IR2 Generic Manual

Eaton Power System Handbook
Eaton Power System
IR2 Power System Handbook
This document has been approved for use by qualified personnel only.
Document No 11800501
Issue: 01
Issue Date: 21th October 2015
Eaton Electrical Limited

Eaton Corporation
Telecommunications Solutions Business Unit
11800501_IR2 Generic Copyright © 2011-2014 Eaton Corporation. All Rights Reserved Page |1
Manual
www.eaton.com/telecompower
e-mail: - dc.info@eaton.com
Manual
Revision History
Issue Issue Date Amendment Description Author

01 21 Oct 2015 Original Version Andrew McAvoy
Abbreviations
AC – Alternating Current
DC – Direct Current
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 Eaton products. No such warranty, representation or guarantee is expressed or implied.
Furthermore, information contained in this document, does not guarantee or imply any ownership of site specific design. It
is therefore the total responsibility of the installation designer to ensure compliance with any legal or statutory
requirements in the country of use.
Additionally, 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
Customer’s personal use, without the express written permission of Eaton Corporation.
Document produced and published by the Engineering Department of Eaton Electric Ltd, Bognor Regis, West Sussex.
Copyright © 2011-2014 Eaton Corporation. All Rights Reserved.
Manual
Table of Contents
Introduction ............................................................................................................................................ 6
Purpose ........................................................................................................................................... 6
Personal Protection in Restricted Access Areas.............................................................................. 6
Health and Safety ............................................................................................................................ 6
Reporting Problems with this Manual ............................................................................................ 6
Contact Information........................................................................................................................ 6
Symbols Used in this Document ..................................................................................................... 7
Standards and Approvals ................................................................................................................ 8
Health & Safety Guidelines ................................................................................................................. 9
Introduction .................................................................................................................................... 9
The Electricity at Work Regulations 1989 and The Health and Safety at Work etc. Act 1974 ....... 9
BS7671 Requirements for Electrical Installations ........................................................................... 9
Warnings ....................................................................................................................................... 10
Manual Handling ........................................................................................................................... 14
Battery Safety................................................................................................................................ 14
Anti-Static Precautions.................................................................................................................. 16
Wiring Colours............................................................................................................................... 17
Mechanical Installation Instructions ................................................................................................. 18
Introduction .................................................................................................................................. 18
Installation Fixings Required ......................................................................................................... 19
Installation Tools Required ........................................................................................................... 19
Positioning and Floor Fixing .......................................................................................................... 19
Joining Multiple Cabinets .............................................................................................................. 21
SC200 System Controller............................................................................................................... 23
Alarm Connections ........................................................................................................................ 24
Rectifiers ....................................................................................................................................... 26
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Commissioning .................................................................................................................................. 29
Task 1 - Analog Inputs ................................................................................................................... 29
Task 2 - System Controls ............................................................................................................... 30
Task 3 - System Alarms ................................................................................................................. 34
Task 4 - Digital Inputs .................................................................................................................... 37
Task 5 - Digital Outputs (Relays) ................................................................................................... 37
Commissioning Completion .......................................................................................................... 37
Troubleshooting ................................................................................................................................ 38
Worldwide Support ........................................................................................................................... 42
Appendix A ........................................................................................................................................ 43
Alarm PCB Connections (IOBGP-00).............................................................................................. 43
Appendix B ........................................................................................................................................ 46
Equipment Incident Report........................................................................................................... 46
Appendix C ........................................................................................................................................ 48
Circuit Diagrams ............................................................................................................................ 48
Manual
Introduction
Purpose
This document provides installation and commissioning guidance for installing Eaton power systems.
Personal Protection in Restricted Access Areas
WARNINGS
Restricted Access Area
The Power System must be installed in a Restricted Access Area.
Cabinet Fixing
Cabinet(s) must be securely fixed to a concrete or other non-combustible surface,
capable of supporting the weight of the cabinet(s) including its full fit-out of
rectifier / batteries
Health & Safety
Any maintenance, additions or modifications to the Power System, must only be
performed by suitably trained and qualified personnel, using fully insulated tools.
Refer to the Health & Safety Guidelines.
Energy Hazard
This power system contains high voltage and high energy sources within.
Live working on the Power System, will require the temporary addition of
supplementary insulation to equipment within the cabinet, for example, when
working directly above the rectifier magazine, an insulating cover must be fitted
over the magazine.
Health and Safety

For details regarding health and safety, refer to the Health & Safety Guidelines.
Reporting Problems with this Manual

Please use this fax or email address to report any problems you find in this manual:
Eaton DC Product Marketing Communications
FAX: 01243 868613
EMAIL: dc.info@eaton.com
Contact Information
Manufacturers Address
Eaton Electrical Ltd
Durban Road
Bognor Regis
West Sussex
England
PO22 9QT
Manual
Other Contact Details

General: 01243 810500
Main Fax: 01243 868613
Technical Helpline (Mon-Fri 8am to 5.00pm): 01243-810618
Service Repair RMA Website: http://epsl.powerware.com
Symbols Used in this Document
SYMBOL
WARNING
Advice on hazardous conditions. Possibility of personnel injury and/or equipment
damage
CAUTION
Advice on seriously hazardous conditions. Possibility of severe/fatal personnel
injury and/or serious equipment damage
ELECTRICAL HAZARD
Advice on electrically hazardous conditions. Possibility of severe/fatal personnel
injury and/or serious equipment damage
FLOW ARROW
Advises that the procedure continues below.
NOTE
Note or advice on further information.
RECYCLING
Advice on the recycling of components or equipment.
DISPOSAL
Dispose in accordance with local environmental regulations.
Manual
Standards and Approvals
Eaton power systems have invoked the following standards and approvals.
LVD and EMC directives 2006/95/EC and 2004/108/EC respectively invoking EN60950-1 and EN300
386.
WEEE directive 2002/96/EC
This Telecommunications Power Supply System complies with or exceeds the following Standards:
EN60950-1: Information Technology Equipment – Safety. Part 1 – General Requirements.
EN300 386: Electromagnetic Compatibility and Radio Spectrum Matters (ERM); Telecommunications
Network Equipment; Electromagnetic Compatibility (EMC) requirements.
This Telecommunications Power Supply System output is classed as earthed SELV at a hazardous
energy level.
WEEE Directive
Please Note: - This equipment must be disposed of according to local regulations.
Manual
Health & Safety Guidelines

Introduction
These health and safety rules cover all areas of installation and must be applied during the planning,
installation, test, maintenance and repair of power systems for communication equipment.
This document is to be a complement to general safety rules when working with power systems and
other electrical systems. Local health and safety documentation must also be fully adhered to when
carrying out work associated with power.
Contact the Network Operations Centre (NOC) before commencing work. Inform people around the
equipment that work is in progress and that equipment may be live during the course of the work
that will be carried out.
The Electricity at Work Regulations 1989 and The Health and Safety at Work etc. Act
1974
The Electricity at Work Regulations came into force on the 1st April 1990 and is made under The
Health and Safety at Work etc. Act 1974. The regulations apply to all places of work and impose
duties on people in respect of electrical systems, equipment and all work activities on or near
electrical equipment.
All work is to be conducted in accordance with the Regulations.
The Electricity at Work Regulations 1989 state principles of electrical safety in a form that can be
applied to any electrical equipment and work activity. They apply to all electrical systems and
equipment whether manufactured, purchased or installed even if this pre-dates the Regulations.
Where this is the case, this does not necessarily mean that it contravenes the Regulations. The
equipment or system need only be replaced when it becomes un-safe or needs to be modified. The
frequency of work on the electrical equipment or installation, the practicality of providing screening
from live conductors and the inconvenience of making the equipment or system dead are key factors
in deciding on replacement.
WARNING:
A breach of the requirements contained within this directive may be used in
criminal and or civil proceedings as evidence that statutory requirements have been
contravened.
BS7671 Requirements for Electrical Installations

Requirements for Electrical Installations BS7671 are non-statutory. They relate to the design,
selection, erection, inspection and testing of electrical installations. BS7671 is widely recognized and
accepted in the UK and it is the view of the Health and Safety Executive (HSE) that compliance with
them is likely to achieve compliance with relevant aspects of The Electricity at Work Regulations
1989.
Manual
Warnings
WARNING: Personal Protection

Before staring work, inspect the access routes and the area to be worked in for any
potential hazards. E.g. holes in floors, sharp edges of installed equipment, either at
normal working levels or at high level, etc.
When working with electrical equipment, the necessary protective measures must
be taken to ensure maximum safety for the people as well as property.
Keep the area tidy and ensure the equipment is protected against damage and
unauthorized intervention during the course of the work.
Remove all metal bracelets, rings etc. that can cause short circuits when working on
the equipment.
Use only single-ended, fully insulated tools. Shafts of screwdrivers etc., are to be
insulated.
Use only isolated test instruments.
All work at height where there is a risk of a fall liable to cause personal injury must
comply with the Work at Height Regulations 2005. For further information contact
the Health and Safety Executive ( www.hse.gov.uk ).
Observe any markings/labels on this power system relating to the new European
Harmonized wire colours (Amendment No.2 To BS7671:2001)
WARNING: Electrical Safety

This apparatus must be installed by a professional installer.
When installed, a protective earth must be provided for safety, in accordance with
BS6701:1994 (which refers to the IEE wiring regulations BS7671) or local wiring
regulations. The protective earth connection must be hard wired.
The power cabinets operate from a mains voltage power supply. Isolate supply
inputs before removing any covers for maintenance access.
High leakage current. Earth connection essential before connecting supply.
While working on this equipment, unsafe voltage and energy sources may be
exposed, and only trained, approved installation and maintenance engineers should
install, test and repair these units. No person other than those trained to work on
live equipment must be present in the working area during installation or
maintenance unless under direct supervision of a competent person.
Hazardous voltages can be retained on both AC input and DC output parts after
removal of AC line input. Proceed with caution and test parts before touching.
All voltages should be treated as potentially hazardous.
Remember that voltage sources from other equipment may be present in the
equipment being worked on, via parallel systems, alarms, etc.
Hazardous energy levels occur in batteries and capacitors, even when not charged
to hazardous voltages.
When re-connecting sources of power and/or stored energy, such as rectifiers,
batteries and large capacitors, switch on the rectifiers first and check that the
voltage difference between the items to be inter-connected is small before making
the connection.
11800501_IR2 Generic Copyright © 2011-2014 Eaton Corporation. All Rights Reserved P a g e | 10

Manual
WARNING: Labels and Instructions

Take note of all warning labels.
Take note of any installation instructions supplied separately with the rectifier
units.
Take note of any installation instructions supplied separately with the system
controller.
WARNING: Location and Environment

This equipment must be located in a restricted access location where access is
through the use of a tool, or lock and key, or other means of security, and is
controlled by the authority responsible for the location.
It is mandatory to fix the equipment to the building. This equipment must only be
mounted on a concrete or other non-combustible surface that is capable of
supporting the total weight, including batteries if applicable.
For ease of access and to maintain optimum system cooling, observe the clearances
stated in the appropriate manual or guide. Equipment that has a rear panel with
openings must be spaced away by the distance stated on the design diagram
supplied with the equipment.
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.
To ensure reliable operation the maximum ambient temperature into which the
equipment is placed must not exceed that stated on the design diagram supplied
with the equipment.
This equipment must not be operated in an altitude exceeding 2000m otherwise all
safety approvals will be invalidated.
WARNING: 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.

Manual
WARNING: Isolation
There must be an isolator external to the DC power system to provide emergency
shutdown or isolation of all AC power to the system.
If the equipment is to be isolated, the following areas must be considered:
AC and DC inputs from all sources
Output from parallel systems
Power factor correction and filter capacitors
Battery. Use of the isolator, if fitted, may not be sufficient, as it may be necessary
to work close to the isolator's connections. In this case, also remove at least one
cable from the battery and isolate the exposed connections.
"Isolation" in terms of the UK Electricity at Work Regulations means the methods
by which it is assured that hazards such as batteries and power cannot be re-
connected inadvertently by those working on the equipment, or by others. Such
methods include having a switch in view at all times (an external readily accessible
isolator), and the use of lock-outs.
WARNING: AC Rating
Ensure that the AC incoming supply voltage, number of phases and frequency
aligns with that marked adjacent to the equipment AC input terminals. For three
phase input, the rotation can be in any order.
Refer to the design diagram supplied with the equipment to ensure that the AC
input and DC output earth wiring and termination is dimensioned correctly.
WARNING: AC Disconnect Device and External Overload Device

Should the equipment not contain an AC disconnect device then a readily accessible
disconnect device shall be incorporated external to the equipment.
For those units where the plug on the power supply cord is the disconnect device
then the socket shall be installed near the unit and be easily accessible.
It is essential that AC overload protection is provided by an external device, whose
rating is not greater than that stated on the design diagram supplied with the
equipment. This device shall be installed near the unit and be easily accessible.
Note: AC disconnect and overload may be incorporated in the same device.
WARNING: Multiple Power Sources

Should the equipment have multiple AC input power sources, then ensure that the
external disconnect devices are clearly labelled to ensure that there is no ambiguity.
All of the devices should make reference to all of the other devices to ensure that all
power is removed before access to the equipment.

Manual
WARNING: 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 in the appropriate guide or
manual.
Ensure that any upstream Residual Current Devices (RCDs) are appropriately rated
for the rectifiers' maximum earth leakage current (see Specifications in the
appropriate guide or manual for value).
WARNING: 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:
The 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.
For all installations, use the appropriate connector for the conductor size as
specified by the connector manufacturer. And use only the connector
manufacturer's recommended tooling or tooling approved for that connector.
Follow all applicable local and national rules and regulations when making field
connections.
Tighten all electrical connections to the torques stated in the appropriate guide or
manual or on the OEM's label.
Refer to the design diagram supplied with the equipment to ensure that the AC
input and DC output earth wiring and termination is dimensioned correctly.
WARNING: Earthed-end Connections

Always remove earthed-end connections first, and re-connect them last.
WARNING: Smoking
Smoking is generally prohibited in buildings.

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Manual Handling
In the UK, The Manual Handling of Loads Regulations, 1993, require that all persons are familiar with
the Regulations, that they take care to minimize risk of injury to themselves and others, that they
are properly trained, and that the correct equipment is used.
1. Before lifting loads, stand as close as

possible to the load.
2. Keep the back straight and as vertical

as possible.
3. Use the leg muscles to lift in preference

to the arms.
4. Minimize twisting, stretching and

stooping.
5. Loads should be lifted, withdrawn,

inserted and lowered evenly, without
jerking, maintaining the load level and
balanced, with adequate support. The
limits on lifting imposed by the
Regulations are shown in the diagram.
The diagram shows recommended limits for

men. The weights should be reduced by 30%
for the average woman. If twisting is involved,
the weights should be reduced by 20%. For
further details, refer to the Manual Handling of
Loads Regulations, 1993.
Battery Safety
For Eaton supplied equipment, mechanical battery lifting aids must be used at all times.
WARNING: Battery Disposal

For the disposal of batteries either:
Contact the battery manufacturer for instructions. The manufacturer's address is
printed on each battery, or
Refer to local legislation regarding disposal.

Manual
WARNING: Batteries (if fitted)

The plastic cases of batteries installed in Eaton DC power system racks must have a
flammability rating of UL 94-V2 or better.
Flooded cell lead acid batteries must be installed in a battery room. Do not install
flooded lead acid batteries in an Eaton DC power system rack.
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 or EN50272-2.
Do not wear a synthetic dust-coat or overalls. Synthetic fabrics can hold static
electric charge that creates sparks during discharge.
Remove rings, wristwatch and other metal jewellery 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.
Always use insulated tools.
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.
WARNING: Battery Replacement

Should the equipment contain batteries then these should be replaced with the
same type and rating.
CAUTION –RISK OF EXPOLSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE.
DISPOSE OF BATTERIES ACCORDING TO THE INSTRUCTIONS

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Safety checks
Before inserting/closing battery protection devices (fuses, links, MCBs or MCCBs):
1. Read and follow the safety instructions.

2. Read and follow the user instructions.
3. If a fault is found, do not proceed further without clearing the fault.
4. Check polarity of battery connections.
5. Check sequence of battery connections.
6. Measure the voltage between the common return and each battery protection device.
7. Check that the battery voltages are correct according to the user instructions.
8. Check that the battery polarities are correct according to the user instructions.
9. Check that the difference between battery voltages is no more than 2V.
10. With load isolated, connect Rectifiers and switch on, following the user instructions. See also
Note below.
11. Check the system voltage and polarity against the value given in the user instructions.
12. Check that the voltage measured across the first battery protection device is less than 6V.
13. If the voltage measured in 12 above is satisfactory, insert/close the protection device.
14. Repeat (12) and (13) for each battery in turn.
Anti-Static Precautions
WARNING: Supply Voltage

Ensure that the supply voltage indicated on the cabinet identification/data plate is
correct for the installation.
WARNING: Semiconductor Components

All stages which involve handling of assemblies fitted with any semiconductor
components should contain protection against the possibility of static induced
damage.
WARNING: Wrist Straps

The printed circuit cards should only be removed from their protective carriers in
static-safe handling areas by persons wearing static protection such as wrist straps.
Eaton cabinets have anti-static connection points for wrist straps which must be
used when installing/removing printed circuit board (PCB) assemblies.

Manual
Wiring Colours
Function Alphanumeric Colour
Earth
Protective conductors Green-and-yellow
AC Power Circuit
Phase of single-phase circuit L Brown
Neutral of single- or three-phase circuit N Blue
Phase 1 of three-phase AC circuit L1 Brown
Phase 2 of three-phase AC circuit L2 Black
Phase 3 of three-phase AC circuit L3 Grey
DC Power Circuit
Positive Common (0V) M Black (red heatshrink)
Negative Live (-48V) L- Blue

Manual
Mechanical Installation Instructions

Introduction
The system cabinets are part of Eaton’s Integrated Rack 2 range of cabinets. Each cabinet is modular
in construction with various options depending on the application. All have front ventilated lockable
doors. The cabinets have the following overall size:
• 48U Cabinet - 2200mm high, 600mm wide and 600mm deep.
2200mm
2200mm
600mm 600mm
Front View Side View

Manual
Installation Fixings Required

Item no Description Qty per Cabinet
1 M10 Floor Anchor Bolt to suit floor type/construction 4
2 M10 Plain Washer 4
3 M10 Locking Washer 4
Installation Tools Required

Ref Description
1 17mm A/F Spanner or Socket (insulated)
2 Pozidriv® screwdriver (insulated)
3 Flat bladed screwdriver (insulated)
4 Drill to suit Floor Fixings
5 Electric Drill
Positioning and Floor Fixing
Preliminary Works
Before installation ensure that:
• The floor surface where the equipment is to be installed is level.

• The floor surface where the equipment is to be installed, and any areas over which the
equipment must be moved, are sufficiently strong to take the weight of the cabinets and the
point loading of the transport mechanism.
• The installation area is clean and dry.
All areas of floor are protected from damage by the transport of the equipment. Use
hardboard or a similar material. This material must be removed once installation is
complete.
This cabinet must be secured to a concrete or other non-combustible surface.
No space is necessary at the sides or rear. Allow distances from other equipment as required by the
installation requirements of that equipment (although the cabinet does not require space at the
sides or rear, adjacent equipment may do so).
Bear in mind the space required for door opening. The minimum recommended space is 840mm
The doors are right opening (hinges on the right hand side).
When installing on a raised "Computer floor", locate the first cabinet over one tile. If load spreading
is required due to cabinet weight then this must be installed prior to cabinets being installed.

Manual
Preparing the Cabinets

Before fixing any cabinet to the floor remove the front door by opening to 90 degrees and then lift
off the hinges. Remove all the cabinet front panels both fixed and hinged to allow easy access into
the cabinet. Note hinged access panels also lift off. Place removed doors and panels in a safe
location ready to be refitted after the installation is complete.
Fixing the Cabinets

The cabinets can be mounted directly to the floor, or can be mounted onto pre-installed picture
frame plinths. The method of fixing must be suitable for the cabinet size and weight, and for the
surface to which the cabinet is being secured.
Recommended procedure:
1. Place the cabinet in position and align to other cabinets.

2. Mark fixing holes in base of cabinet with permanent marker.
3. Remove cabinet.
4. Drill all marked holes. De-burr all holes.
5. Place cabinets back in position.
6. Fix cabinet using appropriate floor anchors to secure the cabinets.
416.0 TYP
FRONT
The footprint diagram above shows the cabinet dimensions and location of floor fixings.

Manual
Joining Multiple Cabinets
Mechanical Connection
Join together multiple cabinets using the linking plates and M4 screw fixings provided. Two brackets
are used at the top of the cabinet on the lid and two are used at the bottom on the lower side rail
(see pictures below).
Top Link Plate Bottom Link Plate
Earth Link Connection (optional)

Cabinet earth links are optionally supplied with each cabinet. The earth link is fitted on the top of
each cabinet at the front or rear. The outer M8 threaded inserts are used to secure the link to each
cabinet (see picture below).

Manual
Main Busbar Electrical Connection

The centre section of each cabinet consists of a pair of busbars which connect together using busbar
fishplates (see typical example picture below). For this application each positive and negative
busbar is joined to the adjacent cabinet with fishplates. Each fishplate is fixed by 8 x M10 Nuts and
Belleville washers, 4 in each cabinet.
All M10 fixings must be torque set to 26Nm.
Note that the picture below shows both positive and negative busbars together. Some system will
have the positive busbar positioned at the top or bottom of the cabinet but the method of suiting
the busbar to adjoining cabinets is the same.
Busbar Fishplate
Communications Cable Connection

The cabinets are connected together using RJ45 CAT5e cables, the number of which depends on the
particular configuration of the cabinets. The comms cables are normally supplied coiled up in the
cabinets and can be routed to the next cabinet and a connection made using the supplied RJ45
adapter.
Refer to electrical drawings in Appendix C of this guide for details.

Manual
SC200 System Controller

This system utilizes the Eaton controller, SC200.
The Eaton® SC200 System Controller is an advanced control and monitoring

controller providing a full suite of advanced communications options,
including built-in Ethernet interface, Web server, and SNMP agent.
Alarm notifications may be by SNMP traps, SMS, dial-out to

PowerManagerII remote monitoring software, or relay contact closures.
An intelligent new “Smart Alarms” feature provides highly con-configurable

control and alarms for automated site management. Smart Alarms enables
improved site performance and reduced site energy consumption. Some
examples include disconnection of non-essential loads during peak AC grid
loading for reduced energy costs, running outdoor cabinets in low noise
mode at night, intelligent management of cooling, and customizing site
alarms to match network requirements.
The SC200 is supplied preconfigured with either a default configuration file, or with one factory
customized for a particular application. This ensures fast and problem free installation.
If on-site changes are needed then these can be easily made from the front panel or with a Windows
PC using DCTools configuration software.
The front panel incorporates a high-resolution back-lit color LCD display with easy to read characters
and easy to use menu system. All system values and alarms can be displayed and the keypad
provides easy access to check or edit settings.
The SC200 works with separate system I/O boards for powerful and user-friendly interfacing. Easy
and low cost I/O expansion is possible by adding additional I/O boards.
Features
• Ethernet interface built-in
• SNMP agent
• Battery mid-point monitoring (if enabled)
• Eaton Fuel Saver
• SMS alarm messages (with GSM modem)
• Comprehensive system control functions
• Color display with user-friendly menus
• Setup via web, keypad or DCTools configuration software
• Different language options
• Optional extra I/O boards or SiteSure-3G modules for expansion
• Smart Alarms
• Modbus
• Battery time remaining during discharge

Manual
Alarm Connections
Introduction
The power system is controlled by an Eaton SC200 Controller, which is connected to the system
Input/Output interface board IOBGP-00.
All system monitoring and alarm connections are made on the IOBGP.
Input/Output Interface Board - IOBGP

The input/output (I/O) board provides the system I/O interfaces and connections for the SC200
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

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 and connector pin-outs see document no IPN 997-00012-50,
SC200 System Controller Operation Handbook. The Latest version of the handbook is available from
www.powerquality.eaton.com/DC-Manuals
SC200-00 IOBGP-00

Manual
IOBGP Connections:
XH9 Bus voltage sense input XH8 LVD power input connector
XH15A & B Digital inputs D1-D6 (6 user XH16- Digital (relay) outputs RY1-RY6 (6)
defined) XH21
XH12 Battery Mid-point Monitoring XH5 LVD2 control connector
inputs
YH11 Power and RXP comms input XH4 LVD1 control connector
XH6 Current sense inputs (3) XH7 Temperature sense inputs (2)
The Alarm Outputs from the IOBGP Board are made in the screwless terminal blocks XH16 and XH21
and are numbered RY1 to RY6.
The wire size for connection to these terminal blocks is in the range between 0.5 - 2.0mm².
For Troubleshooting regarding the I/O board LED signals, see document no IPN 997-00012-50, SC200
System Controller Operation Handbook.

Manual
Rectifiers
This system utilizes one of the following Eaton rectifiers.
Rectifier APR-Rectifiers
AC Supply 120V/208-240V, 50/60Hz (nominal)
185-275V full output power up to 50°C [122°F]
90-185V reduced output power
Power Factor 0.99 (50 – 100% output current)
Operating Temperature -40°C – +70°C [-40°F – +158°F].
Output current is de-rated above 50°C [122°F] and below -10°C
[14°F]
Dimensions H,W,D 3U: 133mm [5.25”], 42mm [1.65”],
266mm [10.45”] overall
Weight 1.7kg [3.7 lb]
Image Rectifier APR48-ES

DC Output (V) 48V: 43 – 57.5V
Efficiency >96% peak

>95% (20 – 100% output power)
DC Power 2000W @ 48V
Image Rectifier APR48-3G

DC Output (V) 48V: 43 – 57.5V

>91.5% (50 – 100% output power), 230VAC
DC Power 1800W @ 48V
Image Rectifier APR24-3G

DC Output (V) 24V: 21.5V – 32V

<89% (50 – 100% output power), 230VAC
DC Power 1440W @ 28.8V

50A (24V to 28.8V)
For details of rectifier alarms and configuration, see the appropriate controller handbook.
The SC200 Controller Handbooks can be downloaded from www.powerquality.eaton.com/DC-
Manuals

Manual
Rectifier Indicators
The rectifier has three LEDs providing visual indication of the status of the rectifier.
1 Power On LED (Green)

2 Minor Alarm LED (Yellow)
3 Major Alarm LED (Red)
4 Retaining Screw
WARNING: Rectifiers
To reduce the risk of electric shock and maintain optimum system cooling, always
cover empty rectifier slots with blanking panels.
To avoid electric shock do not place hands inside the rectifier shelf/magazine.
Do not attempt to disassemble faulty rectifiers. Return them for service or
replacement in their original packaging.
Keep fingers clear when inserting rectifiers to avoid injury
The rectifier may be hot, especially after prolonged operation. Use suitable gloves.
To avoid damage to the rectifier connector, do not rest it on its connector, once it
has been removed from the shelf.
Fitting APR Rectifiers
Step 1
Align the rectifier in a slot in the

magazine.
Slowly push in the rectifier until it

starts to engage with the magazine
connector.
Note - Do not force the rectifier in.

Manual
Step 2
Using a Pozidriv® screwdriver, turn

the screw at the front of the rectifier
to pull the rectifier into a fully
engaged position.
Step 3
Rectifier should register and power

up with no alarms. Use the rectifier
menu or DCTools to check that the
serial number on the front of the
rectifier is registered in the rectifier
table on the controller.
Removing Rectifiers
The Eaton APR48 Rectifiers are hot-pluggable and do not require the system or rectifier to be off
before removing.
Loosen the rectifier retaining screw with a Pozidriv® screwdriver .
Grip the rectifier front panel with one hand and slowly pull it out from the shelf, supporting the base
of the rectifier with your other hand.
Fitting Blanking Plates

Place the Rectifier Blanking Plate in position on the Rectifier Magazine.
Tighten the Blanking Plate Retaining Screw to a torque of 1.7Nm.

Manual
Commissioning
This section is a generic guide to the commissioning tasks normally performed on a DC system. Local
site and equipment arrangements may require different tasks to be completed or a reduced number
of tests from the ones documented below.
Before starting these Commissioning tasks:

• Complete all the Installation tasks in the previous sections.
• Save a copy of the configuration file.
Complete the Commissioning tasks in the following order:

During the testing, note any changes to the configuration file that are incorrect.
Task Description
1 Analog Inputs
2 System Controls
3 System Alarms
4 Digital Inputs
5 Digital Outputs (Relays)
Task 1 - Analog Inputs

Equipment required:
• Digital Voltmeter
• DC Load bank
• DC Current Clamp meter
• Trim pot adjustment tool
• Thermometer
Test Test procedure Adjustment

dc Voltage Measure the DC voltage across the DC bus. None
Ensure the bus voltage on the SC200 display and in
DCTools/Web is within specifications.
Battery Current Conduct the load test and turn off the rectifiers. Adjust the gain setting on the
(High current test) Measure the load current with a DC clamp meter. current sensor by moving the trim
Note 1 Ensure the current displayed on the SC200 and in pot.
DCTools/Web is within specification. Adjust the gain setting in the
Ensure the current is the correct polarity. SC200
Load Current Connect a load bank to the DC load connection Adjust the gain setting on the
(High current test) Apply a high load to the system current sensor by moving the trim
Note 2 Measure the load current with a DC clamp meter pot.
Ensure the load current displayed on the SC200 and Adjust the gain setting in
in DCTools/Web is within specification. DCTools/Web.
Ensure the current is the correct polarity.
Total System Repeat the load test. None
Current Ensure the system current displayed on the SC200
(High current test) and in DCTools/Web is within specification.
Load Current Disconnect the load bank from the system. Adjust the current offset setting of
(No current test) Ensure the load current displayed on the SC200 and the SC200.
in DCTools/Web is 0 amps.
Battery Current Disconnect the load bank from the system. Adjust the current offset setting of
(No current test) Ensure the battery current displayed on the SC200 the SC200.
and in DCTools/Web is 0 amps.
Manual

Total System Disconnect the load bank from the system. None
Current Ensure the total system current displayed on the
(No current test) SC200 and in DCTools/Web is 0 amps.
Temperature With thermometer, measure the temperature at the Some temperature sensors have
power system temperature sensor. an adjustable trim pot.
Ensure the temperature input displayed on the
SC200 and in DCTools/Web is within specification.
Test each temperature input.
User assigned Test the accuracy and alarm mapping for all analog See Note 3.
Analog Inputs inputs.
Note 3 Check the name, severity and alarm thresholds are
correct.
Notes
1. When the rectifiers are turned off, the battery current will supply all the current to the load.
At this time the battery current will equal the load current.
This test assumes there is a current sensor on the DC Load Bus. If batteries are not installed
on the system, connect the load bank to the battery bus.
If the battery current is determined by a summation, conduct the load current test before
the battery current test.
2. The test should be done at the maximum expected system load current.
This test assumes there is a current sensor on the DC load bus.
3. As the analog inputs can be configured for many different types of analog signal, tests have
not been detailed on this test sheet.
User assigned analog inputs are not available on all systems.
Task 2 - System Controls

Equipment Required:
DC Load bank

Voltage Control Apply a load to the power system. None
Note 1 With DCTools, ensure the bus voltage matches the Target
Voltage as shown on the Voltage Control Summary of
DCTools.
Temperature Heat the battery temperature sensor. None
Compensation Ensure the system voltage changes in accordance with the
Note 2 configured slope.
Equalize Set the Equalize Duration to 1 minute. None
Start an Equalize.
Ensure the system voltage increases to the Equalize Voltage.
Ensure the SC200 indicates an Equalize has started.
Ensure the Equalize stops after the 1 minute duration.
Return the Equalize duration to the original setting.

Manual

Fast Charge Set the Fast Charge Max Duration to 1 minute. None
Note 3 Set the Fast Charge Voltage Threshold to a value
approximately 1V below the system float voltage.
Connect load to the system.
Turn off the AC to the system.
Allow the system voltage to fall below the Fast Charge
Voltage Threshold.
Turn on the AC.
Ensure the system performs a Fast Charge.
Ensure the SC200 indicates a Fast Charge has started.
Ensure the Fast Charge Voltage is correct.
Ensure the Fast Charge stops after 1 minute.
Return the Fast Charge settings to the original values.
Generator Control Set the Voltage Threshold to a value approximately 1V below None
Option the system float voltage.
Note 4 Turn off the AC to the system.
Allow the system voltage to fall below the Voltage Threshold.
Ensure the system performs a Fast Charge.
Ensure the SC200 indicates a Generator Enable.
Ensure the Generator Enable digital output activates.
Turn on the AC.
Ensure the Generator Enable stops after 1 minute.
Return the settings to the original values.
Battery Current Limit Reduce the Battery Current Limit setting to 5%. None
Note 5 Connect load to the system.
Turn off the AC to the system.
Allow the battery to discharge for a period.
Turn on the AC.
Monitor the battery current to ensure the Battery Current
Limit control process is operating.
Current Share View the individual rectifier currents with the SC200 or None
Note 6 DCTools/Web.
Ensure the currents are all at 0 amps.
Ensure that all rectifiers share the load evenly and any
variation is within specification.

Manual

Battery Test Set the Battery Test Interval to 0 days. None
Set the Battery Test Duration to 30 minutes
Set the Battery Test Termination Voltage to a value
approximately 2 volts below the float voltage.
Start the Battery Test.
Ensure the SC200 indicates that a Battery Test has started.
Wait until the system voltage reduces below the Termination
Voltage.
Confirm the Battery Test fails.
Ensure the Battery Test Fail alarm is displayed on the SC200.
Ensure the Battery Test stops and the system voltage returns
to the float voltage setting.
Clear the Battery Test Fail alarm in DCTools/Web.
Set the Battery Test Duration to 1 minute.

Set the Battery Test Termination Voltage to a value
approximately 10 volts below the float voltage.
Start the Battery Test.
Ensure the SC200 indicates that a Battery Test has started.
Wait for the Battery Test Duration time to expire.
Confirm the Battery Test passes.
Ensure the Battery Test stops and the system voltage returns
to the float voltage setting.
Reset the Battery Test settings to the original values.
Low Voltage Set the LVD manual control to CONNECT. None
Disconnect – Manual Ensure the LVD contactor is connected.
Operation Ensure the SC200 displays an LVD Manual alarm.
Note 7 Ensure the I/O board LVD LED is on.
Set the LVD manual control to AUTO.

Ensure the SC200 shows no LVD alarms.
Ensure the I/O board LVD LED is on.
Set the LVD manual control to DISCONNECT.

Ensure the LVD contactor disconnects.
Ensure the SC200 displays an LVD Manual alarm.
Ensure the I/O board LVD LED is off.
Set the LVD manual control to AUTO.

Ensure the LVD connects.

Manual

Low Voltage Check the LVD contactor is connected. None
Disconnect – Increase the LVD Disconnect Voltage Threshold.
Automatic Operation Reduce the system voltage below the LVD Disconnect Voltage
Note 7 Threshold.
Wait for the configured Recognition Period.
Ensure the LVD disconnects.
Ensure the SC200 displays an LVD Disconnected alarm
Ensure the I/O board LVD LED is off.
Increase the system voltage above the configured Reconnect

Voltage.
Wait for the configured Recognition Period.
Low Voltage Disconnect each LVD control cable from the I/O board. None
Disconnect – Alarms Ensure the SC200 displays an LVD Fail alarm.
Note 7 Ensure the I/O board LVD LED is flashing.
Reconnect the cables.

Notes
1. AVC must be enabled. Allow up to 1 minute for the system to stabilize after load or voltage changes.
2. Breathing on the sensor can increase the temperature.
3. Battery Current Limit control process may have to be turned off to allow the Fast Charge voltage to
reach its value within the 1 minute test duration.
4. For details see Generator Control Option in the System Controller Operation Handbook.
5. There may be slight current fluctuations above and below the configured current limit setting. This
can be due to the current control within the factory preset deadband.
Confirmation of this control process may be witnessed in the Fast Charge test.
6. There may be a delay of up to 2 minutes before the currents stabilize between rectifiers.
7. There may be a delay of up to 10 seconds before the LVD changes state.
APS systems may not display a Manual Connect alarm on the SC200 if the system voltage is above the
LVD disconnect voltage.
Perform the test on each LVD control module within the system.
For manual LVD operation see details.
For an explanation of LVD LED indications see Troubleshooting.

Manual
Task 3 - System Alarms

Equipment Required:
DC load bank
DC power supply

General notes about For all alarms check the following where applicable:
alarm testing SC200 LED status.
SC200 display indication.
DCTools/Web alarm indication
Remote alarm indication (PowerManagerII, SNMP traps, etc)
Digital outputs (relays).
Reducing the alarm recognition time will reduce the alarm
testing time.
There may be more than 1 method to perform the following
alarm tests.
Low Float Increase the Low Float Threshold to just below the float
Note 1 voltage.
Reduce the system voltage by heating the battery
temperature sensor
- or -
Disconnect the battery from the system.
Start a Battery Test.
The system voltage will fall.
Ensure alarm operates.
Low Load Test as for the Low Float test.
Note that the Low Load Threshold is lower than the Low Float
threshold.
High Float Set the system Float Voltage above the High Float Threshold.
Note 1 - or -
Reduce the High Float Threshold and increase the system
voltage by starting an Equalize.
- or -
Reduce the High Float Threshold and increase the system
voltage by cooling the battery temperature sensor.
High Load Increase the system voltage.
Test as for the High Float test.
Note the High Load Threshold is higher than the High Float
Threshold
Rectifier Fail Turn off a rectifier AC MCB (if fitted).
The rectifier will turn off.
Multiple rectifier fail Turn off the AC MCBs to 2 rectifiers (if fitted).
The rectifiers will turn off.
Rectifier comms lost Remove a rectifier from the system.
Multiple Rectifier comms Remove 2 rectifiers from the system.
lost Ensure alarm operates.

Manual

Partial AC Fail Turn off the AC to more than 20% of the rectifiers in the
system.
AC Fail Turn off all AC to the system.
System Overload Reduce the System Overload Recognition Period to 0 minutes.
Apply load to the system.
Turn off rectifiers until the System Overload Threshold is
exceeded.
Load Fuse Fail Apply load to the system.
Note 2 Turn off the MCB feeding the load bank.
Battery Fuse Fail Turn off a Battery MCB or remove a Battery Fuse.
Battery Test Fail See Battery Test for details.
LVD alarms See LVD test on page 30 for details.
Battery Temperature Increase the Battery Temperature Low Threshold above the
Low current temperature.
- or -
Cool the temperature sensor until the threshold is exceeded.
Battery Temperature Reduce the Battery Temperature High Threshold below the
High current temperature.
- or -
Heat the battery temperature sensor until the threshold is
exceeded.
Sensor Fail Disconnect the battery temperature sensor from the I/O
board (XH7).
Replace the battery temperature sensor.
Disconnect the current sensor (XH6).

Replace the current sensor.
Disconnect the voltage sensor (XH9).

Replace the voltage sensor.
Equalize For details see Equalize test in System Controls
Fast Charge For details see Fast Charge test in System Controls
Battery Test For details see Battery Test in System Controls
In Discharge Connect load to the system.
Note 3 Turn off the AC supply to the rectifiers.
Allow the battery to start discharging.
Config Error Load incorrect configuration file.
Note 4 - or -
Remove all rectifiers from the system.
Apply an incorrect external voltage to the system:
24V for a 48V system
48V for a 24V system

Manual

User Assigned Alarms See User Digital Input test.
Battery Current Limit For details see Battery Current Limit test in System Controls.
Rectifier No Load Ensure the DC load and batteries are isolated from the
system.
Rectifier Current Limit Apply a DC load to the system.
Turn off rectifiers until the remaining rectifiers reach the
Rectifier Current Limit threshold.
- or -
Set the Rectifier Current Limit slightly below the existing
rectifier current being delivered to the load.
High Rectifier Unable to test.
Temperature
Note 5
AC Phase 1/2/3 Fail Turn off AC phase 1 to the power system.
Note 6 Ensure alarm operates.
Repeat for phase 2 and phase 3.
AC Phase 1/2/3 Voltage Reduce the High AC Threshold below the existing AC voltage.
Note 6 Ensure alarm operates.
Increase the Low AC Threshold above the existing AC voltage.

AC Frequency Change the Nominal AC Frequency setting.
Note 6 Change the AC Frequency Threshold.
Engine Run Option Change the state of the digital input with Engine Run
Note 7 function.
Notes
1. Ensure Alarm Tracking is disabled. Ensure Temperature Compensation is enabled.

2. If the load is not connected to the load MCBs and if an electronic Fuse Fail detect circuits is
installed, this test can also be performed as follows:
a. Turn off the load MCB
b. Connect a high impedance path >100kΩ) between the end load side of the MCB and
the Common Bus. (The impedance path can also be created by touching these points
with your hand.)
3. Ensure the battery discharge is high enough. Allow for the recognition time.
4. This alarm will be displayed if the incorrect configuration or incorrect rectifiers are used in
the system. It is not recommended that this be tested as it is very unlikely for an incorrect
configuration to be installed after commissioning.
5. This alarm is originated from the rectifier. It can only be tested by increasing the internal
temperature of the rectifier.
6. These alarms are only available with the external AC metering option.
7. A digital input must be configured for this test to function. See details.

Manual
Task 4 - Digital Inputs

Digital Input 1 Change the state of the Digital input.
Ensure any alarms mapped to the digital output (relay)
activate.
Ensure the Digital Input Alarm Name is correct.
Digital Input 2 As for Digital Input 1.
User Assigned Digital As for Digital Input 1.
Inputs Check the severity and digital output (relay) mapping is
Note 1 correct.
Notes
1. As the Digital Inputs can be configured for many different digital input devices, specific tests
have not been detailed on this test sheet.
Task 5 - Digital Outputs (Relays)

Digital Output 1 Set the Test State to Relay Active or Relay Inactive.
Note 1 Ensure the digital output changes state and any remote
alarms are extended.
Wait for the Relay Test Duration time.
Ensure the digital output state and any extended alarms
return to their original state.
Digital Output 2 As for Digital Output 1.
Note 2
User assigned Digital As for Digital Output 1.
Outputs
Notes
1. Digital Outputs can also be checked as other system tests are performed.
2. This digital output is typically configured as the Monitor OK relay. Test extended alarms by
removing the power to the I/O board. This will de-energize the relay.
Commissioning Completion
Restore the original (backed-up prior to the testing) configuration file.
Use DCTools/Web to change any configuration file settings that were noted as incorrect during the
Commissioning tests.

Manual
Troubleshooting
Use the table to troubleshoot minor installation and operational problems.
Return items for replacement or repair with a completed Equipment Incident Report.
Problem Possible Cause Required Action
SC200 alarm. See Troubleshooting in the SC200

Operation Handbook.
All rectifiers are off (no LEDs on) and AC supply to the system is off and the Restore AC supply.
system controller display is blank. batteries are fully discharged or
disconnected.
Green LED of one or more rectifiers is AC supply to rectifier(s) off or one or Restore the AC supply.
off. more phases are off.
Rectifier(s) not fully inserted. Insert rectifier and tighten retaining

screw.
Internal rectifier fault. Remove the rectifier and insert another
one in the same slot. If second rectifier
fails to start then there is a fault with the
rectifier position. Check AC connections.
If the second rectifier operates normally,
the first rectifier is faulty and must be
returned for service.
All rectifier LEDs flash. The rectifier Identify function. Normal operation. See details in the
Rectifier yellow LED flashes. The system controller is starting. Wait for system controller to complete
start-up.
Rectifier has not registered with the Remove then re-insert the rectifier.
system controller. Replace the rectifier with another
rectifier. If second rectifier fails to
register then there is a fault with the
rectifier position. Check rectifier comms
bus wiring.
If second rectifier registers then first
rectifier is faulty and must be returned
for service.

Manual
Rectifier yellow LED on. Rectifier power limit or current limit is Power system is charging the batteries.
active. If required, activate the Battery Current
Limit control process.
Load current exceeds the total rectifier Install additional rectifiers.

capacity.
Rectifier temperature turndown is Power system will return to normal
active due to low AC supply voltage or operation when the AC supply voltage
high ambient temperature. and/or ambient temperature are within
the specified ranges.
Rectifier yellow LED on and rectifier Rectifier has been shut down. Normal operation. See details in the
clicks every 5-15 seconds. System Controller Operation Handbook.
If required, restart the rectifier.
Rectifier red LED on. Very high or low AC voltage, or AC Power system will return to normal
supply failed. operation when the AC supply voltage is
within the specified range.
DC overvoltage Remove and re-insert rectifier(s) or shut
down and restart using DCTools/Web.
Rectifier failed Replace the rectifier.
Low system output voltage (rectifiers Rectifiers off. Restore the AC supply.
not in current limit).
Battery Test and/or Temperature Disable active function(s) if not required.
Compensation is active.
Incorrect float voltage setting at system Correct the float voltage setting of the
controller. system controller.
Record new setting.
Low system output voltage and rectifier Load is too high for rectifier capacity. Install additional rectifiers.
yellow LEDs are on (rectifiers are in
current limit). Battery is recharging after AC supply Check battery has recharged within
failure. expected time.

Manual
High system output voltage. Equalize, Fast Charge and/or Disable active function(s) in system
Temperature Compensation is active. controller if not required.
Incorrect float voltage setting at system Correct the float voltage setting of the
controller. system controller.
Record new setting.
Faulty rectifier. Locate the rectifier with the highest
output 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 DC output (rectifiers are Load fuse or MCB open. Check the load fuses or MCBs.
on).
LVD has disconnected the load. Use DCTools/Web to check LVD is
enabled and set to correct values. (LVD
status LED on the I/O board is on when
LVD is connected.)
Check that the I/O board is connected
(Power LED is on).
Check that the LVD control and power
cables are connected.
Check the connections from the load bus
to the LVD.
System has no battery input Battery MCB open. Switch on the required battery MCB(s).
LVD has disconnected the battery. Use DCTools/Web to check LVD is
enabled and set to correct values. (LVD
status LED on the I/O board is on when
LVD is connected.)
Check that the I/O board is connected
(Power LED is on).
Check that the LVD control and power
cables are connected.
Check the connections from the battery
bus to the LVD.

Manual
String Fail Alarm The Battery Mid-point Monitoring See Battery Mid-point Monitoring
system has detected a voltage section of SC200 manual.
imbalance in one of the battery strings.
A Battery Mid-point Monitoring sense Check the sense wires.
wire is disconnected.
I/O board Power/Comms OK LED is off I/O board is not powered or faulty. Check connection to YH3 on I/O board.
Replace I/O board if faulty.
I/O board Power/Comms OK LED is I/O board is responding to an Identify None, this is normal operation.
flashing. command from the SC200.
LVD1 and/or LVD2 Status LEDs (on I/O LVD is connected (contactor closed). None, this is normal operation.
board) are on.
LVD1 and/or LVD2 Status LEDs are off LVD is disconnected (contactor open). None, this is normal operation.
(I/O board Power On LED is on).
LVD1 and/or LVD2 Status LEDs are The LVD contactor is in the wrong state Check the electrical and mechanical
flashing. (SC200 internal state does not match operation of the contactor and auxiliary
signal from LVD auxiliary switch). switch.
Check all wiring and connectors.
LVD contactor(s) not operating. LVD settings incorrect. Use DCTools/Web to check LVD is
enabled and set to correct values. Check
that the LVD manual control is set to
AUTO. See details in the System
Controller Operation Handbook.
Check that the LVD is correctly mapped
to the I/O board. See details in the
LVD contactor is disconnected. Check that the LVD control and DC
power cables are connected.
All other SC200 problems. See Troubleshooting in the SC200

Operation Handbook.

Manual
Worldwide Support
For product information and a complete listing of worldwide sales offices, visit Eaton's website at:
www.eaton.com/telecompower or email: DCinfo@eaton.com
For technical support contact either your local Eaton DC product representative or the closest office
from the following list.
Australia: 1300 877 359
Canada: 1-800-461-9166
Central America: +52 55 9000 5252
China: +86-571-8848-0166
Europe / Middle East / Africa: +44-1243-810-500
Hong Kong / Korea / Japan: +852-2745-6682
India: +91-11-4223-2325
New Zealand: 0800 DC Power (327-693)
Singapore / South East Asia: +65 6825 1668
South America: +54-11-4124-4000
South Pacific: +64-3-343-7448
Taiwan: +886-2-6600-6688 or free call 0800-038-168
United States of America (Toll Free): 1-800-843-9433

Manual
Appendix A
Alarm PCB Connections (IOBGP-00)
Connector Type Purpose Pin Description
XS1 DB9M RS232 Serial Interface 1 -
2 RD (Receive Data)
3 TD (Transmit Data)
4 DTR (Data Terminal Ready)
5 Common (Ground)
6 -
7 RTS (Request to Send)
8 -
9 -
XS31 RJ45 Ethernet Interface 1 Rx
2 Rx
3 Tx
4 -
5 -
6 Tx
7 -
8 -
YS11 RJ45 RXP System Communications 1 +24/48V (System bus voltage)
2 +24/48V (System bus voltage)
3 -
4 RS485-A
5 RS485-B
6 -
7 0V
8 0V
USB USB B USB Serial Interface 1 VCC (+5 V DC)
2 Data -
3 Data +
4 Ground
1 8
RS232 D9M and RJ45 connector pin-outs RJ45 plug pin-outs

Manual

XH4 MTA LVD1 Interface 1 Coil +
156 2 Coil -
3 LVD1 auxiliary switch
4 Auxiliary switch common
XH5 MTA LVD2 Interface 1 Coil +
156 2 Coil -
3 LVD2 auxiliary switch
4 Auxiliary switch common
XH6 RJ45 Current Sense Inputs 1 Current Input 1 Common
2 Current Input 1
3 +12V out
4 Current Input 2 Common
5 Current Input 2
6 0V out
7 Current Input 3 Common
8 Current Input 3
XH7 RJ45 Temperature sense 1 -
2 -
3 -
4 Temp Sense 1+
5 Temp Sense 1-
6 -
7 Temp Sense 2+
8 Temp Sense 2-
XH8 MTA LVD power 1 Bus live
156 2 Common
XH9 MTA Bus voltage sense 1 Controller reference (Live)
156 2 Controller sense (Com)
XH12A MTA Battery Mid-point 1 String 1 Mid-point
156 Monitoring sense inputs 2 String 2 Mid-point
3 String 3 Mid-point
4 String 4 Mid-point
XH15A Digital inputs D1-D3 1 D1 input
2 0V
3 D2 input
4 0V
5 D3 input
6 0V
XH15B Digital inputs D4-D6 1 D4 input
2 0V
3 D5 input
4 0V
5 D6 input
6 0V

Manual

XH16/XH17 Digital relay outputs 1-2 1 Relay 1 normally closed (NC)
2 Relay 1 normally open (NO)
3 Relay 1 Common (COM)
4 Relay 2 normally closed (NC)
YH3 RJ45 DC power system digital 1 Load Fuse Fail
inputs 2 Battery Fuse Fail
3 +12V out
4 AC Distribution Fan Fail
5 AC Distribution MOV Fail
6 0V out (system live - protected)
7 -
8 System common - protected
YH11 RJ45 RXP System 1 +24/48V (System bus voltage)
Communications 2 +24/48V (System bus voltage)
3 -
4 RS485-A
5 RS485-B
6 -
7 0V
8 0V

Manual
Appendix B
Equipment Incident Report
Please enter as much information as you can. Send the completed form, together with the item for repair to
your nearest authorized service agent. NOTE: Only one fault to be recorded per form.
For further information contact your Eaton DC product supplier or Eaton Corporation, Telecommunications
Power Solutions. Telephone: +44 1243 810500, Fax: +44 1243 810683.
Date:
Customer Information
Company:
Postal Address:
Return Address:
(Not PO Box)
Telephone: Fax: Email:
Contact Name:
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 ___________

Manual
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:
__________
INFORMATION continued (fault details, circumstances, consequences, actions)

Manual
Appendix C
Circuit Diagrams
Drawing Number Description

11539300 Circuit Diagram – AC Input 4 Magazines, 4 x 3-Phase Feeds
11612000 Circuit Diagram – RM10 DC + COMMS + IOBGP
11607800 Circuit Diagram – SC200 + VFN + IOBGP
11613100 Circuit Diagram – FFN + IOBGP Connections
11614200 Circuit Diagram – Fuse/MCB To FFN

Manual
A B C D E F G
A1 DO NOT SCALE THIRD ANGLE PROJECTION IF IN DOUBT ASK
3 INPUT 1 INPUT 2 INPUT 3 INPUT 4

3Phase + Neutral + PE 3Phase + Neutral + PE 3Phase + Neutral + PE 3Phase + Neutral + PE
230/400VAC: 40A / Ph: 50Hz 230/400VAC: 40A / Ph: 50Hz 230/400VAC: 40A / Ph: 50Hz 230/400VAC: 40A / Ph: 50Hz
L1 L2 L3 N E L1 L2 L3 N E N E L1 L2 L3 N E L1 L2 L3
GR/1 40A
GR/1 40A
GR/1 40A
GR/1 40A
BN/1 40A
BN/1 40A
BN/1 40A
BN/1 40A
BK/1 40A
BK/1 40A
BK/1 40A
BK/1 40A
GY/1
GY/1
GY/1
GY/1
BL/1
BL/1
BL/1
BL/1
4
+VE -VE
COM LIVE
GR/2
BL/2
5
GR/1 40A
GR/1 40A
GR/1 40A
GR/1 40A
BN/1 40A
BN/1 40A
BN/1 40A
BN/1 40A
BK/1 40A
BK/1 40A
BK/1 40A
BK/1 40A
GY/1
GY/1
GY/1
GY/1
BL/1
BL/1
BL/1
BL/1
L1 L2 L3 N L1 L2 L3 N N L1 L2 L3 N L1 L2 L3
TO RECTIFIER TO RECTIFIER TO RECTIFIER TO RECTIFIER

MAGAZINE 1/1 MAGAZINE 1/2 MAGAZINE 1/3 MAGAZINE 1/4
AC DISTRIBUTION
RECTIFIER MAGAZINE 1
Ø1 Ø2 N Ø3
E
7
RECTIFIERS ON PHASE = 3 RECTIFIERS ON PHASE = 3 RECTIFIERS ON PHASE = 4
USED ON ............
Ø1 Ø2 N Ø3
8
E
9 Ø1 Ø2 N Ø3
10
Ø1 Ø2 N Ø3
11
+VE -VE
COM LIVE
ALL FIXINGS TO BE ROHS COMPLIANT

FILE N o.
DRAWN MATERIAL
12
TOLERANCES
± 0.2 ...,XX FINISH
NOTES: ± 0.3 ...,X
± 0.5 UNLESS
OTHERWISE STATED
BN/1 = BROWN 6mm ² TRI-RATED UL1015 ANGLES .....± 0.5° CHK'D Details DCN/FIN No. Date Issue
BK/1 = BLACK 6mm ² TRI-RATED UL1015
TITLE
GR/1 = GREY 6mm ² TRI-RATED UL1015 NOTES: LARGER CROSS SECTIONS MAY BE USED THROUGHOUT.
BL/1 = BLUE 6mm ² TRI-RATED UL1015 LIVE (-VE) IS GREY. GROUND BLUE IF CABLE OR BARE IF COPPER BAR.
GY/1 = GREEN/YELLOW 6mm ² TRI-RATED UL1015 © 2012 Eaton Power Solutions Ltd
Not to be used for any purpose other than that for which supplied.
SCALE DIMS IN DRAWING No.
GR/2 = GREY 25mm ² TRI-RATED UL1283 Supplied without contractual or other liability for errors or omisions
where used for manufacture by the company.
BL/2 = BLUE 25mm ² TRI-RATED UL1283 mm
SHEET OF

Manual
Manual
SYxxxxxx
11800501_IR2 Generic
RJ45
RJ45
RM10 - RECTIFIER MAGAZINE 1
0V
-48V DCD/ACD
RJ45
IOBGP-00 YH3
11612002
COM
BL/1 BL/1 BL/1 BATTERY
COM BUS COM BUS COM BUS LVD
POWER MIDPOINT
GR/1 GR/1 GR/1
LIVE BUS LIVE BUS LIVE BUS XH8 POWER CURRENT TEMP XH12A
S3 S1
RXP SENSOR SENSE
YH11 XH6 XH7
BUS
LVD1 VOLTAGE
S2 XH4 XH9
RM10 - RECTIFIER MAGAZINE 2 VFN-00
TB1
0V
-48V
RJ45
P1 LCD2
BL/1 BL/1 BL/1 HX5
COM BUS COM BUS COM BUS P2
GR/1 GR/1 GR/1 LIVE RY6 RY5 RY4 RY3 RY2 RY1 XH15B XH15A
LIVE BUS LIVE BUS LIVE BUS 6 USER DIGITAL OUTPUTS 6 USER DIGITAL INPUTS
RM10 - RECTIFIER MAGAZINE 3
0V
-48V
RJ45
BL/1 BL/1 BL/1
COM BUS COM BUS COM BUS
GR/1 GR/1 GR/1
LIVE BUS LIVE BUS LIVE BUS
RJ45
RM10 - RECTIFIER MAGAZINE 4 NOTES:
Copyright © 2011-2014 Eaton Corporation. All Rights Reserved

GR/1 = GREY 35mm ² TRI-RATED UL1015
0V BL/1 = BLUE 35mm ² TRI-RATED UL1015
-48V
LARGER CROSS SECTIONS MAY BE USED THROUGHOUT.
BL/1 BL/1 BL/1 LIVE (-VE) IS GREY. GROUND BLUE IF CABLE OR BARE IF COPPER BAR.
COM BUS COM BUS COM BUS
GR/1 GR/1 GR/1
LIVE BUS LIVE BUS LIVE BUS
SC
SEE NOTES
IOBGP MIRRORED 02
FIRST DRAFT 01
SEE NOTES
CIRCUIT DIAGRAM
RM10 DC + COMMS + IOBGP (4 x RM10)
NTS
P a g e | 50
1 1 11612000
Manual
SYxxxxxx
BLACK
WHITE
RJ45 BLACK
WHITE
SC200 Controller BLUE IOBGP-00 DCD/ACD

YH3
11607802
COM
LVD BATTERY
POWER MIDPOINT
XH8 POWER CURRENT TEMP XH12A
S3 S1
RXP SENSOR SENSE
YH11 XH6 XH7
RXP BUS
LVD1 VOLTAGE
S2 XH4 XH9
VFN-00
RS232 USB
TB1
P1 LCD2
HX5
GREY P2
LIVE RY6 RY5 RY4 RY3 RY2 RY1 XH15B XH15A
Ethernet 6 USER DIGITAL OUTPUTS 6 USER DIGITAL INPUTS
0V -48V
BUS BUS

SC
SEE NOTES
IOBGP MIRRORED 02
FIRST DRAFT 01
SEE NOTES
CIRCUIT DIAGRAM
SC200 + VFN + IOBGP CONNECTIONS
NTS
P a g e | 51
1 1 11607800
Manual
SYxxxxxx
RJ45
IOBGP-00 DCD/ACD
YH3
11613202
LVD BATTERY
POWER MIDPOINT
XH8 POWER CURRENT TEMP XH12A
RXP SENSOR SENSE
YH11 XH6 XH7
BUS
LVD1 VOLTAGE
XH4 XH9
LCD2
HX5
P5
P1 P2 P3 RY6 RY5 RY4 RY3 RY2 RY1 XH15B XH15A
FFN-00 6 USER DIGITAL OUTPUTS 6 USER DIGITAL INPUTS
S2 S1 P4
RJ45

SC
SEE NOTES
IOBGP MIRRORED 02
FIRST DRAFT 01
SEE NOTES
CIRCUIT DIAGRAM
FFN + IOBGP CONNECTIONS (1 x FFN)
NTS
P a g e | 52
1 1 11613100
Manual
SYxxxxxx
MCB SENSE TO FFN CONNECTION
ADDITIONAL MCB SENSE WIRES
CONNECT TO P2 TO P4
P5
P1 P2 P3
FFN-00
11614201
S2 S1 P4
LOAD LOAD LOAD LOAD LOAD LOAD

MCB MCB MCB MCB MCB MCB
BUS BUS
FUSE SENSE TO FFN CONNECTION
ADDITIONAL FUSE SENSE WIRES

CONNECT TO P2 TO P4

P5
P1 P2 P3
FFN-00
S2 S1 P4
LOAD LOAD LOAD LOAD LOAD LOAD

FUSE FUSE FUSE FUSE FUSE FUSE
BUS BUS
SC
SEE NOTES
FIRST DRAFT 01
SEE NOTES
CIRCUIT DIAGRAM
FUSE/MCB TO FFN CONNECTION
NTS
1 1 11614200
P a g e | 53
Manual
SYxxxxxx
RJ45 RJ45 RJ45 TO ADDITIONAL
SLAVE CABINETS
(OPTIONAL)
11613701
COM COM COM COM
S3 S1 S3 S1 S3 S1 S3 S1
S2 S2 S2 S2
VFN-00 VFN-00 VFN-00 VFN-00
TB1 TB1 TB1 TB1
P1 P1 P1 P1
P2 P2 P2 P2
LIVE LIVE LIVE LIVE
MASTER SLAVE 1 SLAVE 2 SLAVE X

CABINET CABINET CABINET CABINET
(IF APPLICABLE) (IF APPLICABLE)

SC
SEE NOTES
FIRST DRAFT 01
SEE NOTES
CIRCUIT DIAGRAM
CABINET INTERCONNECTION
NTS
1 1
P a g e | 54
11613700
Page Intentionally Blank

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Eaton Power System Handbook

Eaton Power System

IR2 Power System Handbook

Issue Date: 21th October 2015

Eaton Electrical Limited

Issue Issue Date Amendment Description Author

Copyright © 2011-2014 Eaton Corporation. All Rights Reserved.

Personal Protection in Restricted Access Areas

Health and Safety

Reporting Problems with this Manual

Other Contact Details

Symbols Used in this Document

Standards and Approvals

WEEE directive 2002/96/EC

EN60950-1: Information Technology Equipment – Safety. Part 1 – General Requirements.

Please Note: - This equipment must be disposed of according to local regulations.

Health & Safety Guidelines

All work is to be conducted in accordance with the Regulations.

BS7671 Requirements for Electrical Installations

WARNING: Personal Protection

WARNING: Electrical Safety

11800501_IR2 Generic Copyright © 2011-2014 Eaton Corporation. All Rights Reserved P a g e | 10

WARNING: Labels and Instructions

WARNING: Location and Environment

WARNING: Hazardous Energy Levels

11800501_IR2 Generic Copyright © 2011-2014 Eaton Corporation. All Rights Reserved P a g e | 11

WARNING: AC Disconnect Device and External Overload Device

WARNING: Multiple Power Sources

11800501_IR2 Generic Copyright © 2011-2014 Eaton Corporation. All Rights Reserved P a g e | 12

WARNING: Earthed-end Connections

11800501_IR2 Generic Copyright © 2011-2014 Eaton Corporation. All Rights Reserved P a g e | 13

1. Before lifting loads, stand as close as

2. Keep the back straight and as vertical

3. Use the leg muscles to lift in preference

4. Minimize twisting, stretching and

5. Loads should be lifted, withdrawn,

The diagram shows recommended limits for

WARNING: Battery Disposal

11800501_IR2 Generic Copyright © 2011-2014 Eaton Corporation. All Rights Reserved P a g e | 14

WARNING: Batteries (if fitted)

WARNING: Battery Replacement

11800501_IR2 Generic Copyright © 2011-2014 Eaton Corporation. All Rights Reserved P a g e | 15

1. Read and follow the safety instructions.

WARNING: Supply Voltage

WARNING: Semiconductor Components

WARNING: Wrist Straps

11800501_IR2 Generic Copyright © 2011-2014 Eaton Corporation. All Rights Reserved P a g e | 16

11800501_IR2 Generic Copyright © 2011-2014 Eaton Corporation. All Rights Reserved P a g e | 17

Mechanical Installation Instructions

• 48U Cabinet - 2200mm high, 600mm wide and 600mm deep.

Front View Side View

11800501_IR2 Generic Copyright © 2011-2014 Eaton Corporation. All Rights Reserved P a g e | 18

Installation Fixings Required

Installation Tools Required

Positioning and Floor Fixing

• The floor surface where the equipment is to be installed is level.

This cabinet must be secured to a concrete or other non-combustible surface.

11800501_IR2 Generic Copyright © 2011-2014 Eaton Corporation. All Rights Reserved P a g e | 19