Manual Aps SR Ur

Data-Voice-Video Power
Solutions
Installation Guide
(APR-3G Rectifiers)
Issue: IPN 997-00012-46C

Issue Date: December 2006
Eaton Corporation
Telecommunications Solutions Division
www.powerware.com
DC.info@eaton.com
Eaton Corporation disclaims any liability for direct, indirect, incidental, special or
consequential damages arising out of the application or use of any information
contained in this document. The foregoing disclaimer applies to damages or personal
injury, property damage, loss of operation, loss of profits, loss of product or loss of time,
whether incurred by the purchaser, the purchaser’s employees or third party.
Information in this document does not constitute a warranty, representation or
guarantee concerning the suitability or performance of Powerware products. No such
warranty, representation or guarantee is expressed or implied.
Information contained in this document is subject to change without further notice.
Eaton, Powerware, Intergy, CellSure, SiteSure, PowerManagerII and DCTools are trade
names, trademarks, and/or service marks of Eaton Power Quality Corporation or its
subsidiaries and affiliates. Unless otherwise noted, brands, product names, trademarks
or registered trademarks are the property of their respective holders.
Subject to the right to use its equipment, Eaton Corporation does not convey any right,
title or interest in its intellectual property, including, without limitation, its patents,
copyrights and know-how.
No part of this document may be reproduced or transmitted in any form, by any means
or for any purpose other than the Purchaser’s personal use, without the express written
permission of Eaton Corporation.
Copyright © 2005-2006 Eaton Corporation. All Rights Reserved.
About This Guide
4
About This Guide
Purpose
This guide provides instructions to correctly install, commission and operate Powerware
Data-Voice-Video Power Solutions (APR-3G Rectifiers).
Audience
This guide is intended for use by:
• DC power system installers competent in:
• installing and commissioning DC Power Systems
• safe working practices for AC and DC powered equipment
• the relevant local electrical safety regulations and wiring standards
• DC power system operators and maintenance staff competent in:
• operation of DC Power Systems
• safe working practices for AC and DC powered equipment
Scope
This guide covers installation, commissioning and maintenance of Powerware Data-Voice-
Video Power Solutions.
It does not cover:

• Supervisory module operations; installation of external alarm and user digital inputs
cabling; or setup of communications options or software. For details refer to the relevant
supervisory module handbook listed under Related Information on page i.
• Installation and configuration of Powerware SiteSure and CellSure modules. For details,
refer to the relevant guide listed under Related Information on page i.
Related Information
• PowerManagerII Online Help
• DCTools Online Help
• Planning Guide – IPN 997-00012-15
• Powerware SM60 Supervisory Module Handbook – IPN 997-00012-27
• Powerware SM65 Supervisory Module Handbook – IPN 997-00012-35
• SiteSure Installation and Configuration Guide – IPN 997-00012-19
• CellSure Installation Guide – IPN 997-00012-20

IPN 997-00012-46C December 2006
i
3G Data-Voice-Video Power Solutions Installation Guide
Reporting Problems with this Guide

Please use this fax or email address to report any problems you find in this guide:
Powerware DC Product Marketing Communications

FAX: ++64 3 343 5660
EMAIL: DCMarketingNZ@eaton.com
For Further Information and Technical Assistance

For Further Information and Technical Assistance see Worldwide Support on page 57.

ii IPN 997-00012-46C December 2006
Table of Contents
4
Table of Contents
About This Guide

Purpose .......................................................................................................................................i
Audience .....................................................................................................................................i
Scope............................................................................................................................................i
Related Information...................................................................................................................i
Reporting Problems with this Guide .....................................................................................ii
For Further Information and Technical Assistance..............................................................ii
Chapter 1 General Description
Overview.................................................................................................................................... 1
Typical Data-Voice-Video Power Solutions DC Power Systems ....................................... 2
Access Power Rectifiers (AP24-3G/APR48-3G) ................................................................... 3
Supervisory Module Keypad and Display (if fitted) ........................................................... 4
Other Features........................................................................................................................... 5
External communications............................................................................................................... 5
External current shunts/sensors option....................................................................................... 5
Low Voltage Disconnect (LVD) option ........................................................................................ 6
Chapter 2 Preparation
Overview.................................................................................................................................... 7
Warnings.................................................................................................................................... 8
Inspecting the Equipment and Reporting Damage............................................................ 10
Chapter 3 Installation
Overview.................................................................................................................................. 11
Mounting the Powerware Data-Voice-Video Power Solutions........................................ 12
Input Transient Protection..................................................................................................... 13
High AC Voltage Protection.................................................................................................. 16
Connecting to the AC Supply ............................................................................................... 17
AC discrimination ......................................................................................................................... 17
Terminating the AC Supply Cable ....................................................................................... 18
Systems without integrated batteries ......................................................................................... 20
Connecting the DC Output to Earth .................................................................................... 23
DC earth connection...................................................................................................................... 23
AC-DC earth link........................................................................................................................... 23
Connecting the DC Load and Battery Cables ..................................................................... 24
Connecting to External Current Sensors/Shunts (if required)......................................... 25
Installing the Batteries............................................................................................................ 26
Mounting the Battery Temperature Sensor......................................................................... 27
Installing External Alarm and Digital Inputs Cabling ...................................................... 27
Chapter 4 Commissioning
Overview.................................................................................................................................. 29
Inserting Rectifiers.................................................................................................................. 30
Pre-Power-Up Checklist ........................................................................................................ 31
Applying AC Power............................................................................................................... 32
Configuring the DC Power System ......................................................................................32
Using DCTools to configure the system..................................................................................... 33
Using the Supervisory Module Keypad to Configure the System.......................................... 35
Testing Alarms at a Remote Location .................................................................................. 35
Applying DC Power to the Load .......................................................................................... 36

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iii
Chapter 5 Maintenance
Overview ................................................................................................................................. 37
Troubleshooting...................................................................................................................... 38
Replacing a Rectifier............................................................................................................... 41
Monitoring and Replacing Transient Protective Devices ................................................. 42
Replacing the Supervisory Module...................................................................................... 43
Battery Disposal and Recycling............................................................................................ 43
Appendix A Specifications
Appendix B System Components
Low Voltage Disconnect (LVD) Option .............................................................................. 47
LVD control by LVDCS controllers ............................................................................................ 47
LVD selector switch and status LEDs......................................................................................... 48
External Current Sensors....................................................................................................... 48
CS04-A11 current sensor .............................................................................................................. 48
Equipment Incident Report
Worldwide Support

iv IPN 997-00012-46C December 2006
Chapter 1
General Description
4
C h a p t e r 1
General Description
Overview
Topic Page
Typical Data-Voice-Video Power Solutions DC Power Systems 2
Access Power Rectifiers (AP24-3G/APR48-3G) 3
Supervisory Module Keypad and Display (if fitted) 4
Other Features 5

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1
Typical Data-Voice-Video Power Solutions DC Power Systems
2
2

Typical system Typical system with Additional battery

(rectifiers only) integrated batteries rack (option)
"Combined AC* and DC distribution section

#Supervisory module display. See details on page 4. (For more details of the supervisory module refer to the relevant
supervisory module handbook listed under Related Information on page i.)
$Rectifier magazine(s)* for up to 10 Access Power Rectifiers (APR24-3G, APR48-3G) per magazine. See details of rectifiers
on page 3.
%Battery shelves with battery MCBs. (A battery shelf front cover is also supplied, but is not shown.)
!An optional security door (not shown) is also available.
These diagrams show typical layouts of 43U high racks. 26U high racks are also available.
Actual system configuration may vary from that shown.
* In some system configurations the AC distribution module may be installed in place of the top
rectifier magazine.

2 IPN 997-00012-46C December 2006
General Description
Access Power Rectifiers (AP24-3G/APR48-3G)

Powerware Data-Voice-Video Power Solutions can be fitted with either 24V or 48V APR-3G
Access Power Rectifiers (APR24-3G/APR48-3G). All rectifiers are fan-cooled and hot-
pluggable.
See Specifications on page 45 for further information.
"Power On LED (Green)

#Non-Urgent Alarm LED (Yellow)
$Urgent Alarm LED (Red)
%Retaining Screw
See Troubleshooting on page 38 for details of rectifier alarms.

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3
Supervisory Module Keypad and Display (if fitted)
"Backlit LCD Display

#Keypad
$Power On LED (green) – indicates that the ??? SM VARIABLE NOT SET ??? is powered
%Non-urgent Alarm LED (yellow) – indicates one or more active Non-urgent alarms
!Urgent/Critical Alarm LED (red) – indicates one or more active Urgent/Critical alarms
7 Scroll: Press to scroll through lists and menus and to increase or decrease
configuration file values.
6
: Information: Press to view status messages and a list of active alarms in Status View
Mode.
8 Enter: Press to go to Configuration Mode and Edit Mode, save configuration file
changes, clear alarms or toggle relay states.
9 Escape: Press to go to Main Display Mode or cancel configuration file changes.
For operation of the supervisory module refer to the supervisory module handbook. See Related
Information on page i.

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General Description
Other Features
External communications
Powerware Data-Voice-Video Power Solutions have a number of methods of external
communication depending on the model of supervisory module fitted.
External Communications Supervisory Module
SM60 SM65
Communication with Powerware DCTools or PowerManagerII
software on a PC or Laptop via a serial cable.
Communication with Powerware DCTools or PowerManagerII
software on a PC or Laptop via an external PSTN or GSM modem. (Note 1)
Communication with Powerware DCTools or PowerManagerII -

software on a PC or Laptop via an Ethernet comms link.
Communication with any web browser software on a PC or -
Laptop via an Ethernet comms link. (Note 2)
Communication with a Network Management System (NMS) -

using SNMP.
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.
Notes:
1 Dial-in (all version SM65) and Dial-out on Alarm (SM65 v4 or later).
2 Status view only.
Refer to the supervisory module handbook for detailed information on communications

options and set-up.
External current shunts/sensors option

Various models of external current shunts are available for use with the Powerware Data-
Voice-Video Power Solutions to measure battery and/or load currents. The Powerware
CS04-A11 current sensor is also available to measure currents in larger systems. See details
on page 48.
External current shunts/sensors are connected to the supervisory module either directly
(depending on the number of internal current shunts/sensors fitted) or through a Powerware
SiteSure module.

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5
Low Voltage Disconnect (LVD) option

Powerware Data-Voice-Video Power Solutions may be fitted with one or more Low Voltage
Disconnects (LVDs). Powerware LVDs can be connected either as load or battery disconnect
and have two purposes:
• to protect a VRLA battery from deep discharge and premature failure, and/or
• to reduce the load on a battery under discharge so that high priority equipment operates
for a longer time after an AC failure.
The supervisory module has two independent LVD control channels (LVD1 and LVD2.)
These can be set to disconnect at specified voltages or can be set to disconnect a specified
time interval after an AC fail. Both channels reconnect the battery or load equipment when
the AC supply is restored.
For further information refer to LVD options on page 47.
Refer to the supervisory module handbook for information on how to configure the LVD
channels.

6 IPN 997-00012-46C December 2006
Chapter 2
Preparation
4
C h a p t e r 2
Preparation
Overview
Topic Page
Warnings 8
Inspecting the Equipment and Reporting Damage 10

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7
Warnings
This section contains important warnings. Read these warnings before installing or operating
a Powerware Data-Voice-Video Power Solutions DC power system.
Electrical Safety
• The DC earth/ground link must be rated to carry the combined fault current of battery strings.
See details on page 23.
• If the DC power system is to be installed in a location where the ambient temperature may rise
above 50ºC (122ºF), then V110 rated cable must be used for all connections.
• The DC power system is not compatible with IT (Impedance Terra) AC power distribution
topologies. For advice refer to Worldwide Support on page 57.
• A registered electrician (or suitably qualified person) must check the integrity of the installed
cabling, BEFORE the DC power system is powered up.
• Commissioning must be performed in the sequence documented in this guide.
Location and Environment

• For ease of access and to maintain optimum system cooling observe the clearances stated on
page 12.
• Dust build-up within the DC power system may cause premature failure. In dusty environments
filter the ventilation air entering the equipment room. Ensure regular cleaning of the air filters.
• Do not allow water or any foreign object to enter the DC power system. Do not place objects
containing liquid on top of or near the unit.
• Flooded cell and VRLA lead acid batteries can emit explosive gases and must be installed with
adequate ventilation. Refer to the battery manufacturer or supplier for advice on minimum
ventilation levels.
Reverse Polarity
• Always check that the battery cables have been terminated to the correct system polarity
BEFORE connecting the batteries or closing the battery disconnect device. Connecting batteries
to the DC power system with incorrect system polarity will void all warranty claims.
Hazardous Energy Levels

• Rectifiers and batteries contain hazardous energy levels. Only personnel trained and
experienced in DC power systems are to service this equipment.
• Always use insulated tools.
• Do not short-circuit the live and common bus bars or cables.

8 IPN 997-00012-46C December 2006
Preparation
Batteries
• The plastic cases of batteries installed in Powerware 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 a Powerware DC power system rack.
• Flooded cell and VRLA lead acid batteries can emit explosive gases and must be installed with
adequate ventilation. Refer to the battery manufacturer or supplier for advice on minimum
ventilation levels.
• Do not wear a synthetic dust-coat or overalls. Synthetic fabrics can hold static electric charge that
create sparks during discharge.
• Remove rings, wristwatch and other metal jewelry that might be exposed to battery terminals,
before installing batteries.
• Batteries are powerful sources of energy and present a potential electrical shock and energy
hazard. The energy hazard is always present, even if the batteries are not connected. Avoid short
circuiting terminals of opposite polarity.
• Do not place tools, loose cables or metal objects (such as interconnecting bars) on top of batteries.
• Do not drop tools, loose cables or metal objects onto intercell connections or terminals of
opposite polarity.
• Only terminate cables and interconnecting bars after confirming that the termination will not
create a short circuit.
• Always tighten battery terminal bolts according to the battery manufacturer’s specification.
Failing to do so can cause erratic battery performance, possible damage to the battery, and/or
personal injury.
• There is a risk of electric shock if a battery is replaced by an incorrect type.
• Dispose of batteries according to the instructions.
Rectifiers
•
•
Do not install the rectifiers until the room has been cleaned and is dust free.
To reduce the risk of electric shock and maintain optimum system cooling, always cover empty
rectifier slots with blanking panels.
• To avoid electrical shock, do not place hands inside the rectifier magazine.
• Rectifier cases may exceed 100ºC (212ºF), especially after prolonged operation. Use suitable
gloves when removing a rectifier from the magazine.
• Do not attempt to disassemble faulty rectifiers. Return them (in their original packaging) with a
copy of the Equipment Incident Report on page 55.
• Ensure that any upstream Residual Current Devices (RCDs) are appropriately rated for the
rectifiers' maximum earth leakage current (see Specifications on page 45 for value).
DC Distribution(s)
• The DC Common of the DC power system can be connected to earth (ground). If this connection
is made all of the following conditions must be met:
• Your equipment and the DC power system must be located within the same premises.
• No switching or disconnecting devices are allowed in the conductor between the DC
common line and the point of connection to the earth electrode conductor.
Refer to Connecting the DC Output to Earth on page 23 for further information.
Servicing
• The DC power system contains hazardous voltages. Do not attempt to disassemble or service
the unit if you are not qualified.

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9
EMC Compliance
• Powerware Data-Voice-Video Power Solutions DC power systems may be used in close
proximity to other electronic equipment, provided installation is carried out according to
instructions in this guide. However, proper installation and compliance with EMC standards
does not guarantee that the DC power system 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 in which case the user may
be required to take adequate measures.
• Changes or modifications to the DC power system not approved by Eaton Corporation could
void Federal Communications Commission (FCC) authority to operate that equipment.
• This equipment generates, uses, and can radiate radio frequency energy and, if not installed and
used in accordance with the instructions, may cause harmful interference to radio
communications. However, there is no guarantee that the interference will not occur in a
particular installation. If this equipment does cause harmful interference to radio or television
reception, which can be determined by turning the equipment off and on, the user is encouraged
to try to correct the interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver is
connected.
• Consult the dealer or an experienced radio/TV technician for help.
Inspecting the Equipment and Reporting Damage

Unpack the equipment and inspect it carefully for possible damage that may have occurred
while in transit.
Report any damage immediately, using a copy of the Equipment Incident Report on page 55.
Keep the original packaging and use it if any equipment needs to be returned for replacement or
repair.

10 IPN 997-00012-46C December 2006
Chapter 3
Installation
4
C h a p t e r 3
Installation
Overview
Topic Page
Mounting the Powerware Data-Voice-Video Power Solutions 12
Input Transient Protection 13
High AC Voltage Protection 16
Connecting to the AC Supply 17
Terminating the AC Supply Cable 18
Connecting the DC Output to Earth 23
Connecting the DC Load and Battery Cables 24
Connecting to External Current Sensors/Shunts (if required) 25
Installing the Batteries 26
Mounting the Battery Temperature Sensor 27
Installing External Alarm and Digital Inputs Cabling 27

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11
Mounting the Powerware Data-Voice-Video Power Solutions

• The DC power system must be installed in a location classified as ‘Restricted
•
Access’. A key or tool is required to gain access to the power system. A sign must
also be displayed, warning that the power system metalwork may be hot.
The rack of the DC power system must meet the fire and electrical enclosure
requirements specified in AS/NZS 60950.1, EN 60950-1, IEC 60950-1 and UL
60950-1. To maintain compliance with these requirements, all covers must be fitted
(including the bottom cover plate, if bottom cable access is not required.)
• Lifting equipment and at least two people are required to safely move the DC
power system. Without lifting equipment four people are required to move the
power system safely.
Apart from the rectifiers and batteries, Powerware Data-Voice-Video Power Solutions are
always supplied completely assembled. Rectifiers and batteries are always shipped
separately.
Clearance Requirements
The following minimum clearances are required:
• Front Clearance – 600mm (24“) from walls and other equipment required for access.
• Top Clearance – 200mm (8“) from ceilings or overhead cable trays/ducting, required for
optimum system cooling.
• Single Side or Back Clearance – 600mm (24“) from walls and other equipment
recommended to assist access.
• Back Clearance – 600mm (24“) from walls if the vented back panel is fitted.
Unpacking the Power System

1 Before you start unpacking the DC power system, ensure that:
• The site has been thoroughly cleaned and is dust free. (It is strongly recommended
that you do NOT unpack the power system until all building work at the site has
been completed. If building work is still in progress, store the power system in its
original packaging in a dry and level location inside the building.)
• Lifting equipment and at least two people are available. (Without lifting equipment
four people are required to move the power system safely.)
2 Once the site is clean and dust free, remove the packaging from the power system and
stand the rack upright.
3 Carefully inspect the power system for possible damage that may have occurred while
in transit. Report any damage immediately, using a copy of the Equipment Incident
Report on page 55.

12 IPN 997-00012-46C December 2006
Installation
Mounting
1 Before moving the power system into position, ensure that:
• Extra under floor support is in place, if required.
• The plastic dust cover is fitted and sealed to prevent dust and metal shavings from
entering the power system during drilling.
2 Move and align the rack and check the required clearance distances (see previous
section).
3 Drill the mounting holes and bolt down the rack.
4 Remove the plastic dust cover and vacuum clean around the rack to remove any metal
shavings and dust.
Input Transient Protection

To prevent damage to Powerware Data-Voice-Video Power Solutions from lightning and
transient over-voltages, structural lightning protection and transient protection must be
installed at each site.
Transient protection will also protect against other sources of transients, such as:
• Circuit or grid switching by the power company
• Electrical switching of large inductive loads (such as motors, transformers, and electrical
drives) or capacitive loads (such as power factor correction) or manufacturing
equipment.
Use a suitably qualified consultant to develop a transient protection plan (compliant with
IEC 61643-12) for the equipment to be installed at the site. The transient protection plan and
associated installation must:
1 Capture the lightning strike at a known and preferred point outside the building
2 Conduct the main lightning energy safely to earth
3 Dissipate the lightning energy into a low impedance earthing system
4 Eliminate earth potential differences inside the building
5 Protect the AC supply using a coordinated transient voltage 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 control lines using a coordinated transient voltage surge
suppression plan

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13
Earthing (Grounding)
The most important aspect of any power system installation at a site is the integrity of the
earthing systems. Effective earthing will significantly increase site protection. Most sites have
a number of earthing systems such as:
• AC Power earth
• DC Power earth
• Tower / building lightning protection earth
For optimum protection, all earths must be brought together at one "star" point. Otherwise,
surge currents can flow within the system creating large voltages. These can cause damage to
equipment that does not normally require surge protection, such as rectifier outputs and
communications interfaces.
If there is a tower on the site then use the tower earth as the "star" point. This is because it
conducts the majority of the surge to earth, especially if the site is lightning-prone. For other
sites, a 'direct-lightning' earth will not be available therefore a structural or power system
earth will be used. In multi-floor buildings, always try to use structural earths if the common
earth point cannot be found at ground level. For basements / single floor buildings, the AC
power earth is usually the most appropriate.
Primary Transient Protection

Primary transient protection must be considered at all sites. If fitted, primary transient
protection must be installed on the incoming AC supply either at the main AC switchboard
or sub-switchboard.
In the absence of sufficient information, primary transient protective devices with a
minimum repeat strike rating of 100kA (8/20μs wave shape) are recommended.
In addition, primary transient protection must be coordinated with downstream 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
specified, then air-core 15μH surge decoupling coils should be suitable.
Secondary Transient Protection

Secondary transient protection (downstream from the primary transient protection) must be
present at all sites to protect the DC power system from transients.
Some models of Powerware Data-Voice-Video Power Solutions are factory-fitted with
secondary transient protection. These will protect the power system from a limited number
of repeated 15kA transients (8/20µs wave shape).
Factory-fitted secondary transient protection typically co
• Phase-to-neutral metal oxide varistors (MOVs) with a voltage rating of 385V, capable of
withstanding temporary over-voltages
• A neutral-to-earth spark gap (gas discharge tube)
• Surge decoupling coils
If secondary transient protection is not fitted inside the Powerware Data-Voice-Video Power
Solutions, then external secondary transient protection must be installed in the AC
switchboard that supplies the DC power system.
Carefully consider the residual voltage seen by the DC power system (maximum 6kV) and
the decoupling between the transient protection system and the DC power system.
Transients must be limited to less than 2kA.

14 IPN 997-00012-46C December 2006
Installation
Tertiary Transient Protection

Powerware rectifiers are fitted with low-level transient protection. This is designed to protect
the rectifiers from voltage spikes generated during operation of the upstream transient
protection system. Do not install rectifiers without adequate upstream surge protection.
Installation
Install the transient protection according to the following diagram.
"Supply transformer 3Primary/secondary surge decoupling (Spark gap (neutral-earth)

coils (4, refer to text for rating)
#Building entrance )Switchboard earth/ground busbar
4AC sub-switchboard or DC power
$Main switchboard system *Rectifiers
%Fuses 5Secondary transient protection
!Primary transient protection (refer to 'MOVs (3, phase-neutral, refer to text
text for rating) for rating)
&Building earth/ground busbar

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15
Transient protective devices are fitted with alarm contacts and visual indicators. Monitor the
status of all externally installed transient protective devices either by:
• Connection of the alarm contacts to one of the Digital Inputs on the supervisory module
(preferred option) or to the building management system. Refer to the supervisory
module handbook for details of Digital Inputs.
• Regular inspection of the visual indicators
The alarm signal lines of the external transient protective devices must be isolated from the
AC supply (by voltage-free relay contacts) before connecting these signal lines to the
supervisory module.
For information on monitoring and replacing MOVs see details on page 42.
High AC Voltage Protection

If the AC voltage is expected to exceed 275V (L-N), then it is strongly recommended that an
external high voltage protection unit (HVPU) be installed. This will automatically disconnect
the AC at high voltage and reconnect it at normal voltage.
Install the HVPU as in the following diagram. Monitor the status of the HVPU by connecting
the High VAC alarm output to one of the Digital Inputs on the supervisory module. (Refer to
the supervisory module handbook for details of Digital Inputs.)
The High VAC alarm signal lines must be isolated from the AC supply (by a voltage-free relay
contact) before connecting these signal lines to the supervisory module.
"AC supply !Secondary transient protection devices (MOVs)

#Primary transient protection devices &Supervisory module
$High voltage protection unit 3Rectifiers
%DC power system

16 IPN 997-00012-46C December 2006
Installation
Connecting to the AC Supply

• Ensure that any upstream Residual Current Devices (RCDs) are appropriately
•
rated for the rectifiers' maximum earth leakage current (see Specifications on page
45 for value).
If the DC power system is to be installed in a location where the ambient
temperature may rise above 50ºC (122ºF), then V110 rated cable must be used for
all connections.
• There must be adequate discrimination between the rectifier internal fuses, the
MCBs in the AC distribution of the DC Power System and the upstream AC
supply-disconnect devices. Failure to do this may result in the loss of AC power
to all rectifiers if a fault occurs in one rectifier. Refer to AC Discrimination for
more information.
• Only use a three-phase (Δ) AC power source that is referenced to earth, or has a
protection system in place to prevent the phase-earth voltage exceeding the rating
of the rectifier.
AC Installation Practices
Read the following AC installation practices before connecting the AC supply:
• Ensure that each cable entry gland provides firm strain relief and adequate anchorage
for each AC supply cable.
• Prevent excessive strain on the AC wiring and terminal connections.
• Terminate the AC supply cable at the DC power system before terminating the AC
supply cable at the main AC switchboard or sub switchboard of the building.
• Label the main AC switchboard or sub switchboard.
• When all AC supply cabling is in place and terminated, perform electrical insulation and
continuity tests. Remove the MOVs if high AC voltages are used as part of these tests.
AC discrimination
Each rectifier has two internal fast-acting fuses. Under certain internal fault conditions these
fuses will blow.
If there is insufficient discrimination between these fuses and any upstream AC
supply-disconnect device then the upstream AC supply-disconnect device will operate
before a rectifier fuse blows. This will disconnect the AC supply to all rectifiers.
The average time-current curve of the rectifier internal fuses is shown by the following data.
To ensure there is adequate discrimination, the time-current curve of the upstream AC
supply-disconnect device must be entirely outside (to the right of) the curve.
Rated Current 24A 33.6A 44A 44A 64A 64A 160A

min. max. min. max. min. max. max.
Pre-Arcing time 15 min 30 min 40 ms 20 s 10 ms 1s 30 ms
Source: Schurter SP 5x20
The minimum recommended ratings of upstream AC supply-disconnect devices is 40A D-

curve or 63A C-curve.

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17
Terminating the AC Supply Cable

The AC distribution will be configured for connection to one of the following types of AC
supply:
• 1-phase + neutral + protective earth
• 2-phase + protective earth
• 3-phase + neutral + protective earth
• 3-phase + protective earth
The meanings of the labels on the terminals in the AC distribution are:
AC Distribution Description
Terminal Label
L Live/Phase/Active of a single-phase system
L1 Phase 1 of a 2-phase or 3-phase system
L2 Phase 2 of a 2-phase or 3-phase system
L3 Phase 3 of a 3-phase system
N Neutral
E (Note 4) Protective Earth/Ground
Notes:
1 Refer to the warnings and AC installation practices on page 17.
2 All phase cable connection lugs must be insulated with heat shrink wrap.
3 Cable-tie all phase conductors close to their terminations. This prevents the bare end of a
conductor from touching metal parts, if it becomes loose.
4 The AC Distribution earth terminal is also used to reference the DC output to AC
earth/ground for surge protection. A factory-installed AC-DC earth link is connected to
this point for this purpose. See details on page 23.
Position of AC distribution
The AC supply cable is terminated at the AC distribution module. The position of the AC
distribution module depends on the system type and configuration. It is located either above
the rectifier magazines or behind the door covering the AC/DC distribution space.
Systems with integrated batteries

In Data-Voice-Video Power Solutions with integrated batteries connect the AC supply cables
to the AC distribution as outlined in this section.
For systems without integrated batteries refer to details on page 20.

18 IPN 997-00012-46C December 2006
Installation

E N L1 L2 L3 E L1 L2 L3
2 2
Typical arrangement Typical arrangement
with Neutral without Neutral
"Earth cable to rack earth stud.

#Phase and Neutral (if fitted) cables.
$AC isolator switch (1, 2 or 3-phase as required). May be fitted next to MOVs depending on model.
%Rectifier or magazine MCBs (arrangement depends on model)
!Surge protection MOVs (2, 3 or 4 as required).
&Rack earth stud (located behind the isolator switch)
Other cables not shown for clarity.
Step 1 - Access AC Distribution
1 Open AC/DC distribution space door.

2 Switch the AC isolator to the OFF position.
3 Undo the four screws securing the perspex cover and remove the cover.
Step 2 - Fit a suitable size crimp lug to the AC earth cable

IPN 997-00012-46C December 2006
19
Step 3 - Fit and terminate AC cables
If necessary, remove the back and/or side cabinet panel to route the cables to
the AC Distribution.
1 Route the AC earth cable to the rack earth stud (located behind the
isolator switch) and terminate.
2 Route the AC phase and neutral (if fitted) cables to the AC Distribution.
3 Terminate the phase cable(s) on the isolator switch.
4 If fitted, terminate the neutral cable on the neutral connector.
5 Secure all cables with cable ties.
Cable-tie all phase conductors close to their terminations. This prevents

the bare end of a conductor from touching metal parts, if it becomes loose.
Step 4 - Check terminations and test insulation
1 Check all terminations are correct and are tightened.

2 Test the insulation resistance of the cables according to local AC wiring
regulations..
Step 5 - Replace cover and close AC/DC distribution space door
1 Replace the perspex cover.

2 Ensure the AC isolator switch is in the OFF position.
3 Close the AC/DC distribution space door.
Procedure complete
Systems without integrated batteries

In Data-Voice-Video Power Solutions without integrated batteries connect the AC supply
cables to the AC distribution as outlined in this section.
For systems with integrated batteries refer to details on page 18.

20 IPN 997-00012-46C December 2006
Installation

2
"AC isolator switch (shaft not shown) !Rectifier MCBs (3 only shown)
#Neutral bar termination (if fitted) &Surge protection MOVs
$AC cable entry glands 3MOV MCB (located next to rectifier MCBs in some
models)
%Isolator switch terminals
Step 1 - Remove AC Distribution front cover and isolator switch handle
1 Switch the isolator to the OFF position.

2 Undo the four screws holding the front panel.
3 Remove the front cover and isolator switch handle.
Step 2 - Remove top cover
1 Undo the two screws holding the top cover.

2 Remove the top cover.

IPN 997-00012-46C December 2006
21
Step 3 - Route AC cables and fit crimp lugs
If necessary, remove the back and/or side cabinet panel to route the cables and
access the back of the AC Distribution.
1 Route the AC earth cable to the earth stud on the back of the AC
Distribution.
2 Route the AC phase and neutral (if fitted) cables through the AC cable
entry glands in the back of the AC Distribution.
3 Fit suitable size crimp lugs to the AC cables.
4 Insulate all phase cable lugs with heat shrink wrap.
Step 4 - Terminate AC cables
1 Terminate the earth cable on the earth stud.

2 Terminate the phase cables on the isolator switch.
3 If fitted, terminate the neutral cable on the neutral bar.
Re-fit the cardboard shield around the neutral bar.

4 Secure all cables with cable ties.
Cable-tie all phase conductors close to their terminations. This prevents

the bare end of a conductor from touching metal parts, if it becomes loose.
Step 5 - Check terminations and test insulation
1 Check all terminations are correct and all bolts are tightened.
2 Test the insulation resistance of the cables according to local AC wiring
regulations..
Step 6 - Replace top cover
Step 7 - Replace AC Distribution front cover and isolator switch handle
Ensure the isolator switch handle is in the OFF position.
Procedure complete

22 IPN 997-00012-46C December 2006
Installation
Connecting the DC Output to Earth
DC earth connection
Install a separate conductor connected from the DC common busbar to earth. This conductor
must be rated to carry the combined fault current of 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 small for such currents.
AC-DC earth link

The earthing arrangement of your communications equipment determines how you
reference the DC Common to earth. There are two options.
Retaining the Factory-installed AC-DC Earth Link

If your installation uses a mesh earth, we recommend retaining factory installed earth link as
shown in the following diagram.
"Factory installed AC-DC Earth Link

#Mesh earth (ground)
$DC Common
Installing a Surge Protection Device between AC and DC Earth

If your policy is not to bond the AC and communications earth, a surge protection device
must be installed as shown in the following diagram.
"Transient earth clamp surge protection device

#AC earth (ground)
$DC earth (ground) / communications earth
%DC Common
The transient protective device bonds the AC and communications earth during transient
activity to prevent damage to the rectifiers. The preferred transient protective device is a
transient earth clamp (TEC).

IPN 997-00012-46C December 2006
23
Connecting the DC Load and Battery Cables

A wide range of DC distribution modules is available for Powerware Data-Voice-Video
Power Solutions with MCBs or fuses or a combination of both.
DC Installation Practices
Read the following DC Installation Practices before connecting the DC load and battery
cables:
• To avoid excessive voltage drop and overheating, ensure that the DC load and battery
cables are appropriately sized to handle the maximum DC output current of the specific
NPS. We recommend multi-strand cable with insulation rating of 600-1000V.
• Run the DC load and battery cables through cable glands where they pass through metal
parts or covers. Also ensure that each cable gland provides firm strain relief and
adequate anchorage for the cable.
• Secure and support all DC load and battery cabling inside the NPS (especially at their
connection points) to prevent excessive strain on these cables.
• To reduce inductive coupling, separate DC load, battery and control cabling from AC
supply cables. If the cables have to cross, run them at right angles to the AC supply
cables.
• In order to minimize parasitic cable inductance and reduce electromagnetic interference
(EMI), route all DC load cables in close proximity to one another, and avoid large
current loops. The same applies to battery cables.
• Ensure that MCBs/fuses in the DC distribution(s) are clearly labeled.
• Only perform electrical insulation and continuity tests, once all DC load and battery
cabling are in place and DC Common has been earthed.
DC Distributions with MCBs (if fitted)

Before you start, switch off all load and battery MCBs.
"Terminate the load (LIVE)

cable(s) at the load MCB(s).
#Terminate the battery

(LIVE) cable(s) at the
battery MCB(s).
$Ensure that the fuse fail

detection wires are properly
terminated as shown.
In systems with
integrated batteries
the battery MCBs are
mounted individually
at the battery shelves.
Load MCBs Battery MCBs

24 IPN 997-00012-46C December 2006
Installation
DC Distributions with Fuses (if fitted)

Before you start, remove all load and battery fuses.
Load fuses Battery Fuses
"Terminate the load (LIVE) cable(s) at the load fuse(s).

#Terminate the battery (LIVE) cable(s) at the battery fuse(s).
$Ensure that the fuse fail detection wires are properly terminated as shown.
%Battery fuses are fitted with a Battery fuse fail detection board. When replacing a fuse ensure that the board
is removed from the blown fuse and re-fitted to a new striker type fuse.
Connecting to External Current Sensors/Shunts (if required)

External current shunts/sensors are connected to the supervisory module either directly
(depending on the number of internal current shunts/sensors fitted) or through a Powerware
SiteSure module.
Refer to External Current Shunts/Sensors on page 48 for further installation information.
Refer to the supervisory module handbook for details of connection of external current
shunts/sensors. See Related Information on page i.
Refer to the SiteSure Installation and Configuration Guide for information on installing
SiteSure modules. See Related Information on page i.

IPN 997-00012-46C December 2006
25
Installing the Batteries

• Always check that the battery cables have been terminated to the correct system
•
polarity BEFORE connecting the batteries or closing the battery disconnect device.
Connecting batteries to the system with incorrect system polarity will void all
warranty claims.
Because of the wide range of battery types and sizes available, battery installation in not
included in this guide. Always install batteries according to the battery manufacturer’s
instructions.
The following are our recommended Battery Installation Practices. These supplement the
specific installation instructions of the relevant battery manufacturer.
Battery Installation Practices
General
• Do not wear a synthetic dust-coat or overalls. Synthetic fabrics can hold a static electric
charge, creating sparks during discharge.
• Remove rings, wristwatch and other metal jewelry that might be exposed to battery
terminals, before installing batteries.
• Only use a clean soft damp cloth for cleaning the batteries. Do not use cleaning
detergents or chemicals.
• Flooded cell and VRLA lead acid batteries can emit explosive gases and must be
installed with adequate ventilation. Refer to the battery manufacturer or supplier for
advice on minimum ventilation levels.
• Ensure that the battery shelves are disconnected from the DC power system, by
switching off all battery MCBs or removing all battery fuses.
Unpacking and Inspecting the Batteries

• Unpack the batteries and inspect them carefully for leaks, corrosion and possible
damage. Report any damage or other battery related problems immediately to the
battery supplier.
• Do not remove the factory-fitted transit insulation covers from the batteries until access
to the battery terminals is required.

26 IPN 997-00012-46C December 2006
Installation
Interconnecting the Batteries

• Only terminate battery cables and interconnecting bars after confirming that the
termination will not create a short circuit.
• Always tighten battery terminal bolts according to the battery manufacturer’s
specification. Failing to do so can cause erratic battery performance, possible damage to
the batteries, and/or personal injury.
• Do not place tools, loose cables, or metal objects (such as interconnecting bars) on top of
batteries.
• Do not drop tools, loose cables, or metal objects onto intercell connections or terminals of
opposite polarity.
Mounting the Battery Temperature Sensor

The DC power system is supplied with a battery temperature sensor and standard 8 m (26
feet) long RJ45 cable, already connected to the supervisory module.
If required, longer cables are available (refer to Worldwide Support on page 57) or you can
make up your own. We recommend a maximum cable length of 20m (65 feet) because of
noise considerations.
The battery temperature sensor measures the ambient temperature around the batteries and
is required for the temperature compensation control function (see Control Function
Descriptions).
The best location for the battery temperature sensor is on the battery stand (centered and
above the batteries).
To avoid false readings do not:
• Place the sensor on top of battery cases.
• Attach the sensor to battery cables, terminals or interconnecting bars.
• Expose the sensor to direct sunlight or air movements from air-conditioning systems or
open windows.
• Run the sensor cable along AC power cables.
Installing External Alarm and Digital Inputs Cabling

Refer to the supervisory module handbook for details. See Related Information on page i.

IPN 997-00012-46C December 2006
27

28 IPN 997-00012-46C December 2006
Chapter 4
Commissioning
4
C h a p t e r 4
Commissioning
Overview
Topic Page
Inserting Rectifiers 30
Pre-Power-Up Checklist 31
Applying AC Power 32
Configuring the DC Power System 32
Testing Alarms at a Remote Location 35
Applying DC Power to the Load 36

IPN 997-00012-46C December 2006
29
Inserting Rectifiers
• Ensure the room has been cleaned and is dust free BEFORE unpacking the
•
rectifiers.
DO NOT switch on the AC supply at this stage.
Step 1 - Unpack the rectifiers

Unpack the rectifiers and inspect them carefully for possible transport
damage. Report any damage immediately, using a copy of the Equipment
Incident Report on page 55.
Keep the original packaging. You will need this if any equipment needs to be
returned for replacement or repair.
Step 2 - Push in the rectifier
• Keep fingers clear to avoid injury

1 Align the rectifier with the guide rails in the magazine
2 Slowly push in the rectifier.
Step 3 - Tighten the rectifier retaining screw

The retaining screw must be properly tightened to secure the rectifier in the
magazine and ensure reliable operation.
Procedure complete
Repeat procedure for other rectifiers.

30 IPN 997-00012-46C December 2006
Commissioning
Pre-Power-Up Checklist
Complete the checklist to confirm initial work is complete before progressing further.
All cabling is installed, securely tied and correctly insulated
Upstream surge protection is fitted (see Input Transient Protection on page 13)
System earthing is correctly installed (see Connecting the DC Output to Earth on page 23)
DC battery and load cabling has the correct polarity
A registered electrician or other suitable approved person has checked the integrity of the
installed cabling
All panels are in place and all empty rectifier slots are covered with blanking panels
AC isolator (if fitted) and all AC MCBs are switched off
All DC Distribution MCBs are switched off and/or fuses removed
AC supply is isolated at each point of isolation leading back to the external AC distribution
Batteries are electrically isolated from the DC power system
The site is clean

IPN 997-00012-46C December 2006
31
Applying AC Power
• A registered electrician (or suitably qualified person) must check the integrity of
the installed cabling, BEFORE the DC power system is powered up.
1 Switch on the AC supply at the switchboard.

2 Check the AC voltage at the AC distribution module.
3 If fitted, switch on the Surge Protection MCB.
4 Switch on the main isolator switch.
5 Switch on the first rectifier (or magazine) MCB. The first rectifier(s) starts up and the
supervisory module initializes (up to 2 minutes).
6 Check that on the first rectifier(s) the green B Power On LED is on and the red Urgent
< alarm LED is off.
On all other rectifiers the red Urgent < alarm LEDs will be on.
Refer to Troubleshooting on page 38 for further explanation of alarm LEDs.
7 Check that the supervisory module has powered up and that the green B Power On
LED on the supervisory module is on.
The supervisory module takes up to 2 minutes to initialize.

Depending on the configuration file settings, the Urgent and/or Non-urgent alarm LED(s)
may also be on.
8 After the supervisory module has initialized, switch on the remaining rectifier (or
magazine) MCBs one at a time.
9 Check that all installed rectifiers are operating and communicating with the supervisory
module (green B Power On LED on and other LEDs off).
10 Check that the supervisory module has correctly registered all rectifiers, by viewing the
individual rectifier currents in Main Display Mode. See Viewing System Values in the
relevant supervisory module handbook for details.
As no load is connected each rectifier will show 0A.

To solve rectifier communications and registration problems, refer to Troubleshooting on
page 38.
Configuring the DC Power System

The supervisory module is supplied with a pre-loaded configuration file.
It is important that the settings of this configuration file are checked/verified and changed as
required for site-specific conditions. In particular, settings that may affect the performance
and life expectancy of the battery must be checked and set according to the battery
manufacturer’s recommendations.

32 IPN 997-00012-46C December 2006
Commissioning
Only those configuration parameters that are most likely to be changed on-site can be
configured from the supervisory module keypad. A PC or laptop with DCTools is required to
edit all other configuration parameters (such as mapping of alarms to relays and setting up
communications).
We recommend using DCTools (available from www.powerware.com/downloads) for all
configuration tasks.
For information on connecting a PC to the supervisory module refer to Communications

Options in the supervisory module handbook.
Using DCTools to configure the system
Before you start, you need

• A PC or laptop with the latest version of DCTools installed
• A null modem cable
Step 1 - Connect the PC to the RS-232 port of the supervisory module

1 Connect the null modem cable from the supervisory module RS-232
port to the laptop or PC. Refer to Communications Options in the
supervisory module handbook.
2 Start DCTools.
Step 2 - Check that the PC port is specified correctly

1 Double-click the DCTools icon in the Windows task bar to display the
DCTools Connection List. The default connection is COM1.
2 If the port properties are correct, enable the connection by selecting the
Active check box E of that connection.
The correct port properties are: Protocol: S3P and S3P Address: 0.
If the port properties are incorrect, select the relevant connection from
the Connection List and click the toolbar button. In the Comms
Properties dialog, edit the properties as necessary and click OK.
If the connection is successful, the DCTools System Summary (Home)
screen is displayed.
Step 3 - Check through the loaded configuration file and make changes as required

Check through the configuration file in DCTools by clicking on the hotlinks
at the top of the DCTools System Summary (Home) screen. Make changes as
required.
The following table shows the main hotlinks and a list of the items that can
be configured.

IPN 997-00012-46C December 2006
33
Hotlink Click to …
Configuration Enter site specific information and synchronize the real time
clock (SM65 only) under Identity
Set keypad access control, configure modem settings and set-up
SMS messaging (SM60 only); setup Ethernet communications
and SNMP traps (SM65 only) under Communications
Configure SiteSure module addresses under External IOM
For further details refer to the supervisory module handbook.
Alarms Configure system alarms (see following section)
Analogs Configure analog inputs, AC three-phase metering (SM60 only),
current inputs and external analog inputs
Digitals Set-up user alarms (see Setting Up User Alarms in the
supervisory module handbook)
Relays Toggle relay states when performing a Relay Test (see details on
page 35) and configure external digital inputs (see External
Alarm and User Digital Inputs in the supervisory module
handbook).
Control Configure the settings of control functions such as Manual
Equalize, Temperature Compensation, Battery Test, Fast Charge,
Battery Current Limit and Active Voltage Control (for
descriptions see Control Functions).
LVD Enable/disable LVD(s) and configure the LVD settings (for
description see Control Functions).
Rectifiers Configure rectifier settings.

34 IPN 997-00012-46C December 2006
Commissioning
Reconfiguring System Alarms using DCTools

1 From the DCTools System Summary (Home) screen, click Alarms to display the Alarm
Table.
2 To change the urgency of an alarm, double-click on the Urgency for that alarm, then
click D and select the new urgency from the popup list.
3 To change alarm thresholds and recognition times, click C at Alarm Configuration at
the bottom of the Alarm Table screen and change the settings as required.
4 To change alarm relay mapping follow the process for mapping User Alarms.
See Setting Up User Alarms in the supervisory module handbook.
Using the Supervisory Module Keypad to Configure the System

Scroll through supervisory module's Configuration Mode and change the configuration
settings as required. Refer to Viewing and Editing Configuration Parameters in the
supervisory module handbook.
A list of all the configuration settings that can be changed from the keypad can be found on
the inside back cover of the supervisory module handbook.
Testing Alarms at a Remote Location
Step 1 - For each alarm relay used, simulate an alarm at the supervisory module
Using the Supervisory Module Keypad (SM60 only)

Refer to Relay Test Function in the supervisory module handbook.
Using DCTools (SM60 or SM65)

1 From the DCTools System Summary (Home) screen, click Relays to
display the Relay Table.
2 Set the Relay Test Duration as required.
3 To change the state of a relay, double-click on the Test State for that
relay, then click D and select the new test state from the popup list.
Step 2 - Check if the alarm signal has been received at the remote location

Procedure complete

IPN 997-00012-46C December 2006
35
Applying DC Power to the Load
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 Switch on the Battery MCB(s) and/or fit the battery fuses.
2 Check that the Battery Fuse Fail alarm clears.
When connecting multiple battery strings ensure that the individual

strings are of similar voltage.
3 Check the battery current. The actual value depends on the state of
charge of the batteries.
Step 3 - Connect load

1 Switch on the Load MCB(s) and/or fit the Load fuses.
2 Check that the equipment powers up and that the Load Fuse Fail alarm
clears.
Step 4 - Check the rectifier currents

1 Check the rectifier currents.
2 Verify that the load current is representative of what the load and
battery draws.
3 Verify that the DC power system has sufficient capacity.
Step 5 - Charge the batteries

1 Charge the batteries according to the battery manufacturer’s
recommendations.
2 If required start Manual Equalize from DCTools or the keypad.
Manual Equalize increases the system voltage to the pre-configured

equalize voltage for the pre-configured equalize duration. After the pre-
configured equalize duration has expired, the DC power system voltage
reverts back to normal battery float voltage automatically.
Procedure complete

36 IPN 997-00012-46C December 2006
Chapter 5
Maintenance
4
C h a p t e r 5
Maintenance
Overview
Topic Page
Troubleshooting 38
Replacing a Rectifier 41
Monitoring and Replacing Transient Protective Devices 42
Replacing the Supervisory Module 43
Battery Disposal and Recycling 43

IPN 997-00012-46C December 2006
37
Troubleshooting
Use the table to troubleshoot minor installation and operational problems. For additional
assistance see Worldwide Support on page 57. Return items for replacement or repair with a
copy of the Equipment Incident Report on page 55.
Problem Possible Cause Required Action

Supervisory module Refer to Troubleshooting in the
Urgent/Critical or Non- supervisory module handbook.
urgent alarm.
All rectifiers are off (no AC power to the system is off Restore AC power.
LEDs on) and supervisory and the batteries are fully
module display is blank. discharged or disconnected.
Green LED of one or more AC power to rectifier(s) off or Restore AC power.
rectifiers is off. one or more phases are off.
Rectifier is not fully inserted. Fully insert rectifier and tighten

retaining screw
Internal rectifier fault. Remove the rectifier and insert
another one in the same slot.
If the second rectifier operates
normally, the first rectifier is faulty
and must be returned for service.
Rectifier yellow LED on. Rectifier power limit or current Power system is charging the
limit is active. batteries after an AC power outage.
No further action is required.
Load current exceeds the total Install additional rectifiers.
rectifier capacity.
Rectifier temperature turndown Power system will return to normal
is active due to low AC supply operation when the AC supply
voltage or high ambient voltage and ambient temperature are
temperature. within the specified ranges. See
Specifications on page 45.
Rectifier red LED on. Very high or low AC voltage, or Power system will return to normal
AC supply failed. operation when the AC supply
voltage is within the specified range.
See Specifications on page 45.
Rectifier shut down Use DCTools to check if the rectifier
has in fact been shut down. If yes,
restart the rectifier.
DC overvoltage Remove and re-insert rectifier(s) or
shut down and restart using DCTools.
Rectifier failed Replace the rectifier.
Low system output voltage Rectifiers off. Restore AC power.
(rectifiers not in current
limit.) Battery Test and/or Disable active function(s) if not
Temperature Compensation is required.
active.
Activate the battery current limit
control function.

38 IPN 997-00012-46C December 2006
Maintenance

Incorrect float voltage setting at Check the float voltage setting of the
supervisory module. supervisory module.
Record new setting.
Low system output voltage Load is too high for rectifier Install additional rectifiers.
and rectifier yellow LEDs capacity.
are on (rectifiers are in
current limit.) Battery is recharging after AC Check battery has recharged within
power outage. expected time.
High system output voltage. Equalize, Fast Charge and/or Disable active function(s) if not
Temperature Compensation is required.
active.
Incorrect float voltage setting at Check the float voltage setting of the
supervisory module. supervisory module.
Record new setting.
Faulty rectifier. Search for the rectifier that is
supplying the most current and
remove this one first.
If the first rectifier removed is not
faulty, remove each of the remaining
rectifier modules one at a time, until
the 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 no battery input LVD is wired as battery Use DCTools to check LVD is enabled
with the batteries connected. disconnect and has operated. and set to correct values.
Check that the LVD selector switches
are set to AUTO. See details on page
48.
Check that the LVD control and DC
power cables are connected.
Check the battery connections to the
LVD.
Battery fuse or MCB open. Check the battery fuses or MCBs.
System provides no output LVD is wired as load disconnect Use DCTools to check LVD is enabled
(rectifiers are on). and has operated. and set to correct values.
Check that the LVD selector switches
are set to AUTO. See details on page
48.
Check that the LVD control and DC
power cables are connected.
Check the load connections to the
LVD.
Load fuse or MCB open. Check the load fuses or MCBs.

IPN 997-00012-46C December 2006
39

Red or Green LVD LED is LVD auto or manual operation. See details on page 48.
on or flashing.
Both LVD controller LEDs LVD controller not powered or Check power connection to the LVD
off. faulty. controller. Replace LVD controller if
faulty.
LVD controller LEDs flash Faulty contactor auxiliary Check the electrical and mechanical
simultaneously. switch. operation of the contactor auxiliary
switch.
Faulty wiring/connectors. Check all wiring and connectors.
Faulty LVD controller. Replace faulty LVD controller.
Open circuit coil. Replace contactor.
LVD controller LEDs Short circuit in contactor coil. Ensure that the correct contactor is
flashing alternately. used for the system.
Contactor Coil Type jumpers Check and configure the jumpers
incorrectly set (LVDCS only). correctly. See details on page 47.
LVD contactor fails to trip Faulty LVD controller or Replace faulty LVD controller or
after recognition time. contactor. contactor.
Faulty wiring/connections. Check the wiring/connections
between the contactor and the
supervisory module.
Supervisory module Faulty current shunt/sensor. Replace the faulty current
displays current value(s) as shunt/sensor.
AAA
Incorrect connection from Check RJ45 cable from port XU1 on
-OR- current shunts/sensors to the current shunt/sensor to port XS6
DCTools displays current supervisory module. on the supervisory module.
value(s) as N/A. Check that all interconnecting cables
are plugged into the correct ports.
Current input type is set to Enable the current input type in
None in DCTools. DCTools.
Supervisory module or Incorrect voltage sense polarity. Check the polarity of the voltage
DCTools displays zero sense wiring (connected to port XS9
current(s). of the supervisory module) is correct
(as in following diagram).
Incorrectly installed voltage Check that the polarity of the voltage

feed module. feed module is correct. (Common on
the voltage feed module is connected
to the Common bus bar.)
Current shunts/sensors Install current shunt/sensor in the
installed in the Common bus. LIVE bus.

40 IPN 997-00012-46C December 2006
Maintenance

Supervisory module or Incorrect current input gain Change the current input gain in
DCTools displays inaccurate setting in DCTools. DCTools.
current value(s).
Incorrectly calibrated current Recalibrate current shunt/sensor. See
shunt/sensor. details on page 48.
Minor current variations can be
corrected by changing the current
input offset in DCTools.
Faulty shunt/sensor. Replace faulty shunt/sensor.
DCTools displays incorrect Orientation of current Turn the current shunt/sensor
current polarity. shunt/sensor incorrect or around. See details on page 48.
incorrect current input gain
-OR-
polarity in DCTools.
Change the current input gain
polarity in DCTools.
All other supervisory Refer to Troubleshooting in the
module problems. supervisory module handbook.
Replacing a Rectifier
Wait 20 seconds after removing a rectifier before re-inserting it. This allows the rectifier to clear
its internal settings.
Rectifiers can be replaced without switching off the DC power system and disconnecting the
equipment it powers.
• To reduce the risk of electric shock and maintain optimum system cooling, always
I •
•
cover empty rectifier slots with blanking panels.
To avoid electric shock do not place hands inside the rectifier shelf.
Do not attempt to disassemble faulty rectifiers. Return them (in their original
packaging) with a copy of the Equipment Incident Report on page 55.
Removing a Rectifier
Step 1 - Loosen the rectifier retaining screw

IPN 997-00012-46C December 2006
41
Step 2 - Pull out the rectifier
• The rectifier may be hot, especially after prolonged operation. Use
•
suitable gloves.
To avoid damage to the connector do not rest the rectifier on its
connector, once it has been removed from the shelf.
Procedure complete
You must now insert a replacement rectifier into the empty slot or fit a blanking panel to
maintain optimum system cooling.
Inserting a Rectifier
Step 1 - Align the rectifier with the guides

Step 2 - Push in the rectifier
• Keep fingers clear to avoid injury.
1 Slowly push in the rectifier until engaged with the connector.

2 Tighten the rectifier retaining screw.
3 Check that the rectifier’s Power On LED B turns on and the < and =
alarm LEDs are off.
The urgent alarm LED < turns on for about 1 second when the rectifier
powers up. The rectifier will then automatically register with the
supervisory module and download its operating parameters. No
adjustments are required.
Procedure complete
Monitoring and Replacing Transient Protective Devices

For information on transient protection devices refer to Input Transient Protection on page
13.
Metal oxide varistors (MOVs) are the most widely used transient protective devices. MOVs
are generally fitted in the main AC switchboard of the building for primary transient
protection, and in the DC power system's AC distribution module or AC sub-switchboard for
secondary transient protection.

42 IPN 997-00012-46C December 2006
Maintenance
Monitoring the MOVs

MOVs are fitted with alarm contacts and visual indicators. Connect these alarms to the
supervisory module and from there extended to the building or network management
system. If the MOVs are not monitored automatically, then regular visual inspections must
be carried out.
Replacing the MOVs

MOVs must be functional at all times. In practice, it is impossible to predict when a MOV
will fail. That depends entirely on the number and magnitude of the transients sustained.
For that reason we recommend the following, depending on how accessible the site is.
• For easily accessible sites – If a MOV has failed (as indicated by a MOV Fail alarm or
the visual indicator), then replace all the MOVs as soon as possible.
• For remote sites with difficult access – Replace all the MOVs during scheduled
maintenance visits, whether they have failed or not.
We strongly recommend inspecting the MOVs in the main AC switchboard at the same time
and replacing them as appropriate.
If any MOV or other transient protection device has failed then the design of the primary and
secondary transient protection systems, and the maintenance plan, at that site must be
reviewed.
Replacing the Supervisory Module

For details refer to the Maintenance section of the supervisory module handbook.
Battery Disposal and Recycling

Follow Environmental Protection Agency (EPA) guidelines or the equivalent local
regulations to dispose of all batteries. Please remember that the owner is responsible and
liable to ensure those EPA guidelines or equivalent local regulations are followed.
For assistance refer to Worldwide Support on page 57.

IPN 997-00012-46C December 2006
43

44 IPN 997-00012-46C December 2006
Appendix A
Specifications
4
A p p e n d i x A
Specifications
System AC Input
AC Input Voltage Range 208V nominal: 185 – 238V
(Refer to AC connections options on page 18) 240V nominal: 214 – 275V
Frequency Range 45-66Hz
Maximum Earth Leakage Current 2.2mA (per rectifier)
System DC Output
DC Output Voltage (nominal) 24V (with APR24-3G), 48V (with APR48-3G)
DC Output Power (maximum) 24V: 51.84kW for a 36 rectifier system

48V: 64.8kW for a 36 rectifier system
DC Output Voltage Range 24V: 21.5 - 29V
48V: 43 - 57.5V
Over Voltage Shutdown <3ms delay
Environment
Ambient Temperature Range (operating) -5°C – +50°C [23°F – 122°F]
Relative Humidity (operating and storage) <80% (non condensing)
Dimensions H, W, D
Rectifier and battery racks (H, W, D) 43U racks: 2000mm [78.7"], 600mm [23.6”],
600mm [23.6”]
26U racks: 1250mm [49.2"], 600mm [23.6”],
600mm [23.6”]
Rectifier (H, W, D) 3U: 133mm [5.1"], 42mm [1.6”], 266mm [10.5”]
overall
Weight
Rectifier rack 43U racks: 85kg [188 lb] typical
(excluding rectifiers and batteries)
26U racks: 50kg [110 lb] typical
Rectifier rack 43U racks: 1250kg [2756 lb]

(with rectifiers and batteries) (typical with 12 rectifiers and 4 battery strings)
26U racks: 670kg [1474 lb]
(typical with 6 rectifiers and 2 battery strings)
Additional battery rack option 43U racks: 1220kg [2684 lb]
(with batteries) (typical with 4 battery strings)
26U racks: 942kg [2072 lb]
(typical with 3 battery strings)
Rectifier 1.7kg [3.7 lb]

IPN 997-00012-46C December 2006
45
APR24-3G Rectifiers
Rated AC Input Voltage Range 175 – 275V
Full output up to 50 °C [122°F]
90 - 275V
Reduced output below 175V
Maximum AC Input Current 13A RMS (175V AC, 20°C)
Rated Output Power 1440W
Rated Output Current 50A @ 28.8V (Constant current)
Preset Voltage 27 ± 0.1V
Rectifier AC Fuses (internal) 16A phase and neutral
APR48-3G Rectifiers
Rated AC Input Voltage Range 175 – 275V
Full output up to 50 °C [122°F]
90 - 275V
Reduced output below 175V
Maximum AC Input Current 12A RMS (175V AC, 20°C)
Rated Output Power 1800W
Rated Output Current 37.5A @ 48 V, 31A @ 57.6V
Preset Voltage 54.5 ± 0.1V
Rectifier AC Fuses (internal) 16A phase and neutral
Alarm Relays
Refer to the Specifications section of the supervisory module handbook.
Digital Inputs
Refer to the Specifications section of the supervisory module handbook.
Comprehensive supervisory module and rectifier data sheets are available. Refer to Worldwide
Support on page 57.

46 IPN 997-00012-46C December 2006
Appendix B
System Components
4
A p p e n d i x B
System Components
Low Voltage Disconnect (LVD) Option

Powerware Data-Voice-Video Power Solutions may be fitted with one or two Low Voltage
Disconnects (LVD) connected as either load or battery disconnect.
Refer to the supervisory module handbook for information on how to configure the LVD
channel (LVD1).
The supervisory module operates and monitors the LVD via a Powerware LVDCS controller.
LVD control by LVDCS controllers

The Powerware LVDCS Controller drives the LVD contactor and provides feedback (on
whether the contactors are open or closed) to the supervisory module from auxiliary
switches on the contactors.
"Jumpers for configuring the LVD

Controller (see following
section)
#LVD Status LED (green). See

details on page 48.
$LVD Status LED (red). See

details on page 48.
%Automatic/Manual Selector
Switch. See details on page 48.
Jumpers
LVDCS controllers are pre-configured at the factory and do not require jumper changes
under normal conditions. However, if there is a problem, check the positions of the two
jumpers shown in following table.
Purpose Jumper Setting

Enable voltage turn-down on connect 5-6 Fitted.
Coil voltage select 7-8 Not fitted.
9 - 10 Not fitted.
Last in line select 11 - 12 Fitted.

IPN 997-00012-46C December 2006
47
LVD selector switch and status LEDs

Each LVD has an Auto/Manual selector switch and indicator LEDs on either the
Multifunction Controller (see details) or the LVDCS (see details on page 47).
The Auto/Manual selector switch allows manual control of the LVD contactor. The operation
of the selector switch is described in the following table.
Switch Purpose Contactors LEDs/Alarms (Note 2)

position
Manual To disconnect the batteries for Open – batteries/load Red flashing/LVD Manual alarm.
disconnect battery maintenance (Note 1). disconnected
Auto Normal automatic operation Controlled by the Closed: Green/No alarm

supervisory module
Open: Red/LVD Disconnect alarm
Manual Prevents accidental battery/load Closed – batteries/load Green flashing/LVD Manual alarm.
connect disconnection if the supervisory connected
module is removed (Note 1).
Notes:
1 If a selector switch is set to manual (disconnect or connect) during servicing, ensure that
the switch is reset to AUTO when servicing is complete.
2 The LEDs also indicate LVD faults. Refer Troubleshooting on page 38.
External Current Sensors
CS04-A11 current sensor

Current rating: > 500A
Mounting: Screws (supplied) in the LIVE bus
Current sense signal: 60mV at maximum rated current
Communication cable: 8m (26’) RJ45 (supplied)
Extension PCB: For measurement on very large busbars
Busbar material: Copper or Aluminum

48 IPN 997-00012-46C December 2006
System Components
"CS04 Current Sensor Extension PCB

(optional)
#Current Sensor Pickup Contacts

$Input inductor
%Potentiometer for fine-tuning the Current
Sensor Gain
!RJ45 Current Sense Signal Output (XU1)

– to supervisory module (via intermediate
current sensor, if fitted)
&RJ45 Current Sense Signal Input (XU2)

– from other current sensor (if fitted)
Using the CS04 Current Sensor Extension PCB

The CS04 current sensor extension PCB increases the distance between the two pickup points
of the CS04-A11 current sensor. Use the CS04 current sensor extension PCB if:
• measuring current flow in very large bus bars, or
• the required gain of the current sensor is greater than 40.
Current Sensor Preparation
Step 1 – Calculate the required gain of the CS04 current sensor
Gain = - Constant x (CSA / IMAX)

Where: CSA = Cross sectional area of the bus bar (mm²)
IMAX = Maximum expected current through the bus bar (A)
Constant = 68.24V.Ω-1.mm-2 (for copper bus bars)
= 43.57V.Ω-1.mm-2 (for aluminum bus bars)
Step 2 – Determine the need for a CS04 current sensor extension PCB
If the required gain of the current sensor is greater than 40, then calculate the
new required gain of the current sensor as follows:
Gain = - Constant x (CSA / IMAX) x (51/150)

And use the CS04 current sensor extension PCB.

IPN 997-00012-46C December 2006
49
Step 3 – Resistance measurement
Measure the resistance of the inductor located at the back of the CS04 current
sensor PCB as shown.
Step 4 – Set the gain range of the CS04 current sensor
The gain range of the CS04 current sensor depends on:

• The required gain, as calculated in step 1 or step 2
• The resistance value of the input inductor, as measured in step 3
1 Select the required gain range and jumper configuration for the CS04
current sensor from the following table.
2 Connect the jumper(s) according to the selected jumper configuration.
Gain Range – for input inductor resistance values of … Jumper Configuration

90Ω 110Ω 120Ω
16 – 21 13 – 18 12 – 16
19 – 29 16 – 24 15 – 22
27 – 52 22 – 42 20 – 39
38 – 132 31 – 108 29 – 99
40 – 160 33 – 130 30 – 120
The jumper connection points are located on the back of the CS04-A11 current sensor PCB.
To obtain the required jumper configuration, you might have to break the track between
connection points 1 and 3 and solder additional jumpers between connection points.

50 IPN 997-00012-46C December 2006
System Components
Step 5 – Apply heat sink compound as shown
"Input inductor
#Heat sink compound to ensure good
thermal contact between the input inductor
and the busbar.
Procedure complete
Mounting the CS04-A11

The CS04-A11 is supplied with M3x35 mm screws to attach the CS04-A11 current sensor to a
bus bar.
This section covers the following mounting options:
• Through-hole mounting
• Threaded-hole mounting
Step 1 – CS04-A11 placement and orientation
CS04-A11 current sensors must always be mounted onto the LIVE bus bar.
(See following diagram.)
Wherever possible, do not mount the CS04-A11 current sensor closer than
150mm (6”) from:
• A bus bar joint
• Termination bolts
• Bolts joining laminated bus bars
Ensure correct orientation of the CS04-A11 current sensor before drilling the
mounting holes into the bus bar. (See following diagram.)
"Live bus $To rectifiers

#To load or battery

IPN 997-00012-46C December 2006
51
Step 2 – Drill the mounting holes
Drill two mounting holes according to the template below and tap if the
threaded-hole mounting option is used.
Through-hole Threaded-hole
Drill size M3.5 M2.5
Thread size and pitch - M3 x 0.5 ISO
Coarse
Step 3A – Mounting a CS04-A11 – through-hole mounting option
Mount the CS04-A11 current sensor as shown in the following diagrams.

Ensure correct orientation of the CS04-A11 (see Step 1 for details).
Without Extension PCB With Extension PCB

52 IPN 997-00012-46C December 2006
System Components
Step 3B – Mounting a CS04-A11 – threaded-hole mounting option
Mount the CS04-A11 current sensor as shown in the following diagrams.

Ensure correct orientation of the CS04-A11 (see Step 1 for details).
Without Extension PCB With Extension PCB
Procedure complete

IPN 997-00012-46C December 2006
53

54 IPN 997-00012-46C December 2006
Equipment Incident Report
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 Eaton Corporation, Telecommunications Solutions Division. Telephone:
+64 3 343 3314, Fax: +64 3 343 7446. Or email: CustomerServiceNZ@eaton.com
Date:
Customer Information
Company:
Postal Address:
Return Address:
(Not PO Box)
Telephone: Fax: Email:
Location of Failure
Product code: Serial number: Document number:
System type installed in: Serial number:
Site name or location:
Fault discovered Delivery Unpacking Installation

Initial test Operation after ______ years Other ___________
Failure source Design Manufacturing Documentation

Transportation Installation Handling
___________
Effect on system operation None Minor Major _________________
INFORMATION (fault details, circumstances, consequences, actions)
Internal use only.

Reference No: __________ RMA: __________ NCR: __________ Signature: _________________ Date: __________

IPN 997-00012-46C December 2006
55
INFORMATION continued (fault details, circumstances, consequences, actions)
SG/03 ISS04

56 IPN 997-00012-46C December 2006
Worldwide Support
4
Worldwide Support
For product information and a complete listing of worldwide sales offices, visit Eaton's
Powerware website at: www.powerware.com or email: DC.info@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
Australia Tel. +61-2-9693-9366

Canada Tel. 1-800-461-9166
Central America Tel. +52-55-5488-5252
China Tel. +86-571-8848-0166
Europe / Middle East / Africa Tel. +44-1243-810-500
Hong Kong / Korea / Taiwan Tel. +852-2745-6682
India Tel. +91-11-2649-9414 to 18
New Zealand / Pacific Tel: 0800 DC Power (327-693)
Tel. +64-3-343-7448
Singapore / South East Asia Tel. +65-6829-8888
South America Tel. +55-11-3616-8500
Tel: +54-11-4343-6323
United States of America Tel. 1-800-843-9433
(Toll Free)

IPN 997-00012-46C December 2006
57

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Copyright © 2005-2006 Eaton Corporation. All Rights Reserved.

Reporting Problems with this Guide

Powerware DC Product Marketing Communications

For Further Information and Technical Assistance

Copyright © 2005-2006 Eaton Corporation. All Rights Reserved.

About This Guide

Copyright © 2005-2006 Eaton Corporation. All Rights Reserved.

Copyright © 2005-2006 Eaton Corporation. All Rights Reserved.

Typical Data-Voice-Video Power Solutions DC Power Systems 2

Access Power Rectifiers (AP24-3G/APR48-3G) 3

Supervisory Module Keypad and Display (if fitted) 4

Copyright © 2005-2006 Eaton Corporation. All Rights Reserved.

Typical Data-Voice-Video Power Solutions DC Power Systems

Typical system Typical system with Additional battery

"Combined AC* and DC distribution section

Copyright © 2005-2006 Eaton Corporation. All Rights Reserved.

Access Power Rectifiers (AP24-3G/APR48-3G)

See Specifications on page 45 for further information.

"Power On LED (Green)

See Troubleshooting on page 38 for details of rectifier alarms.

Copyright © 2005-2006 Eaton Corporation. All Rights Reserved.

Supervisory Module Keypad and Display (if fitted)

"Backlit LCD Display

9 Escape: Press to go to Main Display Mode or cancel configuration file changes.

Copyright © 2005-2006 Eaton Corporation. All Rights Reserved.

External Communications Supervisory Module

Communication with Powerware DCTools or PowerManagerII -

Communication with a Network Management System (NMS) -

Refer to the supervisory module handbook for detailed information on communications

External current shunts/sensors option

Copyright © 2005-2006 Eaton Corporation. All Rights Reserved.

Low Voltage Disconnect (LVD) option

Copyright © 2005-2006 Eaton Corporation. All Rights Reserved.

Inspecting the Equipment and Reporting Damage 10

Copyright © 2005-2006 Eaton Corporation. All Rights Reserved.

Location and Environment

Hazardous Energy Levels

Copyright © 2005-2006 Eaton Corporation. All Rights Reserved.

Copyright © 2005-2006 Eaton Corporation. All Rights Reserved.

Inspecting the Equipment and Reporting Damage

Copyright © 2005-2006 Eaton Corporation. All Rights Reserved.

Mounting the Powerware Data-Voice-Video Power Solutions 12

Input Transient Protection 13

High AC Voltage Protection 16

Connecting to the AC Supply 17

Terminating the AC Supply Cable 18

Connecting the DC Output to Earth 23

Connecting the DC Load and Battery Cables 24

Connecting to External Current Sensors/Shunts (if required) 25

Installing the Batteries 26

Mounting the Battery Temperature Sensor 27

Installing External Alarm and Digital Inputs Cabling 27

Copyright © 2005-2006 Eaton Corporation. All Rights Reserved.

Mounting the Powerware Data-Voice-Video Power Solutions

Unpacking the Power System

Copyright © 2005-2006 Eaton Corporation. All Rights Reserved.

Input Transient Protection

Copyright © 2005-2006 Eaton Corporation. All Rights Reserved.

Primary Transient Protection

Secondary Transient Protection