Page 1 Access Power Solutions Installation and Operation Guide (APS6-400 Series) Issue: IPN 997-00012-53B Issue Date: December 2010 Refer to the separate SC200 or SC100 system controller handbook for full details of the system controller operation - www.powerquality.eaton.com/DC-Manuals. Eaton Corporation Telecommunications Power Solutions www.eaton.com/telecompower...
Page 2 The information contained in this literature is subject to change without 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
Please use this email address to report any problems you find in this guide: Eaton DC Product Marketing Communications EMAIL: DCMarketingNZ@eaton.com For Further Information and Technical Assistance For further information and technical assistance see Worldwide Support on page 101. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 5: Table Of Contents
Task 3 - Applying AC Power ....................37 Task 4 - Configuring the DC Power System ............... 38 Task 5 - Applying DC Power to Battery and Load ............39 Start-Up Completed ....................... 40 Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 6 Access Power Solutions Installation Guide (APS6-400 Series) Chapter 5 System Controller Configuration File ........................42 Backup and Restore ........................42 Starting the SC200 or SC100 ....................43 SC200 ............................... 43 SC100 ............................... 43 SC200 or SC100 Operation using the Keypad and Screen ..........44 Keypad Access Security ........................
Page 7 System Controls ........................86 System Alarms ........................90 Digital Inputs .......................... 93 Digital Outputs (Relays) ......................94 Commissioning Completed ....................94 Appendix G Circuit Diagrams Equipment Incident Report Worldwide Support Index Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 9: Overview
Chapter 1 General Description   General Description Overview Topic Page Access Power Solutions DC Power Systems Model Numbers Rectifiers System Controller Other Features Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 10: Access Power Solutions Dc Power Systems
Access Power Solutions Installation Guide (APS6-400 Series) Access Power Solutions DC Power Systems Front View   Rectifier modules (see details on page 4) Protective earth termination (M10)   SC200 or SC100 system controller (see details on Load circuit breaker cover page 5) ...
Page 11: Rear View
Battery live cable terminals.  Load and Battery common bar.  Alternate battery terminal bar for 2-pole battery circuit  DC common-chassis (ac ground) link (see details on breakers. page 23). Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 12: Model Numbers
Access Power Solutions Installation Guide (APS6-400 Series) Model Numbers Model Number System Controller LVD Contactor(s) APS6-410 SC100 None * APS6-411 SC100 Battery only APS6-41L SC100 Low-priority load only * APS6-412 SC100 Battery and low-priority load APS6-420 SC200 None * APS6-421...
Page 13: System Controller
The SC100 system controller is a full-featured control and monitoring solution which provides alarm notifications via dial-out modem to PowerManagerII remote monitoring software, SMS text messaging, or by relay contact closures. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 14: Compatible Software
DCTools Configuration Software. Latest version is available free from  www.powerquality.eaton.com/downloads. PowerManagerII Remote Control and Monitoring Software. Contact your Eaton dc product  supplier for further information (see Worldwide Support on page 101). Recommended web browsers (SC200 only): Microsoft Internet Explorer 8 (IE6 is compatible ...
Page 15: Other Features
LVD, either the total battery current must be less than 285A or the APS must be protected by an external battery LVD set to 43V or higher. For information on operation see Low Voltage Disconnect (LVD) in the System Controller Operation Handbook. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 16: Battery Mid-Point Monitoring Option (Sc200 Only)
Access Power Solutions Installation Guide (APS6-400 Series) Battery Mid-point Monitoring Option (SC200 only) Battery Mid-point Monitoring provides a cost-effective method for the early detection of internal battery faults. The voltages of the two halves of a battery string are measured and the system controller generates an alarm signal if a voltage imbalance is detected.
Page 17: Preparation
Chapter 2 Preparation   Preparation Overview Topic Page Warnings Inspecting the Equipment and Reporting Damage Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 18: Warnings
 Electrical Safety  The case of the Access Power Solutions (APS6-400 Series) dc power system is a fire enclosure as specified in UL 60950-1. The system can be installed in an enclosed cabinet or an open relay rack. ...
Page 19  Batteries  The plastic cases of batteries installed in Eaton dc power system racks must have a flammability rating of UL 94-V2 or better.  Flooded cell lead acid batteries must be installed in a battery room. Do not install flooded lead acid batteries in an Eaton dc power system rack.
Page 20: Inspecting The Equipment And Reporting Damage
EMC Compliance  This Eaton product ("the equipment") has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the Federal Communications Commission (FCC) Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment.
Page 21: Installation
Task 5 - Connect the DC Load and Battery Cables Task 6 - Install the Batteries Task 7 - Mount the Battery Temperature Sensor Task 8 - Connect the AC Supply Cable Installation Completed Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 22: Installation Tasks
Access Power Solutions Installation Guide (APS6-400 Series) Installation Tasks Before starting the installation, review the following information: Required Equipment and Tools on page  Warnings and Cautions on page  Inspecting the Equipment and Reporting Damage on page  Complete the Installation tasks in the following order:...
Page 23 If the curve of an upstream ac supply-disconnect device crosses the curve for the rectifier fuse there may not be adequate discrimination. Contact your Eaton dc product supplier for advice (see Worldwide Support on page 101).
Page 24: Task 2 - Customize Aps
Access Power Solutions Installation Guide (APS6-400 Series) Rectifier internal fuses (IEC 60127-2) Time- Current Curve (minimum and maximum) Sources: Schurter SP 5x20 Pigtail data sheet. Step 5 - Check the grounding arrangements at the site Confirm that all grounds are brought together at one "star" point so that surge currents cannot flow in "ground loops"...
Page 25 Fit circuit breaker blank panels to cover any unused positions. Replace the dc circuit breaker cover. Switch all circuit breakers to the OFF ("0") position. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 26 Access Power Solutions Installation Guide (APS6-400 Series)   Circuit breaker cover Battery circuit breaker*  Load circuit breaker*  * Be careful to insert circuit breakers the right way up. Load Circuit Breakers Item Description Part Number 5A, 1-pole, 80V dc (derates to 4A)
Page 27 Tighten the terminals to 3.9 - 4.5Nm (35 - 39 inch-pounds). Step 4 - Fit or remove the battery disconnect LVD (if required)   Battery disconnect LVD contactor. Link bar (in place of contactor). Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 28 Access Power Solutions Installation Guide (APS6-400 Series) Remove the access panel on the side of the APS. Either: To fit the battery LVD contactor:  Undo the two bolts and remove the link bar.  Fit the two pieces of bus work. Tighten the M8 bolts to 9.5 - 11.1Nm (85 - 98 inch-pounds).
Page 29 Ground stud (M6) Remove the ac terminal cover. If necessary, change the live/neutral connections to the rectifiers to suit the ac supply as shown in the following diagrams. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 30: Task 3 - Mount The Aps In The Rack
Access Power Solutions Installation Guide (APS6-400 Series) Rectifier connections for Rectifier connections for 2 x 1W+N or 2 x 2W ac supply 3 x 1W+N or 3 x 2W -wire ac supply    N/L2-L/L1 to Rectifier 1 N/L2-L/L1 to Rectifier 3 N/L2-L/L1 to Rectifier 5 ...
Page 31 (bonded) to the ac ground, via the chassis (Step 4B).  The APS is supplied with the dc common bar bonded to the chassis via a link on the dc common bar. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 32 Access Power Solutions Installation Guide (APS6-400 Series) Step 4A - Bond dc output to a telecom ground electrode (if required) Ignore this Step if the dc supply must be referenced (bonded) to the ac ground, via the chassis (see Step 4B).
Page 33: Task 4 - Connect External Input/Output Cabling (If Required)
If no external devices are to be connected then ignore this task. Step 1 - Access the I/O terminals Remove the Input/Output cover (see the diagram on page 3) and partly withdraw the I/O board. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 34 Access Power Solutions Installation Guide (APS6-400 Series) Step 2 - Terminate the cabling  Connect only voltage-free switch or relay contacts to Digital Inputs.   Do not exceed the voltage and current limits of the relay contacts.  For wire size and I/O ratings see Specifications on page 70.
Page 35  For details on setup refer to the SiteSure-3G Installation Guide. See Related Information on page i.   Voltage feed module RJ45 sockets (S1, S2 and S3) Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 36: Task 5 - Connect The Dc Load And Battery Cables
Access Power Solutions Installation Guide (APS6-400 Series) Step 6 - Connect external communications cables (if required)  See System Controller on page and External Communications on page 7. SC100: Connect RS232 communications cable to the front connector.  Ensure the cable is secured so that no force is applied to the RS232 connector as this may damage the connector.
Page 37 Terminate the load live cable(s) at the load circuit breaker terminal(s). Tighten all terminations to 3.9 - 4.5Nm (35 - 39 inch-pounds). Secure the cables to the tie bar. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 38: Task 6 - Install The Batteries
Access Power Solutions Installation Guide (APS6-400 Series) Load CB Cable size 2-hole Crimp Lug Crimping tool Rating (Note 2) (¼" studs, 5/8" spacing) (Note 3) (Note 1) (Note 3) 5-15A 14 AWG 12 AWG YAV10-2TC14 Y8MRB-1 25-30A 10 AWG 8 AWG...
Page 39: Task 7 - Mount The Battery Temperature Sensor
 The Mid-point Monitoring sense wires must have short-circuit protection fitted close to the battery terminals. Use the Battery Mid-point Monitoring kits from Eaton (see Spare Parts on page 67) or equivalent. Connect a Mid-point Monitoring sense wire to the middle interconnecting link on each string of batteries (see following diagram).
Page 40: Task 8 - Connect The Ac Supply Cable
Access Power Solutions Installation Guide (APS6-400 Series) The best location for the battery temperature sensor is in the middle of the battery stand above the batteries. To avoid false readings do not: Place the sensor on a battery case. ...
Page 41: Installation Completed
Test the insulation resistance of the conductors according to local ac wiring regulations. Procedure complete Installation Completed Installation of the APS is now complete. Follow the instructions in Start-Up on page to make the system operational. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 43: 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 © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 44: Start-Up Tasks
Access Power Solutions Installation Guide (APS6-400 Series) Start-Up Tasks Complete all the Installation tasks (see details on page 14) before starting these Start-Up tasks. Complete the Start-Up tasks in the following order: Task Description Reference Insert the Rectifiers See details on page...
Page 45: Task 2 - Pre-Power-Up Checklist
The LCD module shows the summary screen. See details on page 43.   If no load or battery is connected the current will be 0A. If fitted and enabled, the LVD(s) operate.  Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 46: Task 4 - Configuring The Dc Power System
Access Power Solutions Installation Guide (APS6-400 Series) Check all rectifiers are running and only the rectifier green Power On LEDs are on (no alarm LEDs). On the system controller keypad select Menu > Rectifiers. See details on page 73. Check ...
Page 47: Task 5 - Applying Dc Power To Battery And Load
Check the equipment powers up and the Load Fuse Fail alarm clears. Step 4 - Check the rectifier currents Check the rectifier currents. Verify the load current is as expected for the load and battery size. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 48: Start-Up Completed
Access Power Solutions Installation Guide (APS6-400 Series) Step 5 - Charge the batteries Charge the batteries according to the battery manufacturer’s recommendations. If an Equalize charge is recommended by the battery manufacturer then follow the instructions in the System Controller Operation Handbook.
Page 49 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 © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 50: Configuration File
Access Power Solutions Installation Guide (APS6-400 Series) Configuration File The operational settings of the dc power system are stored in a configuration file loaded into the SC200 or SC100 system controller. The SC200 or SC100 is supplied pre-loaded with a configuration file. If this configuration file has been customized for the site then no further configuration changes will be necessary.
Page 51: Starting The Sc200 Or Sc100
Handbook. All active Critical, Major, Minor and Warning alarms are displayed. SC100  Approx Start-up screen First status screen Main menu All active alarms are displayed. See details on page 74. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 52: Sc200 Or Sc100 Operation Using The Keypad And Screen
Keypad access is Read Only, or PIN Protected and the keypad access PIN is lost. The SC200 will continue to function, but no configuration changes can be made. Contact your Eaton dc product supplier or Eaton for advice (see Worldwide Support on page 101).
Page 53: Alarm Indicators
Critical/Major alarms always override Minor alarms. ► To stop the audible indicator Press any key   The audible indicator will restart at the next active alarm or alert message. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 54: Sc200 Or Sc100 Operation Using A Pc/Laptop
SC200 or SC100 Operation Using a PC/Laptop DCTools is configuration software for editing a system controller's configuration file (on-line) and monitoring the operation of Eaton's dc power systems. It is available free from www.powerquality.eaton.com/downloads. Using DCTools via USB (SC200 only) DCTools can be run on a PC/laptop connected to the SC200's USB port.
Page 55 System Controller Before you start you will need: The latest version of DCTools available from: www.powerquality.eaton.com/downloads.  A PC/laptop with USB port and USB A/B cable (RadioShack 55010997, Jaycar WC7700 or  similar) ► To connect a PC/laptop to the SC200 or SC100: Download the latest version of DCTools from: www.powerquality.eaton.com/downloads.
Page 56: Sc200 Or Sc100 Identity Information
Access Power Solutions Installation Guide (APS6-400 Series) SC200 or SC100 Identity Information The following identity information is stored in the SC200 or SC100. Parameter Description Where to find: Serial Number The SC200 or SC100 serial number SC100: Menu > Identity >SC100 (factory set).
Page 57: Maintenance
Eaton. This includes disassembly and/or servicing of any modules.  For further information on Servicing contact your local Eaton dc product supplier, or refer to the contact details on page 101. Topic Page...
Page 58: Troubleshooting
Access Power Solutions Installation Guide (APS6-400 Series) Troubleshooting Use the table to troubleshoot minor installation and operational problems. For additional assistance see contact details on page 101. Return items for replacement or repair with a completed Equipment Incident Report on page 99.
Page 59 Install additional rectifiers. and rectifier yellow LEDs capacity. are on (rectifiers are in Battery is recharging after ac Check battery has recharged within current limit). supply failure. expected time. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 60 Access Power Solutions Installation Guide (APS6-400 Series) Problem Possible Cause Required Action High system output voltage. Temperature Compensation is None. This is normal operation (if active and the battery batteries are connected). Disable temperature is below the Temperature Compensation if no reference temperature.
Page 61: System Controller Problems
Problem with power or Check all connections (see Connections communications to I/O board. on page 81). SC200 or SC100 or I/O board Replace faulty unit. software corrupt or hardware fault. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 62 Access Power Solutions Installation Guide (APS6-400 Series) Problem Possible Cause Required Action Incorrect battery or load Bus voltage sense polarity is Check the bus voltage sense polarity and current readings. incorrect. correct if necessary. Incorrectly configured shunt Check shunt mapping and gain is correct.
Page 63 Check S3P Access is enabled. See details are disabled. in the System Controller Operation Handbook. Password required to change See Write Access Password in the System settings (using DCTools or Controller Operation Handbook. PowerManagerII). Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 64 Access Power Solutions Installation Guide (APS6-400 Series) Problem Possible Cause Required Action Web communications Ethernet communications See previous entry. problem (SC200 only) problem. Cannot connect to web server. Check IP address and other settings in SC200 are correct. Check correct IP address is used in web browser address bar.
Page 65: Replacing Or Adding A Rectifier
Step 2 - Pull out the rectifier   The rectifier may be hot, especially after prolonged operation. Use suitable gloves.  To avoid damage do not rest the rectifier on its connector. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 66 Access Power Solutions Installation Guide (APS6-400 Series) Step 3 - Replace rectifier or fit blank panel Insert a replacement rectifier into the empty slot (see details in following section), or fit a blank panel. Procedure complete Installing a Replacement Rectifier...
Page 67: Replacing Or Adding A Load Circuit Breaker
Step 4 - Replace dc circuit breaker cover Step 5 - Connect load cable (if required) Follow the procedure on page 28. Procedure complete Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 68: Replacing The System Controller
 contact your Eaton dc power system supplier to obtain a master configuration file to  suit the dc power system. This file will have to be customized for the site.
Page 69 1-10 will be disconnected. Either, arrange to switch off this equipment or connect a temporary external power source to power the equipment when the load LVD disconnects. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 70: Replacing The Input/Output Board
Access Power Solutions Installation Guide (APS6-400 Series) On the SC200 go to: Battery > LVDs > LVD x > Not Characterized > Edit, or on the SC100 go to: Menu > Configuration > LVD1/LVD2  Select Characterize. Press Enter/Save. ...
Page 71 SC100 go to: Menu > Configuration > LVD1/LVD2  Select Characterize. Press Enter/Save.  The LVD contactor will disconnect and connect. Repeat for the second LVD if fitted. Procedure complete Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 72: Battery Mid-Point Monitoring (String Fail) Alarm (Sc200 Only)
Access Power Solutions Installation Guide (APS6-400 Series) Battery Mid-point Monitoring (String Fail) Alarm (SC200 only) Use the following procedure if a String Fail alarm is generated. Step 1 - Identify the faulty battery string Press any button on the SC200 to silence the alarm.
Page 73: Appendix A Equipment And Tools
USB port and USB A/B cable (RadioShack 55010997, Jaycar WC7700 or similar)  DCTools software (download from www.powerquality.eaton.com/downloads).  Test load (to suit maximum output of dc power system)  Labeling tool and labels  Clamp-on ammeter  Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 74: Standard Torque Settings
Access Power Solutions Installation Guide (APS6-400 Series) Standard Torque Settings Use the following torque settings unless specific values are stated on the fastener or elsewhere. Fastener Torque 1/4" cable terminals 3.9 - 4.5Nm (35 - 39 inch-pounds) 3/8" cable terminals 18.7 - 21.9Nm (166 - 194 inch-pounds)
Page 75: Appendix B Spare Parts Lists
RadioShack 55010997, Jaycar WC7700, or equivalent. Battery Mid-point Monitoring Eaton MPTLOOM-3300 (2 x 3m sense wires), or connection kit for use with SC200 Eaton MPTLOOM-7600 (1 x 7m, 1 x 6m sense wires) (for two battery strings) 200A Low Voltage Disconnect Eaton KLVD200-002...
Page 76 Access Power Solutions Installation Guide (APS6-400 Series) Load Circuit Breakers Item Description Part Number 5A, 1-pole, 80V dc (derates to 4A) Heinemann AMA1R-B2-AI-20-D-DU-52-5-1 10A, 1-pole, 80V dc (derates to 8A) Heinemann AMA1R-B2-AI-20-D-DU-52-10-1 15A, 1-pole, 80V dc (derates to 12A) Heinemann AMA1R-B2-AI-20-D-DU-52-15-1...
Page 77: Appendix C Specifications
80% of CB rating 120A, 2-pole: 80% of CB rating Circuit breaker spacing 80-120A load circuit breaker must have adjacent space. Refer to the installation instructions on page Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 78: Lvd Specifications Aps6-400
Access Power Solutions Installation Guide (APS6-400 Series) LVD Specifications APS6-400 Low Voltage Disconnect (LVD) Contactors Battery Disconnect 400A Low-priority Load Disconnect 200A  In APSs without an internal battery disconnect LVD, either the total battery current must be less than 285A or the APS must be protected by an external battery LVD set to 43V or higher.
Page 79 Bus Voltage Sense Input (IOBGP) Number of Bus Voltage Sense Inputs Range –60V to +60V Resolution 30mV Accuracy ±0.5% at 25°C [77°F], ±1% over rated temperature range Connector MTA156 (2-way) Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 80 Access Power Solutions Installation Guide (APS6-400 Series) Battery Mid-point Monitoring (SC200 only) Number of Strings Standard: Maximum: 24 (with additional IOBGP-01 I/O boards) Range –35V to +35V Resolution <30mV Accuracy ±0.5% at 25°C [77°F], ±1% over rated temperature range Communications...
Page 81: Appendix D Controller Menus
At each menu screen press Enter to access the associated configuration menu screen(s). These menus have multiple configuration menu screens. See details in the System Controller Operation Handbook. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 82: Sc100 Menu
Access Power Solutions Installation Guide (APS6-400 Series) SC100 Menu The following diagram shows the Status Screens and main navigation.  See Analog System Values for details of the values displayed.   Any active alarms are displayed in rotation. Operate control processes.
Page 83: Appendix E Connector Pin-Outs
RXP System +24/48V (System bus voltage) Communications +24/48V (System bus voltage) RS485-A RS485-B USB B USB Serial Interface VCC (+5 V dc) (SC200 only) Data - Data + Ground Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 84 Access Power Solutions Installation Guide (APS6-400 Series) RS232 D9M and RJ45 connector pin-outs RJ45 plug pin-outs Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 85: I/O Board (Iobgp-00, -01) Connector Pin-Outs
Controller sense (Com) XH12A Battery Mid-point String 1 Mid-point Monitoring sense inputs String 2 Mid-point String 3 Mid-point String 4 Mid-point XH15A Digital inputs D1-D3 D1 input D2 input Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 86 Access Power Solutions Installation Guide (APS6-400 Series) Connector Type Purpose Description D3 input XH15B Digital inputs D4-D6 D4 input D5 input D6 input XH16/XH17 Digital relay outputs 1-2 Relay 1 normally closed (NC) Relay 1 normally open (NO) Relay 1 Common (COM)
Page 87: Input/Output Board
Relay outputs: 6 (one also used as Monitor OK alarm)  For input and output specifications see details on page 70. For connector pin-outs see details on page 77. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 88 Access Power Solutions Installation Guide (APS6-400 Series)   LVD Power - XH8 Bus voltage sense input - XH9   Power and RXP comms input - YH11 Power/Comms OK LED (green)   Current sense input - XH6 Digital inputs D1-D6 (6 user defined) - XH15A, XH15B ...
Page 89: Connections
I/O and system controller power and RXP comms  Connection to dc common bus connections  For connector pin-outs see details on page 77. For input and output specifications see details on page 69. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 91 See details on page System Controls See details on page System Alarms See details on page Digital Inputs See details on page Digital Outputs (Relays) See details on page Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 92: Analog Inputs
Access Power Solutions Installation Guide (APS6-400 Series) Analog Inputs Equipment required: Digital Voltmeter  DC Load bank  DC Current Clamp meter  Trim pot adjustment tool  Thermometer  Test Test procedure Adjustment  Measure the dc voltage across the dc bus.
Page 93 As the analog inputs can be configured for many different types of analog signal, tests have not been detailed on this test sheet. User assigned analog inputs are not available on all systems. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 94: System Controls
Access Power Solutions Installation Guide (APS6-400 Series) System Controls Equipment Required: DC Load bank  Test Test procedure Adjustment  Apply a load to the power system. Voltage Control None  With DCTools, ensure the bus voltage matches the Target...
Page 95 Set the LVD manual control to DISCONNECT.  Ensure the LVD contactor disconnects.  Ensure the SC200 or SC100 displays an LVD Manual alarm.  Ensure the I/O board LVD LED is off. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 96 Access Power Solutions Installation Guide (APS6-400 Series) Test Test procedure Adjustment  Set the LVD manual control to AUTO.  Ensure the LVD connects.  Ensure the SC200 or SC100 shows no LVD alarms.  Ensure the I/O board LVD LED is on.
Page 97 Perform the test on each LVD control module within the system. For manual LVD operation see details in the System Controller Operation Handbook. For an explanation of LVD LED indications see Troubleshooting on page 50. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 98: System Alarms
Access Power Solutions Installation Guide (APS6-400 Series) System Alarms Equipment Required: dc load bank  dc power supply  Test Test procedure Adjustment  For all alarms check the following where applicable: General notes about  alarm testing SC200 or SC100 LED status.
Page 99 Disconnect the current sensor (XH6).  Ensure alarm operates.  Replace the current sensor.  Disconnect the voltage sensor (XH9).  Ensure alarm operates.  Replace the voltage sensor. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 100 Access Power Solutions Installation Guide (APS6-400 Series) Test Test procedure Adjustment  For details see Equalize test in System Controls on page 86. Equalize  For details see Fast Charge test in System Controls on page Fast Charge  For details see Battery Test in System Controls on page 86.
Page 101: Digital Inputs
Check the severity and digital output (relay) mapping is correct. Note 1 Notes As the Digital Inputs can be configured for many different digital input devices, specific tests have not been detailed on this test sheet. Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 102: Digital Outputs (Relays)
Access Power Solutions Installation Guide (APS6-400 Series) Digital Outputs (Relays) Test Test procedure Adjustment  Refer to Digital Outputs in the SC200 or SC100 handbook. Digital Output 1 Follow the instructions to manually change the state of the Note 1 digital output.
Page 103: Appendix G Circuit Diagrams
Appendix G Circuit Diagrams   Circuit Diagrams Drawing Issue Title Number 3700272 WIRING DIAGRAM APS6-4XX +VE EARTH Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 107: Equipment Incident Report
Please enter as much information as you can. Send the completed form, together with the item for repair to your nearest authorized service agent. NOTE: Only one fault to be recorded per form. For further information contact your local Eaton dc product supplier or Eaton (see contact details on page 101). Or email: CustomerServiceNZ@eaton.com...
Page 108 ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ SG/03 ISS06 Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 109: Worldwide Support
  Worldwide Support For product information and a complete listing of worldwide sales offices, visit Eaton's website at: www.eaton.com/telecompower or email: DCinfo@eaton.com For technical support contact either your local Eaton dc product representative, the closest office from the following list, telephone (+64) 3 343-7448, or email CustomerServiceNZ@eaton.com...
Page 111: Index
Backup and Restore • 42 Battery Installation • 30 Connection to AC Supply • 21, 32, 37 Disposal and Recycling • 65 Current Mid-Point Monitoring (MPM) • 8, 30, 74 Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 112 Access Power Solutions Installation Guide (APS6-400 Series) Battery Current • 54 Load Current • 54 Identity Information • 48 Rectifier Current • 43 IEC Sockets/Cords • 3 Current Sense • 73, 83 Input/Output (I/O) Board Connections to other system components • 83 Connector Pin-outs •...
Page 113 Rectifier blank panel • 58 Communications Rectifier Current • 43 SNMP • 7 Rectifier Fuses • See AC Discrimination SNTP • See Internal Clock Rectifier LEDs • 4 Copyright © 2009-2010 Eaton Corporation. All Rights Reserved. IPN 997-00012-53B December 2010...
Page 114 Access Power Solutions Installation Guide (APS6-400 Series) Software Versions • 6 Sound • See Audible Alarm Indication Spares • 69 Specifications • 71 String Fail Alarm • 53, 64 Target Failed to Respond Error • 54 Technical Assistance • 103 Temperature •...

Eaton APS6-400 Series Installation And Operation Manual

Appendix A Equipment and Tools

Appendix B Spare Parts Lists

Appendix C Specifications

Appendix D Controller Menus

Appendix E Connector Pin-Outs

Appendix G Circuit Diagrams

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Summary of Contents for Eaton APS6-400 Series

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