Eaton APS12-300 Series Operating instructions

Access Power Solutions
Installation and Operation Guide
(APS6-300/500 and APS12-300 Series)
Issue: IPN 997-00012-49G
Issue Date: May 2013
Refer to the separate SC200 or SC100 system controller handbook for full
details of the system controller operation -
dcpower.eaton.com/Manuals.asp
Eaton Corporation
Telecommunications Power Solutions
dcpower.eaton.com
[email protected]

The product discussed in this literature is subject to terms and conditions outlined in Eaton selling policies. The
sole source governing the rights and remedies of any purchaser of this equipment is the relevant Eaton selling
policy.
No warranties, express or implied, including warranties of fitness for a particular purpose or merchantability, or
warranties arising from course of dealing or usage of trade, are made regarding the information,
recommendations and descriptions contained herein.
In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict
liability or otherwise for any special, indirect, incidental or consequential damage or loss whatsoever, including but
not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional
expenses in 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 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.
No part of this literature may be reproduced or transmitted in any form, by any means or for any purpose other
than the Purchaser’s personal use, without the express written permission of Eaton Corporation.
Eaton®, Matrix, Powerware®, IntergyTM, CellSureTM, SiteSureTM, PowerManagerIITM and DCToolsTM are trade
names, trademarks, and/or service marks of Eaton Corporation or its subsidiaries and affiliates. Unless otherwise
noted, brands, product names, trademarks or registered trademarks are the property of their respective holders.
Copyright © 2007-2013 Eaton Corporation. All Rights Reserved.

About This Guide
Copyright © 2007-2013 Eaton Corporation. All Rights Reserved.
IPN 997-00012-49G May 2013
i
AboutT his Gui de
Scope
This guide covers installation, operation and maintenance of Access Power Solutions
(APS6-300/500 and APS12-300 Series) dc power systems (APS), controlled by the SC200 or
SC100 system controller.
Refer to the separate SC200 or SC100 system controller handbook for full details of the system
controller operation - dcpower.eaton.com/Manuals.asp.
Audience
This guide is intended for use by:
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
Operators and maintenance staff competent in:
operation of dc power systems
safe working practices for ac and dc powered equipment
Related Information
SC100 System Controller Operation Handbook* –IPN 997-00012-63
SC200 System Controller Operation Handbook* –IPN 997-00012-50
PowerManagerII Online Help
DCTools Online Help
SiteSure-3G Installation and Operation Guide –IPN 997-00012-51
* Download from: http://dcpower.eaton.com/Manuals.asp.
Reporting Problems with this Guide
Please use this email address to report any problems you find in this guide:
Eaton DC Product Marketing Communications
EMAIL: [e-mail]
For Further Information and Technical Assistance
For further information and technical assistance see Worldwide Support on page 107.

Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series)
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Copyright © 2007-2013 Eaton Corporation. All Rights Reserved.
IPN 997-00012-49G May 2013

Table of Contents
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iii
Table of Co ntents
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
Model Numbers........................................................................................................................ 2
Access Power Solutions DC Power Systems ........................................................................ 3
APS6 Models Front View ............................................................................................................... 3
APS6 Models Rear View.................................................................................................................4
APS12 Models Front View ............................................................................................................. 5
APS12 Models Rear View............................................................................................................... 6
Rectifiers .................................................................................................................................... 7
System Controller..................................................................................................................... 8
SC200 System Controller ................................................................................................................ 8
SC100 System Controller ................................................................................................................ 9
Compatible Software....................................................................................................................... 9
Input/Output Board .............................................................................................................. 10
Connections.................................................................................................................................... 11
Other Features ........................................................................................................................ 12
External communications ............................................................................................................. 12
Low Voltage Disconnect Options................................................................................................ 12
Battery Mid-point Monitoring Description (SC200 only)......................................................... 13
Battery Time Remaining............................................................................................................... 13
Chapter 2 Preparation
Overview ................................................................................................................................. 15
Warnings ................................................................................................................................. 16
Inspecting the Equipment and Reporting Damage ........................................................... 18
Chapter 3 Installation
Overview ................................................................................................................................. 19
Installation Tasks.................................................................................................................... 20
Task 1 - Check the AC Supply and Earthing ...................................................................... 20
Task 2 - Prepare APS.............................................................................................................. 23
Task 3 - Connect the AC Supply Cable(s) ........................................................................... 26
Task 4 - Mount the APS in the Rack .................................................................................... 28
Task 5 - Connect the DC Load and Battery Cables ............................................................ 29
Task 6 - Install the Batteries .................................................................................................. 30
Task 7 - Mount the Battery Temperature Sensor ............................................................... 31
Task 8 - Connect External Input/Output Cabling (if required)....................................... 32
Task 9 - Connect Additional Input/Output (if required - SC200 only) .......................... 33
Task 10 - Connect to the AC Supply Point.......................................................................... 33
Installation Completed .......................................................................................................... 34

Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series)
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IPN 997-00012-49G May 2013
Chapter 4 Start-Up
Overview..................................................................................................................................35
Start-Up Tasks .........................................................................................................................36
Task 1 - Inserting the Rectifiers .............................................................................................36
Task 2 - Pre-Power-Up Checklist ..........................................................................................37
Task 3 - Applying AC Power.................................................................................................37
Task 4 - Configuring the DC Power System........................................................................38
Task 5 - Applying DC Power to Battery and Load.............................................................39
Start-Up Completed................................................................................................................40
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 ................................................................................................................44
Alarm Indicators ............................................................................................................................45
SC200 or SC100 Operation Using a PC/Laptop .................................................................46
Using DCTools via USB (SC200 only) .........................................................................................46
Using DCTools via RS232 .............................................................................................................46
SC200 or SC100 Identity Information...................................................................................48
Chapter 6 Maintenance
Overview..................................................................................................................................49
Troubleshooting ......................................................................................................................50
System Problems ............................................................................................................................50
System Controller Problems.........................................................................................................53
Replacing or Adding a Rectifier............................................................................................58
Replacing or Adding a Load MCB .......................................................................................60
Replacing the System Controller...........................................................................................61
Replacing the Input/Output Board......................................................................................64
Battery Mid-point Monitoring (String Fail) Alarm (SC200 only) .....................................68
Battery Disposal and Recycling.............................................................................................68

Table of Contents
Copyright © 2007-2013 Eaton Corporation. All Rights Reserved.
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v
Appendix A Equipment and Tools
Safety Equipment .......................................................................................................................... 69
Essential Tools................................................................................................................................ 69
Recommended Tools..................................................................................................................... 69
Spare Parts............................................................................................................................... 70
Standard Torque Settings...................................................................................................... 71
Appendix B Specifications
Appendix C Cable Ratings
Appendix D Controller Menus
SC200 Menu ............................................................................................................................ 81
SC100 Menu ............................................................................................................................ 82
Appendix E Connector Pin-outs
System Controller Connector Pin-outs................................................................................ 83
I/O Board (IOBGP-00, -01) Connector Pin-outs................................................................. 84
Appendix F Transient Protection
Appendix G Earth Bonding
Appendix H Commissioning
Analog Inputs ......................................................................................................................... 94
System Controls...................................................................................................................... 96
System Alarms........................................................................................................................ 99
Digital Inputs ........................................................................................................................ 102
Digital Outputs (Relays)...................................................................................................... 103
Commissioning Completed ................................................................................................ 103
Equipment Incident Report
Worldwide Support
Index

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Chapter 1
General Description
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IPN 997-00012-49G May 2013
1
C h a p t e r 1
General Descrip tion
Overview
Topic Page
Model Numbers 2
Access Power Solutions DC Power Systems 3
Rectifiers 7
System Controller 8
Input/Output Board 10
Other Features 12

Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series)
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Model Numbers
Model Number
DC Output Power (max.)
System Controller
LVDs
24V nominal
48V nominal
APS6-310
-
12.0kW
SC100
-
APS6-311
-
8.6kW (Note 1)
SC100
1
APS6-312
-
8.6kW (Note 1)
SC100
2
APS6-320
-
12.0kW
SC200
-
APS6-321
-
8.6kW (Note 1)
SC200
1
APS6-322
-
8.6kW (Note 1)
SC200
2
APS6-510
8.64kW
12.0kW
SC100
-
APS6-511
8.64kW
12.0kW
SC100
1
APS6-512
8.64kW
12.0kW
SC100
2
APS6-520
8.64kW
12.0kW
SC200
-
APS6-521
8.64kW
12.0kW
SC200
1
APS6-522
8.64kW
12.0kW
SC200
2
APS12-310
-
17.2kW (Note 2)
SC100
-
APS12-311
-
17.2kW (Note 3)
SC100
1
APS12-312
-
17.2kW (Note 3)
SC100
2
APS12-320
-
17.2kW (Note 2)
SC200
-
APS12-321
-
17.2kW (Note 3)
SC200
1
APS12-322
-
17.2kW (Note 3)
SC200
2
Notes
1 Limited by maximum LVD current.
2 Limited by maximum battery MCB ratings.
3 Temperature limited. See Specifications on page 74.

General Description
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3
Access Power Solutions DC Power Systems
APS6 Models Front View
System labels
Rectifier modules (see details on page 7)
SC200 or SC100 system controller (see details on
page 8)
AC Miniature Circuit Breakers (MCBs) (if fitted)
AC MCB cover
DC common bus battery terminals
DC common bus load terminals
Load and battery cable tie rod
DC distribution with:
Up to 16 Load Miniature Circuit Breakers (MCBs).
See Note 1.
Up to 4 Battery Miniature Circuit Breakers (MCBs)
DC distribution cover

Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series)
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APS6 Models Rear View
AC cable entry gland
AC earth conductor connection point (see connection
details on page 26)
I/O Board (see details on page 10)
Voltage Feed Module with connector for optional
SiteSure-3G I/O module
Optional battery disconnect Low Voltage Disconnect
(LVD) (see details on page 12)
Optional (low priority) load disconnect Low Voltage
Disconnect (LVD) (behind side panel) (see details on
page 12)
Up to 16 Load Miniature Circuit Breakers (MCBs).
See Note 1.
Up to 4 Battery Miniature Circuit Breakers (MCBs)
Notes:
1 If a load disconnect LVD is fitted then load MCB positions 1-8 are for low priority loads
and MCB positions 9-16 are for high priority loads. For more details see Low Voltage
Disconnect Option on page 12.
2 Optional 19" rack mount top cover (IPN 621-08917-15) not shown.
3 AC supply cord(s) may be pre-fitted.
4 The diagram shows an APS6-300 model. APS6-500 models have dc inter-shelf connection
cables (from the rectifier shelf to dc distribution) instead of the bars shown.

General Description
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5
APS12 Models Front View
System labels
Rectifier modules, 48V only (see details on page 7)
SC200 or SC100 system controller (see details on
page 8)
AC Miniature Circuit Breakers (MCBs) (if fitted) for
bottom rectifier shelf
AC MCB covers
AC Miniature Circuit Breakers (MCBs) (if fitted) for
top rectifier shelf
DC common bus battery terminals
DC common bus load terminals
Load and battery cable tie rod
DC distribution with:
Up to 16 Load Miniature Circuit Breakers (MCBs).
See Note 1.
Up to 4 Battery Miniature Circuit Breakers (MCBs)
DC distribution cover

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APS12 Models Rear View
AC earth conductor connection point for top and
bottom rectifier shelf (see connection details on page
26)
AC cable entry glands for top and bottom rectifier
shelves
I/O Board (see details on page 10)
Voltage Feed Module with connector for optional
SiteSure-3G I/O module
Optional battery disconnect Low Voltage Disconnect
(LVD) (see details on page 12)
Optional (low priority) load disconnect Low Voltage
Disconnect (LVD) (see details on page 12)
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 loads
and MCB positions 9-16 are for high priority loads. For more details see Low Voltage
Disconnect Option on page 12.
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 for
clarity.

General Description
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7
Rectifiers
Access Power Solutions APS6-500 models can be fitted with either 24V or 48V Access Power
Rectifiers (APR24-3G/APR48-3G/APR48-ES).
Access Power Solutions APS6-300 and APS12-300 models can be fitted with 48V Access Power
Rectifiers (APR48-3G or APR48-ES) only.
All rectifiers are fan-cooled and hot-pluggable.
See Specifications on page 73 for further information.
Left: APR24-3G and APR48-3G
Right: APR48-ES
Power On LED (Green)
Minor Alarm LED (Yellow)
Major Alarm LED (Red)
Serial Number label
Retaining Screw. Tighten to 1.5Nm (13.3
inch-pounds).
See Troubleshooting on page 50 for details of rectifier alarms.

Access Power Solutions Installation and Operation Guide (APS6-300/500 and APS12-300 Series)
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System Controller
The SC200 or SC100 system controller provides control, communications and alarm functions.
The system controller is supplied pre-configured. Configuration changes can be made with the
keypad, or via a PC connected to the USB connector (SC200) or RS232 (SC100) connector. Or
changes can be made remotely (see External Communications on page 12).
For basic operating information see System Controller on page 41. For further details refer to
the System Controller Operation Handbook (see Related Information on page i).
See Troubleshooting on page 50 for details of system controller alarms.
SC200 System Controller
The SC200 system controller is an advanced control and monitoring solution which provides a
full suite of communications options, including built-in Ethernet interface, Web server, and
SNMP agent.
Alarm notifications may be by Email, SNMP traps, SMS text messaging, dial-out to
PowerManagerII remote monitoring software, or relay contact closures.
Power on LED (green)
Minor alarm LED (yellow)
Critical/Major alarm LED (red)
Color LCD
Soft keys (2)
Navigation keys (4)
USB 1.1 connector (12Mb/s)
Retaining screw
Power and system
communications connector
RS232 connector
Ethernet connector and
status LEDs

General Description
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9
SC100 System Controller
The SC100 system controller is a full-featured control and monitoring solution which provides
alarm notifications via dial-out modem to PowerManagerII remote monitoring software, SMS
text messaging, or by relay contact closures.
Power on LED (green)
Minor alarm LED (yellow)
Critical/Major alarm LED (red)
LCD
Navigation keys (4)
RS232 D9M connector
Retaining screw
Power and system
communications connector
Compatible Software
The following software is compatible with the SC200 or SC100 system controller:
DCTools Configuration Software. Latest version is available free from
dcpower.eaton.com/downloads.
PowerManagerII Remote Control and Monitoring Software. Contact your Eaton dc product
supplier for further information (see Worldwide Support on page 107).
Recommended web browsers (SC200 only): Microsoft Internet Explorer 8 or later (IE6 is
compatible but with reduced performance), Mozilla Firefox 3.0 or later.

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Input/Output Board
The input/output (I/O) board provides the I/O interfaces and connections for the SC200 or
SC100 system controller.
The I/O board includes a range of sense inputs for dc power system control and monitoring. It
also allows real time data collection from building services and other external devices, and relay
outputs for alarm signals or control of external devices.
The I/O functions are:
Sensors:
Current - 3, Bus voltage - 1, Temperature - 2, Battery Mid-point - 4
(SC200 only)
Input/Output:
Digital inputs: 4 pre-defined system functions, 6 user-defined
Relay outputs: 6 (one also used as Monitor OK alarm)
LVD contactor outputs: 2
For input and output specifications see details on page 75. For connector pin-outs see details on
page 84.
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
LVD contactor 2 status LED (green)
LVD contactor 2 connector - XH5
LVD contactor 1 status LED (green)
LVD contactor 1 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 (SC200
only) - XH12
DC power system digital inputs (4 pre-defined:
Load Fuse Fail, Battery Fuse Fail, AC Distribution
Fan Fail, AC Distribution MOV Fail) - YH3
See Troubleshooting on page 50 for details of I/O board LED signals.

General Description
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11
Connections
The following diagram shows the connections between the SC200 or SC100, the I/O board, the
other dc power system components and external devices.
SC200 or SC100 system controller
I/O board
Voltage feed module
USB communications (SC200 only)
Ethernet communications (SC200 only)
RS232 communications
Digital relay outputs (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) (SC200 only)
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, AC
Distribution MOV Fail)
Connections for battery mid-points (4)
(SC200 only)
Connection for temperature sensors (2)
Connection for current sensors (3)
Connection for LVD contactor and auxiliary switch
Connection for LVD contactor and auxiliary switch
Bus voltage sense and LVD power connections
I/O and system controller power and RXP comms
connections
For connector pin-outs see details on page 84. For input and output specifications see details on
page 73.

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Other Features
External communications
Refer to the system controller handbook for information on these communications options.
Communications options
SC200
SC100
Communication with DCTools via USB

-
Communication with DCTools or PowerManagerII via RS232


Communication with DCTools or PowerManagerII via
an external PSTN or GSM modem (dial-in and dial-out on alarm)


Communication with DCTools or PowerManagerII via Ethernet

-
Communication with web browser software via an IP network

-
Communication with a Network Management System (NMS) using
SNMP

-
Communication with a Building Management System (BMS) using
Modbus

-
Alarm and status messages to GSM Short Messaging Service (SMS)
text capable cell phones


Communication with an alarm management system using
voltage-free relay contacts (on an IOBGP I/O board)


Low Voltage Disconnect Options
Single or dual optional Low Voltage Disconnects (LVD) are available for the Access Power
Solutions (APS6-300/500 and APS12-300 Series). See the diagram on page 4(APS6 models) or
diagram on page 6(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 see Low Voltage Disconnect (LVD) in the System Controller
Operation Handbook.
The maximum output current of APS6-300 and APS12-300 models with the LVD option is
limited. See System Output.