Eaton SC200 Installation And Operation Manual

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Installation and operation manual (112 pages)

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Enterprise Power Solutions

Installation and Operation Guide

Issue: IPN 997-00012-56C

Issue Date: September 2008

Refer to the separate SC200 or SC100 system controller handbook for full

details of the system controller operation -

www.Powerware.com/DC_manuals.

Eaton Corporation

Telecommunications Solutions Division

www.powerware.com

DCinfo@eaton.com

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Page 1 Enterprise Power Solutions Installation and Operation Guide Issue: IPN 997-00012-56C Issue Date: September 2008 Refer to the separate SC200 or SC100 system controller handbook for full details of the system controller operation - www.Powerware.com/DC_manuals. Eaton Corporation Telecommunications Solutions Division www.powerware.com...
Page 2 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.
Page 3: About This Guide
About This Guide Scope This guide covers installation, operation and maintenance of Enterprise Power Solutions. Refer to the separate SC200 or SC100 system controller handbook for full details of the system controller operation - www.Powerware.com/DC_manuals. Audience This guide is intended for use by: Electronic equipment installers competent in: •...
Page 5: Table Of Contents
Task 3 - Applying AC Power....................31 Task 4 - Configuring the DC Power System ............... 32 Task 5 - Applying DC Power to Battery and Load ............34 Start-Up Completed ....................... 34 Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 6 Backup and Restore........................36 Starting the SC200 or SC100....................37 SC200............................... 37 SC100............................... 37 SC200 or SC100 Operation using the Keypad and Screen ..........38 Keypad Access Security........................ 38 Alarm Indicators..........................39 SC200 or SC100 Operation Using a PC/Laptop..............39 Using DCTools via USB (SC200 only)..................
Page 7: Overview
Chapter 1 General Description General Description Overview Topic Page Enterprise Power Solutions DC Power Systems Rectifier Modules (APR48-3G/EPR48-3G) System Controller Optional Battery Modules Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 8: Enterprise Power Solutions Dc Power Systems
EPS2 models accommodate one or two EPR48-3G or APR48-3G rectifier modules, an • SC200 or SC100 system controller, and a circuit breaker distribution module. EPS5 models accommodate up to five EPR48-3G rectifier modules, an SC200 or SC100 • system controller, and a circuit breaker distribution module.
Page 9: Front Views
EPS2 models, up to 5 in EPS5 models. terminals 1-10 on rear) (Use Rectifier blank panel RM3B-A01 to cover SC200 or SC100 system controller (see details an un-used rectifier position) on page 5) Battery circuit breaker 1 (connected to battery...
Page 10: Rear Views
See details on page battery circuit breaker 1 on front) DC terminal cover Negative (live) dc terminals 1-10 (connected to load circuit breakers 1-10 on front) Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 11: Rectifier Modules (Apr48-3G/Epr48-3G)
The system controller is supplied pre-configured. Some configuration file changes can be made with the keypad, or all settings can be changed via a PC connected to the USB (SC200) or RS232 (SC100) interface. Basis operating information is available in System Controller on page 75. For further details refer to the System Controller Operation Handbook (see Related Information on page i).
Page 12: Sc100 System Controller
SMS text messaging, or by relay contact closures. Power on LED (green) Minor alarm LED (yellow) Critical/Major alarm LED (red) LCD display Navigation keys (4) RS232 D9M connector Retaining screw Power and system communications connector Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 13: External Communications
Communication with an alarm management system using voltage-free relay contacts (on an IOBGP I/O board) Compatible Software The following software is compatible with the SC200 or SC100 system controller: DCTools Configuration Software. Latest version is available free from • www.powerware.com/downloads.
Page 14: Low Voltage Disconnect (Option)
An audible click will be heard when the LVD operates or releases (whether or not battery modules are connected). This is normal. For further information refer to Low Voltage Disconnect (LVD) in the System Controller Operation Handbook (see Related Information on page i). Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 15: Preparation
Chapter 2 Preparation Preparation Overview Topic Page Warnings Inspecting the Equipment and Reporting Damage Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 16: Warnings
• Do not attempt to disassemble faulty rectifiers. Return them (in their original packaging) with a completed Equipment Incident Report on page 71. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 17 • Consult the dealer or an experienced radio/TV technician for help. • Changes or modifications to the equipment not approved by Eaton Corporation could void the FCC authority to operate the equipment. Telecom Ground and dc Supply Bond to Chassis •...
Page 18: Inspecting The Equipment And Reporting Damage
Report any damage immediately, using a completed Equipment Incident Report on page 71. Keep the original packaging and use it if any equipment needs to be returned for replacement or repair. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 19: Installation
Task 6 - Mount the Battery Temperature Sensor (if required) Task 7 - Connect communications cable (if required) Task 8 - Connect to the AC Supply Point Installation Completed Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 20: Installation Tasks
EPS2/EPS5. Only use an ac supply referenced to ground, or with a protection system so that the phase-ground voltage cannot exceed the rating of the rectifier. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 21: Task 2 - Customize Eps2/Eps5
Refit the brackets and plates at the required location. Tighten the screws. Rack-mounting bracket Alternative position for module connection plate Module connection plate Alternative position for rack bracket mounting Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 22 Switch the circuit breaker(s) to the OFF (O) position. Circuit breaker cover Circuit breaker blank cover (to cover unused circuit breaker position 2 if Battery circuit breaker (1of 2 shown) required) Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 23 Bottom row (8-10): any value (6-30A) Fit circuit breaker blank covers in all unused positions. Replace the circuit breaker cover. Switch the circuit breakers to the OFF (O) position. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 24: Task 3 - Mount The Eps2/Eps5 In The Rack
(recommended 1U minimum). No heat source greater than 50°C below the EPS2/EPS5. Sides: if required, adequate space for access to protective ground terminal and telecom ground terminal. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 25 FCI-Burndy type MY29-11 • Tighten terminal to 36 in-lb (4Nm). • Terminate the Protective Earthing Conductor at a point connected to the protective earth wire in the building. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 26 If the equipment to be powered requires that the dc output of the EPS2/EPS5 is "floating" (not bonded to ground), then remove the output-ground screw. No further action is required. Output-ground screw removed for "floating" output. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 27: Task 4 - Connect The Output Cables
Telecom ground link cable to the positive connected to ground. telecom ground bar (if required). Procedure complete Task 4 - Connect the Output Cables Step 1 - Remover the dc terminal cover Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 28 Check all terminations are correct and are tightened. Secure the cables with cable ties to ensure there will be no strain on the terminals. Test the insulation resistance of the cables. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 29: Task 5 - Install The Batteries Modules (If Required)
If not already fitted, fit fixed rails or shelves (starting at the bottom of the rack) to suit the number of battery modules. Refer to Spare Parts on page for available fixed rails. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 30 CKBATT-00 (see Spare Parts on page 66). If required, connect from battery connector 2 (BATT 2) on the EPS2/EPS5 to the cable plug on the first battery in group 2. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 31 (maximum 5 per group, 10 total) Step 5 - Switch off the battery circuit breakers Procedure complete See Battery Care on page for details of battery maintenance. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 32: Task 6 - Mount The Battery Temperature Sensor (If Required)
The following procedure is to connect an Ethernet and/or RS232 communications cable to the rear ports on an SC200 system controller only. Ignore this task if the system controller is an SC100 type (SC100 has a front connect RS232 connector only).
Page 33 Installation Step 2 - Route communications cable(s) to rear of SC200 Top cover Communications cable Cable entry (also used by temperature SC200 system controller sensor cable) Step 3 - Plug into Ethernet and/or RS232 port as required See the diagram on page for position of Ethernet or RS232 port on rear of SC200.
Page 34: Task 8 - Connect To The Ac Supply Point
Do not switch on the ac supply at this stage. Installation Completed Installation of the EPS2/EPS5 is now complete. Follow the instructions in Start-Up on page to make the system operational. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 35: Overview
Task 2 - Pre-Power-Up Checklist Task 3 - Applying AC Power Task 4 - Configuring the DC Power System Task 5 - Applying DC Power to Battery and Load Start-Up Completed Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 36: Start-Up Tasks
Push in the rectifier until the retaining screw contacts the shelf. Tighten the retaining screw to 1.5Nm (13.3 inch-pounds). This will locate the rectifier in its rear connector. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 37: Task 2 - Pre-Power-Up Checklist
• The rectifier alarm LEDs will turn on for a short time. • The SC200 or SC100 system controller will turn on (green Power On LED is on) when • the rectifiers start. During start-up of the system controller the rectifier yellow alarm LEDs will flash •...
Page 38: Task 4 - Configuring The Dc Power System
Enterprise Power Solutions Installation and Operation Guide After start-up of the system controller: Press any key on the system controller to silence the alarm (SC200 only). • Depending on the configuration file settings, one or both alarm LED(s) may be on and the system controller may display some system alarm messages.
Page 39 Start-Up Step 2 - Systems without batteries connected Ignore this Step if the EPS2/EPS5 system has batteries connected. In the SC200 or SC100 configuration file, set the battery capacity to zero (to indicate no batteries are connected): • Either: On SC100 go to: Menu > Configuration > System > Edit > Battery Capacity >Edit, or...
Page 40: Task 5 - Applying Dc Power To Battery And Load
Start-Up of the EPS2/EPS5 is now complete and the system is operational. For information on how to use the SC200 or SC100 system controller see SC200 or SC100 Operation in the System Controller Operation Handbook (see Related Information) on page For information on alarms, or operation problems see Maintenance on page 43.
Page 41 Topic Page Configuration File Starting the SC200 or SC100 SC200 or SC100 Operation using the Keypad and Screen SC200 or SC100 Operation Using a PC/Laptop SC200 or SC100 Identity Information Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C...
Page 42: Configuration File
39) or remotely, see Communications Options in the System Controller Operation Handbook. Backup and Restore The configuration file settings in the SC200 or SC100 can be saved to (Backup) or loaded from (Restore) a PC/laptop using DCTools/Web. Backup and Restore can be used to: Load a standard (master) configuration file into an SC200 or SC100 for customization.
Page 43: Starting The Sc200 Or Sc100
System Controller Starting the SC200 or SC100 When dc power is applied to the SC200 or SC100 (via the RXP connector YS11) the start-up sequence begins. SC200 Approx.  Start-up screen Summary screen Main menu All active alarms are See details on page 61.
Page 44: Sc200 Or Sc100 Operation Using The Keypad And Screen
• Protected - keypad access is denied (can be temporarily over-ridden, see below), or • PIN Protected (SC200 only) - keypad access is allowed when a 4-digit number is • entered in the Access PIN field. ► To temporarily enable keypad access when access is set to Protected Press Up and Down keys together for approximately 10 seconds.
Page 45: Alarm Indicators
DCTools can be run on a PC/laptop connected to the SC200's USB port. DCTools can also be run on a remote PC/laptop connected to the SC200's RS232 serial port (via a modem) or Ethernet port. For remote PC/laptop connection details see Communications Options in the System Controller Operation Handbook.
Page 46: Using Dctools Via Rs232
System Operation in the System Controller Operation Handbook. For help using DCTools press F1. Using DCTools via RS232 DCTools can be run on a PC/laptop connected to the SC200 or SC100's RS232 port. For remote PC/laptop connection details see Communications Options in the System Controller Operation Handbook.
Page 47: Sc200 Or Sc100 Identity Information
For details of the SC100 control and monitoring functions available via DCTools see System Operation in the System Controller Operation Handbook. For help using DCTools press F1. SC200 or SC100 Identity Information The following identity information is stored in the SC200 or SC100. Parameter Description Where to find:...
Page 48 Enterprise Power Solutions Installation and Operation Guide If required, the following site specific information can be stored in the SC200 or SC100 to assist site management. Parameter Description Where to find: System The manufacturer of the dc power Manufacturer system.
Page 49: Maintenance
Maintenance Overview Topic Page Troubleshooting Replacing or Adding a Rectifier Replacing or Adding a Circuit Breaker Replacing or Adding a Battery Module Battery Care Replacing the System Controller Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 50: Troubleshooting
Check rectifier comms bus wiring. If second rectifier registers then first rectifier is faulty and must be returned for service. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 51 System and Rectifier Selection on are on (rectifiers are in page 63. current limit). Battery is recharging after ac Check battery has recharged within supply failure. expected time. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 53: Replacing Or Adding A Rectifier
Insert a replacement rectifier into the empty slot (see details in following section), or fit a blank panel. Procedure complete Installing a Replacement Rectifier Step 1 - Remove rectifier blank panel (if fitted) Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 54: Replacing Or Adding A Circuit Breaker
If removing a battery circuit breaker: • Switch OFF (O) the battery circuit breaker. A Battery Fuse Fail alarm will appear. • Unplug the battery cable (if any) connected to the circuit breaker. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 55 For a battery circuit breaker a Battery Fuse Fail alarm will occur at the system controller. • For a load circuit breaker a Load Fuse Fail alarm will occur at the system controller if equipment is connected to the circuit breaker. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 56 The battery module(s) will begin to charge. The batteries will charge to 90% capacity in approximately 3 hours. However, it is recommended that they are charged for 24 hours after long-term storage. Procedure complete Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 57: Replacing Or Adding A Battery Module
Either: • Insert a replacement battery module into the empty position (see details in following section), or • Reconnect the cables and switch on the battery circuit breaker. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 58 Enterprise Power Solutions Installation and Operation Guide Step 6 - Adjust battery capacity in configuration file (if required) • In the SC200 or SC100 configuration file, set the battery capacity according to the number of battery modules connected: • Either: On SC100 go to: Menu >...
Page 59 CKBATT-00 (see Spare Parts on page 66). If required, connect from battery connector 2 (BATT 2) on the EPS2/EPS5 to the cable plug on the first battery in group 2. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 60 24 hours after long-term storage. Step 7 - Adjust battery capacity in configuration file (if required) • In the SC200 or SC100 configuration file, set the battery capacity according to the number of battery modules connected: •...
Page 61: Battery Care
24 hours after long-term storage. Check the battery recharge date on the shipping carton label. Do not use the batteries if • the date has expired and the batteries were never recharged. Contact your Eaton dc product representative for advice. Battery Disposal and Recycling Follow Environmental Protection Agency (EPA) guidelines or the equivalent local regulations to dispose of all batteries.
Page 62: Replacing The System Controller
Enterprise Power Solutions Installation and Operation Guide Replacing the System Controller The SC200 or SC100 system controller can be replaced without switching off the dc power system and disconnecting the equipment it powers. Before you start, you need A PC/laptop with the latest version of DCTools software installed and a connection •...
Page 63 Check the power system identification parameters and communications settings. Change the configuration file as required to ensure that the system controller operates as intended. Check the system controller time (SC200 only). See details in system controller handbook. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C...
Page 64 If there is no LVD Characterization alarm then ignore this step. If the SC200 or SC100 indicates an LVD Characterization Error alarm then: On the SC200 go to: Battery > LVDs > LVD1 > Options, or on the SC100 go to: Menu > Configuration > Low Volts Disconnect If available, select Characterize With IOB Values.
Page 65: Appendix A Specifications
120V ac: 2200W 208-240V ac: 3600W EPS5 models without batteries: 120V ac: 2750W 208-240V ac: 4500W *In systems with batteries one rectifier module is redundant and provides battery recharge. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 66 External modem options Type: PSTN or GSM Operation: Dial in/Dial out on alarm* * Can operate as a backup for Ethernet communications (SC200 only). Optional Battery Modules Model Powerware 5125 EBM Battery 48V, 18Ah total (2 strings), VRLA Dimensions (H, W, D) 2U (85mm/3.4"), 19"...
Page 67: Controller Menus
Appendix B Controller Menus Controller Menus SC200 Menu ↓ ↓ LVDs Setup IOBs Battery Info Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 68: Sc100 Menu
The following diagram shows the Status Screens and main navigation. Any active alarms are displayed in rotation. Operate control processes. Scroll to show any other rectifiers. SC200 or SC100, I/O board and rectifier identity information. List of any active alarms. Configure control processes.
Page 69: System Sizing
Supply Voltage: 208-240V ac Connectable Equipment Power (W): 1800 1800 2700 3600 System model: EPS2 EPS2 EPS5 EPS5 EPS5 Rectifier type: EPR48-3G APR48-3G EPR48-3G EPR48-3G EPR48-3G Number of rectifiers: Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 70: Battery Module Selection (Optional)
Run Times are based on an end voltage of 43.2V (1.8V per cell). Example: (as shown on the graph) for a total Equipment Power of 1800 watts and a battery run-time of 60 minutes, connect four battery modules. Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 71: Equipment And Tools
RS232 port and null-modem cable (see Spare Parts on page 66) - for EPS2/EPS5 • systems with SC100 system controller. DCTools software (download from www.powerware.com/downloads). • Labeling tool and labels • Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 72: Spare Parts
North America: NEMA L6-15 Other countries: 10A min. rating Connector 2: IEC type C-15 USB A/B cable - for use with SC200 system RadioShack 55010997, Jaycar WC7700, or equivalent. controller RS232 DB9 F/F Null-modem cable - for use with RadioShack 55010600, Jaycar WC7513, or equivalent.
Page 73: Appendix E Circuit Diagrams
Drawing Number Issue Title 3701337 Block Diagram - EPS5 with 4 x Option, +ve Earth Only 3692979 WIRING DIAGRAM RM3-X2X (applies to RM3-420 models) 3700801 Wiring Diagram DCD1M +ve Earth Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 77: Equipment Incident Report
Please enter as much information as you can. Send the completed form, together with the item for repair to your nearest authorized service agent. NOTE: Only one fault to be recorded per form. For further information contact your Powerware dc product supplier or Eaton Corporation, Telecommunications Solutions Division. See contact details on page 73. Or email: CustomerServiceNZ@eaton.com...
Page 79: Worldwide Support
Worldwide Support Worldwide Support For product information and a complete listing of worldwide sales offices, visit Eaton's Powerware website at: www.powerware.com or email: DCinfo@eaton.com For technical support contact either your local Powerware dc product representative, the closest office from the following list, telephone (+64) 3 343-7448, or email CustomerServiceNZ@eaton.com...
Page 81: Index
Fuse Fail Detect • See MCBs Location • 3 Circuit Diagram • 67 Clearances • 18 Ground Communications • 5, 60 Ground Leakage Current • 59 Communications Options • 7 Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 82 Identity Information • 41 SNMP Keypad • 38 Location • 3 Problems • See Troubleshooting PC/Laptop (Connection via USB) • See USB Repair and Return • 71 Communications Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...
Page 83 Repair and Return • 71 Servicing • 11, 71, 73 Technical Assistance • 73 Connector • 5 Problems • See Troubleshooting USB Cable • 39, 66 USB Communications • 39 Copyright © 2008 Eaton Corporation. All Rights Reserved. IPN 997-00012-56C September 2008...

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Eaton SC200 Installation And Operation Manual

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