 1 auxiliary switch 4 Auxiliary switch common XH5 MTA 156 LVD 2 Interface 1 Coil 2 Coil 3 LVD 2 auxiliary switch 4 Auxiliary switch common XH3 MTA...

Page 86: ...int 1 2 String 2 Mid point Quarter point 2 3 String 3 Mid point Quarter point 3 4 String 4 Mid point Quarter point 4 XH15A Digital inputs D1 D3 Digital input signals are referenced to live bus 1 D1 in...

Page 87: ...pen NO 6 Relay 6 Common COM XH22 XH23 Digital relay outputs 7 8 IOBGP 10 11 20 21 only Digital outputs are voltage free 1 Relay 7 normally closed NC 2 Relay 7 normally open NO 3 Relay 7 Common COM 4 R...

Page 88: ...on All Rights Reserved IPN 997 00012 07A1 July 2018 Connector Type Purpose Pin Description YH11 YH11A IOBGP 10 11 20 21 only RJ45 RXP System Communications 1 System Positive 24 48V 2 System Positive 2...

Page 89: ...surge suppression plan that includes Primary surge protection Secondary surge protection Primary secondary surge decoupling coils Secondary tertiary surge decoupling coils 6 Protect the data and contr...

Page 90: ...secondary transient protection via suitably rated surge decoupling coils These should have been specified as part of the transient protection plan for the site If no surge decoupling coils were speci...

Page 91: ...models of Access Power Solutions are factory fitted with secondary transient protection to protect the power system from a limited number of repeated 15kA transients 8 20 s wave shape Factory fitted s...

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Page 93: ...mmends that this factory fitted ac dc earth link is retained No further action is required However if your policy is not to bond the ac communications earth and dc earth no mesh earth then refer to th...

Page 94: ...at the dc power system then replace the ac dc earth link with a surge protection device The surge protection device bonds the ac and dc earths during transient activity to prevent damage to the rectif...

Page 95: ...tion tasks see details on page 16 Complete all the Start Up tasks see details on page 34 Save a copy of the configuration file Complete the Commissioning tasks in the following order During the testin...

Page 96: ...within specification Ensure the current is the correct polarity Adjust the gain setting on the current sensor by moving the trim pot Adjust the gain setting in DCTools Web Total System Current High c...

Page 97: ...us 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 te...

Page 98: ...to the system Turn off the ac to the system Allow the system voltage to fall below the Fast Charge Voltage Threshold Turn on the ac Ensure the system performs a Fast Charge Ensure the SC300 indicates...

Page 99: ...float voltage Connect load to the system Start the Battery Test Ensure the SC300 indicates that a Battery Test has started Wait for the Battery Test Duration time to expire Confirm the Battery Test p...

Page 100: ...load or voltage changes 2 Breathing on the sensor can increase the temperature 3 Battery Current Limit control process may have to be turned off to allow the Fast Charge voltage to reach its value wit...

Page 101: ...Start a Battery Test The system voltage will fall Ensure alarm operates Low Load Test as for the Low Float test Note that the Low Load Threshold is lower than the Low Float threshold Ensure alarm oper...

Page 102: ...ry Fuse Ensure alarm operates Battery Test Fail See Battery Test in the System Controller Operation Handbook for details MOV Fail Remove a MOV cartridge from the MOV housing if fitted Ensure alarm ope...

Page 103: ...rrent Limit test in System Controls on page 92 Rectifier No Load Ensure the dc load and batteries are isolated from the system Ensure alarm operates Rectifier Current Limit Apply a dc load to the syst...

Page 104: ...alarm is originated from the rectifier It can only be tested by increasing the internal temperature of the rectifier 6 These alarms are only available with the external ac metering option 7 A digital...

Page 105: ...he Monitor Fail alarm relay It will de energize if the I O board loses power or loses communication with the SC300 Test extended alarms by removing the power to the I O board This will de energize the...

Page 106: ...________________________________________________________________ Location of Failure Product code ___________ Serial number __________ Document number _____________ System type installed in __________...

Page 107: ...____________________________________________ ______________________________________________________________________________________ ____________________________________________________________________...

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Page 109: ...office from the following list telephone 64 3 343 7448 or email CustomerServiceNZ eaton com Australia 1300 877 359 Canada 1 800 461 9166 Central America 52 55 9000 5252 China 86 755 2757 2666 extensio...

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Page 111: ...on APR 3G Series Rectifiers See Rectifiers Audible Alarm Indication 42 B Battery Battery Charging 37 Battery Current 53 Battery Fuses 52 Battery Installation 28 Disposal and Recycling 65 Mid Point Mon...

Page 112: ...Problems See Troubleshooting F Factory 47 Fuse Battery Fuses 52 Rectifier Fuses See AC Discrimination G Generic System Types 47 GSM Modem Communications 9 55 H High AC Voltage Protection 16 I Identity...

Page 113: ...Description 4 Earth Leakage Current 16 71 Inserting the Rectifiers 34 Location 2 Output Voltage and Current 71 Problems See Troubleshooting Rectifier Alarms 4 35 Rectifier blank panel 58 Rectifier Cu...

Page 114: ...rsions 5 Sound See Audible Alarm Indication Spares 68 Specifications 71 String Fail Alarm 9 52 65 System Power 71 T Target Failed to Respond Error 54 Technical Assistance 103 Temperature 71 Temperatur...