Access Power Solutions Installation Guide: (SM45 Controlled)

Access Power Solutions
Installation Guide
(SM45 Controlled)
Issue: IPN 997-00012-38D

Issue Date: April 2006
Eaton Corporation
Telecommunications Solutions Division
www.powerware.com
dc.info@powerware.com
About This Guide
4
Scope
This guide covers installation, commissioning and operation of Access Power Solutions
(APS) DC power systems, controlled by SM45 supervisory modules.

This guide does not cover the following:

x Installation and configuration of other Powerware products. For details, refer to the
relevant guide listed under Related Information on page i.
x Detailed instructions for setting up , except for the
communications settings on page 67.
x Detailed instructions for setting up user alarms and configuring individual parameters
in the SM45. There are brief explanations of SM45 alarms on page 83 and control
functions on page 85.
x Supervisory module upgrade from SM40 to SM45. This is covered in application note
AN0056. To receive application notes refer to Worldwide Support on page 93.
Audience
This guide is intended for use by:
x DC power system installers competent in:
x installing and commissioning DC Power Systems
x safe working practices for AC and DC powered equipment
x the relevant local electrical safety regulations and wiring standards
x DC power system operators and maintenance staff competent in:
x operation of DC Power Systems
x safe working practices for AC and DC powered equipment
Related Information
x Online Help
x Online Help
x SiteSure Installation and Configuration Guide – IPN 997-00012-19
x CellSure Installation Guide – IPN 997-00012-20
i
Access 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: dc.info@powerware.com
For Further Information and Technical Assistance

For Further Information and Technical Assistance see Worldwide Support on page 93.
ii
Table of Contents
4
About This Guide

Scope............................................................................................................................................i
Audience .....................................................................................................................................i
Related Information...................................................................................................................i
Reporting Problems with this Guide .....................................................................................ii
For Further Information and Technical Assistance..............................................................ii
Chapter 1 General Description
Overview.................................................................................................................................... 1
APS3 Series DC Power Systems.............................................................................................. 2
APS6 Series DC Power Systems.............................................................................................. 3
APS12/18/24 Series DC Power Systems............................................................................... 4
Access Power Rectifiers ........................................................................................................... 5
SM45 Supervisory Module ...................................................................................................... 6
I/O Interface Boards................................................................................................................. 6
Low Voltage Disconnect Option............................................................................................. 8
Chapter 2 Preparation
Overview.................................................................................................................................. 11
Warnings.................................................................................................................................. 12
Chapter 3 Installation
Overview.................................................................................................................................. 15
Mounting the APS DC Power System ................................................................................. 16
Input Transient Protection..................................................................................................... 17
Connecting the APS DC Power System to the AC Supply ............................................... 20
AC discrimination ......................................................................................................................... 21
APS3 AC connection options ....................................................................................................... 22
APS6 AC connection options ....................................................................................................... 24
High AC Voltage Protection.................................................................................................. 27
Connecting the DC Load and Battery Cables ..................................................................... 28
APS3 DC power systems .............................................................................................................. 28
APS6 DC power systems .............................................................................................................. 30
Connecting the DC Output to Earth .................................................................................... 32
Installing the Batteries............................................................................................................ 33
Mounting the Battery Temperature Sensor......................................................................... 34
Installing External Alarm and Digital Inputs Cabling ...................................................... 34
Chapter 4 Commissioning
Overview.................................................................................................................................. 37
Inserting the Rectifiers ........................................................................................................... 38
Pre-Power-Up Checklist ........................................................................................................ 39
Applying AC Power............................................................................................................... 39
Configuring the DC Power System ...................................................................................... 40
Using the keypad to configure the system................................................................................. 40
Using DCTools to configure the system..................................................................................... 40
Testing Alarms at a Remote Location .................................................................................. 44
Applying DC Power to the Load .......................................................................................... 45
iii
Chapter 5 SM45 Operations

Overview.................................................................................................................................. 47
Keypad and Display (if fitted) .............................................................................................. 48
About Display Modes ............................................................................................................ 50
Changing display modes.............................................................................................................. 50
Scrolling within a display mode.................................................................................................. 50
Using Edit mode............................................................................................................................ 50
Viewing System Values (Main Display Mode)................................................................... 51
Viewing Alarms and System Status Messages (Status View Mode) ............................... 52
Viewing Software Version..................................................................................................... 53
Viewing and Editing Configuration Parameters................................................................ 54
Synchronizing the SM45 Real-Time Clock .......................................................................... 54
Interfacing the SM45 with CellSure...................................................................................... 55
Interfacing the SM45 with SiteSure ...................................................................................... 58
LVD Test .................................................................................................................................. 59
Rectifier Restart....................................................................................................................... 59
External AC Metering Option............................................................................................... 60
Language Options .................................................................................................................. 61
Chapter 6 Communications
Overview.................................................................................................................................. 63
Communications Options...................................................................................................... 64
Setting up Modem Communications ................................................................................... 65
Setting up SMS Text Messaging............................................................................................ 66
DCTools and PowerManagerII Setup .................................................................................. 67
Ethernet Setup ......................................................................................................................... 67
Setting Up SNMP Traps......................................................................................................... 68
Accessing the SM45 Web Pages ............................................................................................ 69
Remote Access Password ...................................................................................................... 70
Chapter 7 Maintenance
Overview.................................................................................................................................. 71
Troubleshooting...................................................................................................................... 72
Replacing a Rectifier............................................................................................................... 77
Replacing the SM45 Supervisory Module ........................................................................... 79
Replacing the Real-time Clock Battery ................................................................................ 81
Monitoring and Replacing Transient Protective Devices.................................................. 82
Battery Disposal and Recycling ............................................................................................ 82
Appendix A Alarm Descriptions
Appendix B Control Functions
Active Voltage Control........................................................................................................... 85
Battery Current Limit (BCL).................................................................................................. 85
Battery Test .............................................................................................................................. 85
Current Share .......................................................................................................................... 86
Equalize.................................................................................................................................... 86
Fast Charge .............................................................................................................................. 86
Load-based Rectifier Shutdown............................................................................................ 86
Low Voltage Disconnect (LVD) ............................................................................................ 87
Relay Test................................................................................................................................. 87
Temperature Compensation.................................................................................................. 87
Appendix C Specifications
Equipment Incident Report
Worldwide Support
iv
Chapter 1
General Description
4
C h a p t e r 1
Overview
APS3 Series DC Power Systems 2
APS6 Series DC Power Systems 3
APS12/18/24 Series DC Power Systems 4
Access Power Rectifiers 5
SM45 Supervisory Module 6
I/O Interface Boards 6
Low Voltage Disconnect Option 8
1
APS3 Series DC Power Systems

2
General Description
APS6 Series DC Power Systems

3
APS12/18/24 Series DC Power Systems

The following diagram shows a typical APS24 DC power system with four APS6-00 rectifier
power shelves. This is the maximum expandable system size. Other system configurations
can be built with two (APS12) or three (APS18) APS6-00 rectifier power shelves.
For more details about APS12/18/24 series DC power systems refer to Worldwide Support
on page 93.
4
General Description
Access Power Rectifiers

Three types of fan-cooled, hot-pluggable Access Power Rectifiers are available.
x APR24 - 24V, 750W, 240V AC
x APR48 - 48V, 1500W, 240V AC
x APU48 - 48V, 720W, 110/240V AC

5
SM45 Supervisory Module

The SM45 supervisory module is an advanced control and monitoring solution for Access
Power Solutions (APS) DC power systems with up to 24 rectifiers.
It provides a full suite of advanced communications options, including built-in Ethernet
interface, Web server and SNMP agent. See details about the communications options on
page 64.
The SM45 supports the suite of optional add-on SiteSure input/output expansion modules
(see details on page 58) and CellSure battery management modules (see details on page 55).
Alarm notifications may be by SNMP traps or relay contact closures.
The SM45 has an onboard audible indicator and two alarm LEDs. Alarm relay, digital input,
temperature sensor(s), LVD and fuse fail terminations are located on the I/O Interface Board
(see details on page 6).
6
General Description
New I/O Interface boards with different combinations of alarm relays, digital inputs,
temperature sensor(s), MOV/load/battery fuse fail and LVD driver card(s) can be created to
meet virtually any specific requirement. For details refer to Worldwide Support on page 93.
The basic I/O Interface board is shown in the following diagrams (with and without LVD
driver cards). These diagrams may vary from installed I/O Interface boards.

7
Low Voltage Disconnect Option

Refer to the Control Function Descriptions on page 85 for a description of Low Voltage
Disconnect (LVD). LVDs for APS3 and APS6 power systems are shown in the following
diagrams.
APS3 Power System LVD

APS3 power systems can have a single-card 100A LVD module (combined LVD driver and
disconnect). See diagram on page 2 for position of LVD module.
8
General Description
APS6 Power System LVD

APS6 power systems can have one or two 200A contactors and separate LVD driver cards
(one LVD driver card per contactor). See diagram on page 3 for position of the contactor(s).
The LVD driver cards are on the I/O Interface board (see details on page 6).
The Auto/Manual selector switch allows manual control of the LVD contactor. The operation
of the selector switch is described in the following table.
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 72.
9
10
Chapter 2
Preparation
4
C h a p t e r 2
Overview
Warnings 12
11
Warnings
This section contains important warnings. Read these warnings before installing or operating
a Powerware Access Power Solutions DC power system.
x Powerware Access Power Solutions DC power systems must be mounted in an enclosed cabinet
that meets safety and fire enclosure requirements as specified in AS/NZS 60950.1, EN 60950-1
and UL 60950-1.
x The DC power system may be powered from multiple AC sources. All AC power sources must
be isolated before internally servicing the equipment.
x The DC power system MCBs are not a disconnect device. The APS DC power system must be
connected to a suitable upstream AC supply disconnect device such as Miniature Circuit
Breaker(s) (MCB) or fuses. This device must isolate both the phase and neutral conductors in
single-phase and three-phase connections, unless the neutral conductor is clearly identified.
x If the DC power system is to be installed in a location where the ambient temperature may rise
above 50ºC (122ºF), then V90 rated cable must be used for all connections.
x The DC power system is not compatible with IT (Impedance Terra) AC power distribution
topologies. For advice refer to Worldwide Support on page 93.
x A registered electrician (or suitably qualified person) must check the integrity of the installed
cabling, BEFORE the DC power system is powered up.
x Commissioning must be performed in the sequence documented in this guide.
x For ease of access and to maintain optimum system cooling observe the clearances stated on
page 16.
x Dust build-up within the DC power system may cause premature failure. In dusty
environments, either install the power system in a sealed and air-conditioned equipment room,
or provide fan assisted filtered air to create a positive pressure environment inside the
equipment room. Both options require regular cleaning of the air filters.
x 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.
x 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.
x Rectifiers and batteries contain hazardous energy levels. Only personnel trained and
experienced in DC power systems are to service this equipment.
x Always use insulated tools.
x Do not short-circuit the live and common bus bars or cables.
12
Preparation
x The plastic cases of batteries installed in Powerware DC power system racks must have a
flammability rating of UL 94-V2 or better.
x Flooded lead acid batteries can emit explosive gases and must be installed in a battery room
with adequate ventilation. Do not install flooded lead acid batteries in a Powerware DC power
system rack.
x Do not wear a synthetic dust-coat or overalls. Synthetic fabrics can hold static electric charge that
create sparks during discharge.
x Remove rings, wristwatch and other metal jewelry that might be exposed to battery terminals,
before installing batteries.
x 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.
x Do not place tools, loose cables or metal objects (such as interconnecting bars) on top of batteries.
x Do not drop tools, loose cables or metal objects onto intercell connections or terminals of
opposite polarity.
x Only terminate cables and interconnecting bars after confirming that the termination will not
create a short circuit.
x 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.
x There is a risk of electric shock if a battery is replaced by an incorrect type.
x Dispose of batteries according to the instructions.
x Do not install the rectifiers until the room has been cleaned and is dust free.
x To reduce the risk of electric shock and maintain optimum system cooling, always cover empty
rectifier slots with blanking panels.
x To avoid electrical shock, do not place hands inside the rectifier magazine.
x Rectifier cases may exceed 100ºC (212ºF), especially after prolonged operation. Use suitable
gloves when removing a rectifier from the magazine.
x Do not attempt to disassemble faulty rectifiers. Return them (in their original packaging) with a
copy of the Equipment Incident Report on page 91.
x Ensure that any upstream Residual Current Devices (RCDs) are appropriately rated for the
rectifiers' maximum earth leakage current (see Specifications on page 89 for value).
x 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:
x Your equipment and the DC power system must be located within the same premises.
x 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 32 for further information.
x The DC power system contains hazardous voltages. Do not attempt to disassemble or service
the unit if you are not qualified.
13
x This Powerware Access Power Solutions DC power system ("the equipment") has been tested
and found to comply with the limits for a Class B digital device, pursuant to part 15 of the
Federal Communications Commission (FCC) Rules. These limits are designed to provide
reasonable protection against harmful interference in a residential installation.
x The equipment generates, uses, and can radiate radio frequency energy and, if not installed and
used in accordance with the instructions in this installation guide, may cause harmful
interference to radio communications. However, there is no guarantee that the interference will
not occur in a particular installation.
x If the 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:
x Reorient or relocate the receiving antenna.
x Increase the separation between the equipment and receiver.
x Connect the equipment into an outlet on a circuit different from that to which the receiver is
connected.
x Consult the dealer or an experienced radio/TV technician for help.
x Changes or modifications to the equipment not approved by Eaton Corporation could void the
FCC authority to operate the equipment.
14
Chapter 3
Installation
4
C h a p t e r 3
Overview
Mounting the APS DC Power System 16
Input Transient Protection 17
Connecting the APS DC Power System to the AC Supply 20
High AC Voltage Protection 27
Connecting the DC Load and Battery Cables 28
Connecting the DC Output to Earth 32
Installing the Batteries 33
Mounting the Battery Temperature Sensor 34
Installing External Alarm and Digital Inputs Cabling 34
15
Mounting the APS DC Power System

APS3 and APS6 power systems are pre-assembled with two 19-inch rack-mounting brackets
as shown in the following diagram. If required, the brackets can be moved to alternative
positions.
Rack-mounting brackets are also available for use in 23-inch wide racks.
16
Installation
Input Transient Protection

To prevent lightning damage to Powerware Access Power Solutions, structural lightning
protection and transient overvoltage protection must be installed at each site.
Transient protection is also required to protect against other sources of transients, such as:
x Circuit or grid switching by the power company
x 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:
x Primary surge protection
x Secondary surge protection
x Primary / secondary surge decoupling coils
x Secondary / tertiary surge decoupling coils
6 Protect the data and control lines using a coordinated transient voltage surge
suppression plan
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:
x AC Power earth
x DC Power earth
x 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.
17
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 (8/20 µs 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 15PH 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 Access Power Solutions are factory-fitted with secondary
transient protection. These will protect the power system from a limited number of repeated
15 kA transients (8/20 µs wave shape).
Factory-fitted secondary transient protection typically consists of:
x Phase-to-neutral metal oxide varistors (MOVs) with a voltage rating of 385 V, capable of
withstanding temporary overvoltages
x A neutral-to-earth spark gap (gas discharge tube)
x Surge decoupling coils
If secondary transient protection is not fitted inside the Powerware Access 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 6 kV) and
the decoupling between the transient protection system and the DC power system.
Transients must be limited to less than 2 kA.
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.
18
Installation
Installation
Install the transient protection according to the following diagram.
19
Installation
x Label the switchboard.

x Once 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.
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 in the following graph.
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 shown.

21
APS3 DC power systems can be connected to various AC power sources. See AC connection
diagrams on page 23.
AC power is connected to the internal AC circuit breaker(s) of an APS3 DC power system (if
fitted). If no internal AC circuit breaker(s) are fitted, then the AC power source needs to be
connected to the AC circuit breaker(s) of an external AC distribution.

A typical example of connecting a single-phase (L-N) AC supply cable to the internal AC
Distribution of an APS3 DC power system is shown in the following diagram.
Use this diagram in conjunction with the appropriate AC connection diagram on page 23,
and warnings and installation practices on page 20, to connect the AC supply cord to the
APS3 DC power system.
22
Installation
23
APS6 DC power systems can be connected to various AC power sources. See AC connection
diagrams on page 25.
AC power is connected to the internal AC circuit breaker(s) of an APS6 DC power system (if
fitted). If no internal AC circuit breaker(s) are fitted, then the AC power source needs to be
connected to the AC circuit breaker(s) of an external AC distribution.

A typical example of connecting a three-phase (L-N) AC supply cable to the internal AC
Distribution of an APS6 DC power system is shown in the following diagram.
Use this diagram in conjunction with the appropriate AC connection diagram on page 25,
and warnings and installation practices on page 20, to connect the AC supply cord to the
APS6 power system.
24
Installation
25
26
Installation
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 I/O Interface Board (see
diagram on page 6 for location).

27
Connecting the DC Load and Battery Cables
The system voltage of APS3 power systems is referenced to either positive or negative earth.
This can be verified by checking the label on the DC Common bus bar(s). The following
diagram shows a negative earth referenced APS3.
Use this diagram in conjunction with the relevant instructions on the next page to connect
the DC load and battery cables to the APS3 power system.
28
Installation
29
The system voltage of APS6 power systems is referenced to either positive or negative earth.
This can be verified by checking the label on the DC Common bus bar(s). The following
diagram shows a positive earth referenced APS6.
Use this diagram in conjunction with the relevant instructions on the next page to connect
the DC load and battery cables to the APS6 power system.
30
Installation
31
Connecting the DC Output to Earth

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

During a lightning surge, very large voltages can develop between AC earth and DC
common as the surge current flows through the earth cables to earth.
APS DC power systems are fitted with an earth link (see following diagrams) to prevent
these very large voltages from developing, thus protecting the rectifiers from surge related
damage. We therefore strongly recommend that you do not remove the earth link, unless
this earthing practice is prohibited.
32
Installation
The transient earth clamp must have the following minimum specifications.
x Nom. DC Spark-over Voltage : 600 V
x Impulse Spark-over Voltage at 1 kV/µs : < 1400 V
x Nom. Impulse Discharge Current – 8/20 µs wave shape : 20 kA
x Insulation Resistance at 100 V : t 1010 :
x Capacitance : < 1.5 pF
A larger transient earth clamp with a high kA rating must be used if the potential severity of
a lightning strike is high.
Installing the Batteries

x Always check that the battery cables have been terminated to the correct system
polarity BEFORE connecting the batteries or closing the battery disconnect device.
x 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
x Do not wear a synthetic dust-coat or overalls. Synthetic fabrics can hold a static electric
charge, creating sparks during discharge.
x Remove rings, wristwatch and other metal jewelry that might be exposed to battery
terminals, before installing batteries.
x Only use a clean soft damp cloth for cleaning the batteries. Do not use cleaning
detergents or chemicals.
x When installing wet flooded lead acid batteries, ensure that the battery area has
adequate ventilation.
x 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

x 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.
x Do not remove the factory-fitted transit insulation covers from the batteries until access
to the battery terminals is required.
33
Interconnecting the Batteries

x Only terminate battery cables and interconnecting bars after confirming that the
termination will not create a short circuit.
x 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.
x Do not place tools, loose cables, or metal objects (such as interconnecting bars) on top of
batteries.
x 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 2m (6.5
feet) long cable, already connected to the backplane or I/O Interface board.
If required, longer cables are available (refer to Worldwide Support on page 93) 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 is to measure the ambient temperature around the batteries
and is required for the temperature compensation control function (see Control Function
Descriptions on page 85). It is important to mount the sensor at a location that truly reflects
the average ambient temperature of the batteries. A position above the middle of the
batteries may provide the most representative temperature reading.
If possible, avoid:
x Placing the battery temperature sensor on top of battery cases.
x Attaching the battery temperature sensor to battery cables, terminals or interconnecting
bars.
x Exposing the battery temperature sensor to direct sunlight and drafts from the
air-conditioning system or open windows.
x Running the battery temperature sensor cable along power cables.
Installing External Alarm and Digital Inputs Cabling
Step 1 - Remove the top cover (if fitted)
Slide forward and lift.
34
Installation
Step 2 - Access the alarm relay and digital input terminations
Alarm relay and digital input terminations are located:

APS3 - either on the backplane or optional I/O Interface board (see diagram on
page 2 for location).

APS6 - on the I/O Interface board (see diagram on page 3 for location).
Step 3 - Terminate the cabling
1 Pass the cabling through a spare cable gland at the back of the APS DC power
system.
2 Route the cabling to the terminal blocks on the backplane or I/O Interface
board.
3 Terminate the cabling as in the following diagram. (See also the alarm relay
and digital input specifications on page 89.)

Step 4 - Check the cabling
1 Visually check for cable damage and test the insulation of the cabling.
2 Check the continuity of the cabling.
Procedure complete
For details about setting up user alarms refer to Configuring the APS DC Power System for
Operation on page 41. For testing alarm reception at a remote location see details on page 44.
35
36
Chapter 4
Commissioning
4
C h a p t e r 4
Overview
Inserting the Rectifiers 38
Pre-Power-Up Checklist 39
Applying AC Power 39
Configuring the DC Power System 40
Testing Alarms at a Remote Location 44
Applying DC Power to the Load 45
37
Inserting the Rectifiers

x Do NOT install the rectifiers until the room has been cleaned and is dust free.
x 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 91.

Step 2 - Align the rectifier with the guides in the shelf
Step 3 - Push in the rectifier
x Keep fingers clear to avoid injury, as in following diagram.
1 Slowly push in the rectifier until it plugs firmly into the connector.
2 Tighten the rectifier retaining screw.
38
Commissioning
Pre-Power-Up Checklist
39
Commissioning
Step 2 - Check that the PC port is specified correctly
1 Double-click the 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 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 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 by clicking on the hotlinks

at the top of the 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.
41
Commissioning
Step 2 - Check that the PC port is specified correctly
1 Double-click the 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 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 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 by clicking on the hotlinks

at the top of the 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.
41
Testing Alarms at a Remote Location

The Relay Test function can be used to test the relay configuration and wiring to a remote
location.
Step 1 - For each alarm relay used, simulate an alarm at the SM45
DCTools
1 Ensure that the SM45 is powered and connected to (refer to the
Communications Options on page 64).
2 From the System Summary (Home) screen, click the Relays hotlink at the top of
the screen. The Relay Table screen is then displayed.
3 Set the Relay Test Duration as required.
4 To change the state of a relay, double-click on the Test State for that relay, then click
and select the new test state from the popup list.
5 Click on the button. The selected relay state will be toggled for 10 seconds
(the default which is configurable in ), before returning to its
original configured state.
1 From the Main Display Mode, press to enter Configuration Mode.

2 Press to scroll down to Relay Test.
3 Press to enter Relay Test Mode.
4 Press either or to select a relay.
5 Press to toggle the state (active or inactive) of the selected relay (relay must be . The
selected relay state will be toggled for 10 seconds (the default Relay Test Duration,
which is configurable in ), before returning to its original configured state.

6 Press to return to Configuration Mode. (All relays return to their configured states.)

Step 2 - Check the alarm signal has been received at the remote location
44
Commissioning
Setting Up User Alarms

Use to set up user alarm configurations. Only limited setup can be done from the
keypad.
DCTools
1 From the System Summary (Home) screen, click the Digitals hotlink. The
Digital Input Table screen is then displayed.
2 Type the assigned alarm name into the Name column for that user alarm. Assigned
alarm names (up to 15 characters long) are displayed on the LCD display.
3 Set the active state of a Digital Input (Closed or Open). Double-click on the Active State
for that user alarm, then click and select the new active state from the popup list.
4 Go to the Alarms Table to set the urgency of the user alarm (Disabled, Event, Non-
urgent, Urgent, Critical). Double-click on the Urgency for that user alarm, then click
and select the new urgency from the popup list.
5 If required, map the alarm to an alarm relay (using Relay Mapping A or B) or two
different alarm relays (using Relay Mapping A and B). Double-click on Relay Mapping
A or B for that user alarm. Then click and select the relay number from the popup list.
6 If required, enter additional text. Double-click in the field.

7 If a relay is used (in step 5) set the active state of the relay (Energized or De-energized).
Go to the Relay Table and double-click on the Active State for that relay. Then click
and select the new active state from the popup list.
Engine Run
Enable External Input
Enable External Input
43
Testing Alarms at a Remote Location

The Relay Test function can be used to test the relay configuration and wiring to a remote
location.
Step 1 - For each alarm relay used, simulate an alarm at the SM45
DCTools
1 Ensure that the SM45 is powered and connected to (refer to the
Communications Options on page 64).
2 From the System Summary (Home) screen, click the Relays hotlink at the top of
the screen. The Relay Table screen is then displayed.
3 Set the Relay Test Duration as required.
4 To change the state of a relay, double-click on the Test State for that relay, then click
and select the new test state from the popup list.
5 Click on the button. The selected relay state will be toggled for 10 seconds
(the default which is configurable in ), before returning to its
original configured state.

2 Press to scroll down to Relay Test.
3 Press to enter Relay Test Mode.
4 Press either or to select a relay.
5 Press to toggle the state (active or inactive) of the selected relay (relay must be . The
selected relay state will be toggled for 10 seconds (the default Relay Test Duration,
which is configurable in ), before returning to its original configured state.

6 Press to return to Configuration Mode. (All relays return to their configured states.)

Step 2 - Check the alarm signal has been received at the remote location
44
Commissioning
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.

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.

Procedure complete
45
46
Chapter 5
SM45 Operations
4
C h a p t e r 5
Overview
Keypad and Display (if fitted) 48
About Display Modes 50
Viewing System Values (Main Display Mode) 51
Viewing Alarms and System Status Messages (Status View Mode) 52
Viewing Software Version 53
Viewing and Editing Configuration Parameters 54
Synchronizing the SM45 Real-Time Clock 54
Interfacing the SM45 with CellSure 55
Interfacing the SM45 with SiteSure 58
LVD Test 59
Rectifier Restart 59
External AC Metering Option 60
Language Options 61
47
Keypad and Display (if fitted)
48
SM45 Operations
Audible indicator
x One beep – indicates an invalid key press
x One beep every 2 seconds – a Non-urgent alarm is active
x Continuous sound – an Urgent/Critical alarm is active

x Press any key

Display time-out
If no keys are pressed for a predetermined time interval the SM45 display goes back to the
default screen (total rectifier current).
The display time-out intervals are:
x Edit Mode – no time out
x All other display modes – 2 minutes
Changing the display contrast

The display contrast can be adjusted from 0 (lowest contrast) to 63 (highest contrast).
1 Press to enter Configuration Mode.

2 Press to scroll down to Display Contrast.
3 Press to enter Edit Mode.
4 Press or to change the display contrast as appropriate. (Contrast changes are
immediately visible.)
5 Press to save the new value.
6 Press to return to Main Display Mode.
49
About Display Modes

The SM45 menu structure has four display modes:
x Main Display Mode – for viewing system values
x Status View Mode – for viewing system statuses as well as viewing and clearing alarms
x Configuration Mode – for viewing settings of configurable parameters
x Edit Mode – for editing the configurable parameters in Configuration Mode
For easy reference see the supervisory module menu structure on the inside front and back
covers.
x From Main Display Mode, press to enter Status View Mode and Alarm Mode.
x From Main Display Mode, press to enter Configuration Mode and Edit Mode.
x Press to return from any mode to Main Display Mode.

x Press
50
Viewing Alarms and System Status Messages (Status View Mode)

Status View Mode displays alarm and status messages.
indicates an Urgent/Critical alarm
indicates a Non-urgent alarm
Refer to SM45 Keypad and Display on page 48 for details about the other display indicators.
Rules for displaying alarms and system status

x Active alarms are always displayed before status messages.
x Urgent/Critical alarms are always displayed before Non-urgent alarms.
x Alarms with their urgency set to None are not displayed.
Important note about Rectifier (Rect) Comms Lost alarm

If a rectifier is removed, a alarm is displayed after 10 seconds. If this alarm is
cleared within the configurable (default is 10 seconds) an external
alarm will not be generated.

1 From Main Display Mode, press to enter Status View Mode.

2 Press to scroll through the list of alarms.
3 Press to clear the alarms. (Only three alarms can be cleared – Rect Comms Lost, Rects
Comms Lost and Battery Test Fail.)

1 From Main Display Mode, press to enter Status View Mode.

2 Press to view additional text for the first alarm.

3 Press to view additional text for the next alarm(s).
4 Press to return to Status View Mode.
52
SM45 Operations
1 Press to enter Status View Mode.

If there are active alarms, press to scroll to the bottom of the alarm list. The control
status list is displayed after the last alarm.
2 Press or to scroll through the list of status messages.
Viewing Software Version
1 Press to enter Status View Mode.

2 Press to scroll to the Identity screen to view the software version of the SM45, as
shown below.
DCTools
1 Start (refer to the Communications Options on page 64).
2 From the System Summary (Home) screen, go to >
53
Viewing and Editing Configuration Parameters

Configuration Mode displays only those configuration file parameters that are most likely to
be changed on-site. These parameters can be changed in Edit Mode.
For viewing and editing all other configuration file parameters a laptop computer or remote
access is required. See the communications options on page 64 for details.
1 From Main Display Mode, press to enter Configuration Mode.

2 Press to scroll down to the required parameter.
3 Press to enter Edit Mode.
4 Press either or to change the value as appropriate.
5 Press to save the new value and return to Configuration Mode, or
6 Press to cancel the change and return to Configuration Mode.
Synchronizing the SM45 Real-Time Clock

The SM45 features a battery-backed real-time clock for accurate date-time stamping of all
alarms and control functions. Battery back-up ensures that the date and time is kept while
the SM45 is not powered.
If required, the time can be synchronized to the internal time of a PC or laptop.

DCTools
1 Ensure that the SM45 is powered and connected to . (For details refer to
Communications Options on page 64.)
2 From the System Summary (Home) screen, click Configuration then Identity to
display the System Identification view.
3 Under Time Synchronization, click the Synchronize button to synchronize the real-time
clock.

54
SM45 Operations
Interfacing the SM45 with CellSure

Interfacing the SM45 with a battery management system allows:
x and to communicate with up to four
(CBC) via the SM45. The SM45 acts as an Ethernet interface using the S3P Passthrough
protocol.

x three related alarms (CBC Comms Failed, CBC Urgent and CBC Non Urgent) to
be mapped to alarm relays, or sent as SNMP traps to up to eight different SNMP trap
receivers.
x all internal alarms to be displayed as urgent or non-urgent status messages on
the SM45 display and in or .
x the SM45 to use the average string temperature (measured by the battery
temperature sensor) instead of its own battery temperature input.
Before a CBC can communicate through an SM45 over an IP network with or

, the following setup is required.

Step 1 – Connect the CBC to the SM45
Connect the CBC(s) to the rack communications port (RCP) on the APS
backplane (see diagram on page 2 for location) as shown in the following
diagram.

55
Step 2 – Setup first (or only) CBC
1 Connect a null modem cable from the RS-232 port of the CBC to the
serial port of the PC.
2 From the CellSure Battery Monitoring System Summary (Home)
screen, go to > and check the following
settings:
x RCP address: 150 (default)
x Baud Rate Port RS485: B 19200 Baud
x Protocol Port RS485: Rcp
Step 3 – Setup additional CBCs (if fitted)
As required, repeat the previous step for the second, third and fourth CBCs,
except set the RCP addresses to 151, 152 and 153 respectively.
56
SM45 Operations
Step 4 – Configure the SM45 to operate with CellSure
1 From the System Summary (Home) screen, go >

to display the External Input/Output Communications
view.
2 Scroll down to CellSure Battery Controller (CBC) and set Fitted to .
3 From the System Summary (Home) screen, go to to display
the CellSure Battery Controller (CBC) Summary view.
4 Set Number of CBCs as appropriate.
5 To allow the SM45 to use the average string temperature from the
battery temperature sensor (instead of its own battery
temperature input) click next to Batt Temp Source and select
from the list.
Step 5 – Configure the DCTools / PowerManagerII communications settings
Create a new connection for CellSure in DCTools and/or PowerManagerII

with the following settings. Then check that DCTools or PowerManagerII
communicates correctly.
Comms Enabled : True

Protocol : S3P Passthrough
Connect Using : Local Network
S3P Address : 1:150 (Note 1)
Server IP Address : Enter the SM45 IP Address
Server Port : 14000
Telnet : Cleared
Notes:
1 The format is: (SM45 S3P Address : CBC RCP Address). Change the CBC RCP address as
required (150 - 153). Refer to Steps 2-3 for further information.
2 DCTools can not connect to multiple CBCs simultaneously. To connect to a second CBC,
close the connection to the first and create a new connection to the second CBC.
57
Interfacing the SM45 with SiteSure

is a suite of add-on modules to provide control and monitoring of a wide range of
external devices. It uses the communications capability of a Powerware DC power system to
monitor and control security, air conditioning, engine alternators and other building services,
or sense DC currents for load metering. modules can be added as required to
provide the number of inputs and outputs needed for a particular application.
Four modules are available:
x SiteSureGP – collects site-specific status information via configurable analog and digital
inputs
x SiteSureDI – provides additional configurable digital inputs
x SiteSureDO – provides configurable relay outputs for local control or alarm indication
x Current Input Module (IOM-CS) – provides configurable current sensor inputs
1 Connect the master modules (SiteSureGP and IOM-CS) as shown in the

following diagram.
2 Use (Configuration > External I/O) to check the master module
addresses.
3 If more than one SiteSure master module is to be connected then change the addresses as
follows:
x Connect one module at a time to the SM45.
x Double-click in the Change module number to: column to set the new module
number.
4 Configure the external analog inputs, digital inputs and digital outputs.

58
SM45 Operations
LVD Test
The LVD Test function allows the LVD contactors to be manually connected or disconnected
from or the keypad.
DCTools
x Start (refer to the Communications Options on page 64).
x From the System Summary (Home) screen, go to
x Click on or as required.
x Click on the button.
x Click the button.
x Press to go to Status View Mode.

x Press until the display shows LVD1 Test. If required, press again to access LVD2
Test.
x Press to edit the LVD state.
x Press to confirm the change.
x Press to connect/disconnect the LVD as required.
x Press to go to Status View Mode.
x Press to go to Main Display Mode.
Rectifier Restart
This function temporarily restarts rectifiers that have either been shutdown automatically by
Load-based Rectifier Shutdown (LBRS) (see details on page 86), or manually shutdown from
DCTools or PowerManagerII.
Rectifiers shutdown will have the (red) alarm LED on. Therefore, use this function to
restart all rectifiers to identify a faulty rectifier.

1 Press to go to Status View Mode.

2 Press until the display shows Auto Rect Shutdown
3 Press to restart all shutdown rectifiers.
4 Press to go to Main Display Mode.
59
1 Start (refer to the Communications Options on page 64).

2 From the System Summary (Home) screen, go to
3 Click on the button.
4 Click the button.
External AC Metering Option

The SM45 supervisory module (v2.00 or later software) supports AC metering and associated
alarms.
A Carlo Gavazzi WM4-96 Universal Utility Meter and Moxa NPort DF-311 Device Server are
required. See application note AN0063 for implementation details.

60
SM45 Operations
Language Options
The SM45 supervisory module language default is English. Text on the LCD display and web
pages (see details on page 69) can be shown in other languages by loading the appropriate
Translation Upgrade File (SM65-xx.icp) into the SM45.
Contact Eaton for available Translation Upgrade Files (refer to Worldwide Support on page
93).
1 Obtain the appropriate Translation Upgrade File (sm-xx.icp) from Eaton.

2 Save the file.
3 Connect to the SM45 via an Ethernet connection. Refer to Communications Options on
page 64.
4 Open a web browser and browse to the SM45 IP address.
5 Go to the page.
6 Click on and select the Translation Upgrade File.
7 Click on to add the language.
x Press to go to the (default) screen in Main Display Mode.

x Press
61
62
Chapter 6
Communications
4
C h a p t e r 6
Overview
Communications Options 64
Setting up Modem Communications 65
Setting up SMS Text Messaging 66
DCTools and PowerManagerII Setup 67
Ethernet Setup 67
Setting Up SNMP Traps 68
Accessing the SM45 Web Pages 69
Remote Access Password 70
63
Communications Options
The SM45 supervisory module has a standard RS-232 serial interface (XS1) and an Ethernet
10BaseT interface (XS31) for communication with a local or remote PC or laptop. See
diagrams on page 2 for locations of these connectors.
The standard communications options for SM45 supervisory modules are shown below. For
other communications options refer to Worldwide Support on page 93.

64
Communications

Setting up Modem Communications

For communications to PowerManagerII use a GSM (cellular) or PSTN (fixed line) modem.
Refer to Communications Options on page 64.

1 Connect to the SM45 with (refer to Communications Options on page 64).

2 Go to >
3 Click on to expand Modem.
4 Set Enable Modem to .
5 If the SM45 is to report alarms to PowerManagerII then set Alarm Report to .

6 Enter the telephone numbers the SM45 is to dial when an alarm is active.
Modem Retry
Interval Modem Maximum Retries
65
Setting up SMS Text Messaging

1 Connect the SM45 to a GSM modem (refer to Communications Options on page 64).
2 Connect to the SM45 with .
3 Go to > .
4 Click on to expand SMS.
5 For each cellphone to receive SMS alarm messages set the telephone number and level.
is optional.
1 From any cellphone write a SMS (text) message starting with "P" (any following
characters are ignored).
2 Send the message to the SM45 GSM modem telephone number.
3 The SM45 will reply with a DC power system status message.
66
Communications
DCTools and PowerManagerII Setup

For the chosen communications option (see diagrams on page 64) configure the
communications settings in either or according to the following
table.
Then check that / communicates correctly.

Comms Enabled True True True

Protocol S3P S3P S3P
Connect Using COM1 Ethernet Select a COM port
S3P Address 0 0 0
Phone Number – – User specific
Modem Logon – –
Server IP Address – 192.168.33.60 –
Server Port – 14000 –

Telnet – Cleared –
0 = Broadcast, 1-65279 = individual address
Clear if a logon script is not required for the modem.
Select if a logon script is required. Click the Logon Script button to define.
For more details, see online help (press F1).
Allocated by network supervisor
Some Ethernet interfaces (such as routers) may require this to be set.
Ethernet Setup
Before an SM45 supervisory module can communicate over a TCP/IP network with
or , the SM45 must be set up for Ethernet communications.
Use or the keypad to configure the SM45 for Ethernet communications.
DCTools
1 From the System Summary (Home) screen, click Configuration then
Communications to display the Communications view.
2 Under Ethernet, enter the assigned IP address, subnet mask and gateway address
assigned by the network administrator.

67
Setting Up SNMP Traps

The SM45 supervisory module can be configured to send alarms as SNMP traps to up to
eight different SNMP trap receivers on a Network Management System (NMS).
1 Set up Ethernet Communications (see details on page 67).

3 Click the next to SNMP to display the SNMP configuration view.
4 Do not change the default settings of SNMP Read Community (public) and SNMP
Write Community (private), unless requested by the network administrator.
5 Set Trap Type to or as appropriate.

6 Configure Trap Repeat and Trap Repeat Rate as appropriate.
7 For each SNMP trap receiver, configure the following parameters.
Name Enter the name of the SNMP trap receiver (20 characters maximum).
Level SNMP Trap Level – controls reporting of specific events for each receiver as
follows:
x Select All Events And Alarms to receive events and Critical, Urgent
and Non-urgent alarms. (Typically events are status messages such as
Equalize Active.)
x Select Urgent And Non Urgent Alarms to receive Critical, Urgent and
Non-urgent alarms.
x Select Urgent Alarms Only to receive only Critical and Urgent alarms.
x Select Critical Alarms Only to receive only Critical alarms.
x Select Disabled to temporarily disable notifications to the receiver.
IP Address IP address of the trap receiver assigned by the network administrator.
Port The default setting is 162. Do not change this setting, unless requested by
the network administrator.
Trap A form of password. Use public, unless the network administrator has
Community assigned a new password.
Mode Select:
x Normal Traps for sending traps to any network management system,
except
x Acknowledged Summary Trap for sending traps to
only
68
Communications
Entering the sysObjectID of a Power System (if required)

The sysObjectID is a unique Object Identifier that allows a network management system to
identify the type of device (in this case a power system) on the network.
Objects are named in the iso.org.dod.internet.private.enterprises (1.3.6.1.4.1) sub-tree for
enterprise-specific objects. The default Object Identifier for an SM45-based DC power system
is: 1.3.6.1.4.1.1918.2.12
A network administrator can specify a new Object Identifier within the (1.3.6.1.4.1) sub-tree,
if required.
DCTools
2 Click next to SNMP and enter only the last part of the new system Object Identifier
(as specified by the network administrator) into the System Object ID field.

Accessing the SM45 Web Pages
When connected to an IP network (via an Ethernet connection, see details on page 64), an
SM45-based DC power system can be monitored through a standard web browser.
To access the SM45 web pages, type the IP address of the SM45 into the address bar of the
web browser to display the System Overview page.
69
Remote Access Password

The remote access password prevents unauthorized changes to the SM45 configuration via
the RS232 serial port or the Ethernet port.

1 Connect to the SM45 with DCTools (see details on page 64).

2 Go to >
3 Type a password into the field.

4 Click the button.
1 Connect to the SM45 with DCTools (see details on page 64).

2 Go to >
3 Type a new password into the field or leave the field blank for no
password control.
4 Click the button.
5 Enter the old password.

2 Press to scroll down to Serial Password.
3 Press to clear the password.

70
Troubleshooting
Use the table to troubleshoot minor installation and operational problems. For additional
assistance see Worldwide Support on page 93. Return items for replacement or repair with a
copy of the Equipment Incident Report on page 91.
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 AC power to rectifier(s) off or Restore AC power.

more 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 89.
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 89.
Rectifier shut down Use 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 .
Rectifier failed Replace the rectifier.
Rectifier numbering is Magazine addressing incorrect. Check that the magazine addressing
incorrect (evident when is correct. See details.
viewing or the
individual rectifier currents Incorrect configuration file Verify that the number of rectifiers
displayed by the setting. per shelf is set to 1 and the rectifier
supervisory module, for offset is set to 0 (view in the
example, gaps in the rectifier screen.) Set the screen
numbering.) in to pictorially display the
number of rectifiers per shelf.
72
Maintenance
Rectifier numbers are offset Incorrect setting in Use to verify that the
by one. configuration file. Rectifier Offset is set to 0.
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.
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 provides no output LVD is wired as load disconnect Use heck 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.
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.
73
System has no battery input LVD is wired as battery Use heck 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.
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.
LVD contactors are inhibited by Connect battery with correct polarity.
the Multifunction Controller
(see details) because the battery
polarity is incorrect.
MOV Fail Alarm active. One or more MOVs have failed Check the visual indicators on all the
because of lightning strike(s) or MOVs. If a visual indicator indicates
AC transients. a failed MOV, replace all the MOVs
as soon as possible. See Monitoring
and Replacing Transient Protective
Devices on page 82.
One or more MOV cartridges Check that the MOV cartridges are
not properly fitted. properly inserted in the MOV
cartridge holders.
Faulty MOV Fail alarm wiring. Check the MOV Fail alarm wiring.
Red or Green LVD LED is LVD auto or manual operation. See details.
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.
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.
74
Maintenance
SM45 does not correctly Local/External current shunt Set the Local/External selector
register the current shunts selector switches in the wrong switches on the backplane to Local.
and the displayed values are position.
over range.
SM45 LCD display is blank. Ribbon cable to display and Reconnect ribbon cable. Wait 10
keypad module is disconnected seconds for operation.
(panel mount modules only).
Faulty display module Replace faulty unit.
SM45 Green Power On SM45 not powered. Check SM45 power connections.
LED off.
The AC supply is off and the None. The power system including
batteries are not connected the SM45 will return to normal
because of the Low Voltage operation when the AC supply is
Disconnect (LVD) unit tripped. within its specified voltage range.
Faulty Voltage feed Module Replace faulty unit.
(VFM) or faulty SM45
SM45 Red LED or Yellow Urgent/Critical or Non-Urgent Check the type of alarm on the LCD
LED on Alarm display or with or
. Refer to the Alarm
Descriptions on page 83.
Monitor OK relay (RLY6) is An active alarm is mapped to Check alarm relay mapping (see
de-energized this relay details on page 41).
SM45 software corrupt or Replace faulty unit.
hardware fault.
Incorrect battery or load Bus voltage sense polarity Measure the bus voltage sense and
current readings. incorrect. correct if necessary.
SM45 displays Failed, disconnected or Replace, connect or configure sensor.

unconfigured sensor.
Serial communications Incorrect, disconnected or faulty Check a null modem cable is
problem. cable plugged into the correct PC port.
Replace faulty cable.
Incorrect communications See DCTools / PowerManagerII
settings Setup on page 67.
Modem communications Incorrect modem setup string Refer to the modem's AT command
does not work manual.
Incompatible modem Contact Eaton for advice. Refer to
Worldwide Support on page 93.
Ethernet communications Disconnected or faulty cable Check cable connections.
problem.
Replace faulty cable.
Ethernet link is not active On the Ethernet connector (XS31)
check:
Left hand LED is continuously lit to
show link is active.
Right hand LED flashes to show
traffic is reaching the SM45.
See diagrams for position of the
Ethernet connector.
75
Incorrect communications See DCTools / PowerManagerII

settings Setup on page 67.
Real-time clock is incorrect Real-time clock time needs to be See Synchronizing the SM45 Real-
set. Time Clock on page 54.
Real-time clock battery is dead. See Replacing the Real-time Clock
Battery on page 81.
SM45 displays Config Error Missing or invalid configuration Download configuration file into the
file SM45. Refer to Replacing an SM45 for
details.
Incorrect rectifier voltage, Check that all rectifiers are of the
because installed rectifiers have same type and replace as necessary.
different output voltages.
Number of cells per battery Check the number of cells entered in
entered in SM45 configuration the configuration file and the voltage
file does not match the rectifier of the rectifiers.
output voltage.
SM45 displays a DC power Refer to Alarm Descriptions on page
system alarm message. 83.
76
Maintenance
Replacing a Rectifier
Rectifiers can be replaced without switching off the DC power system and disconnecting the
equipment it powers.
x To reduce the risk of electric shock and maintain optimum system cooling, always
cover empty rectifier slots with blanking panels.
x Rectifier case may be live under fault conditions. Test for high AC voltage before
touching rectifier case.
x To avoid electric shock do not place hands inside the rectifier shelf.
x Do not attempt to disassemble faulty rectifiers. Return them (in their original
packaging) with a copy of the Equipment Incident Report on page 91.
Removing a Rectifier
Step 1 - Loosen the rectifier retaining screw
Step 2 - Pull out the rectifier
x The rectifier may be hot, especially after prolonged operation. Use

suitable gloves.
x To avoid damage to the connector do not rest the rectifier on its
connector, once it has been removed from the shelf.
77
Installing a Replacement Rectifier
Step 1 - Align the rectifier with the guides
Step 2 - Push in the rectifier
x 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 turns on and the and
alarm LEDs are off.

78
Maintenance
Replacing the SM45 Supervisory Module

The SM45 supervisory module can be replaced without switching off the APS DC power
system and disconnecting the equipment it powers.
Before you start, you need

x A PC with the latest version of software installed.
x A copy of the appropriate SM45 configuration file, which can be one of the following -
the old configuration file, a backed-up configuration file or a modified default
configuration file
x A null modem cable
x To wear an anti-static strap to prevent possible damage of the static sensitive
components on the SM45 card
Step 1 - Isolate the LVD(s) (if fitted) to avoid unexpected LVD operation
To isolate the LVD(s) in:

x APS3 systems, disconnect the LVD control cable on the single-card LVD
module (see details on page 8).
x APS6 systems, switch the Automatic/Manual selector switch on the LVD
driver card(s) (see details on page 9) to CLOSED.

Step 2 - Backup the configuration file of the old SM45
If the old SM45 is still operational or if you are just upgrading the supervisory
module, use to backup its configuration file.
Step 3 - Remove the old SM45 from the shelf
1 Remove the front panel.
79
2 Disconnect the keypad/display module ribbon cable.
80
Maintenance
Step 7 - Check that the new SM45 operates as intended
1 Check all control functions, alarms and current measurement.

2 Check the power system identification parameters and communications
settings.
3 Change the configuration file as required to ensure that the SM45 operates
as intended.
4 Check that all rectifiers are communicating and that the SM45 has registered
all rectifiers. This can be checked from the LCD display by viewing the
individual rectifier currents in Main Display Mode. See supervisory module
menu structure on inside front cover or Viewing System Values on page 51
for details.
Procedure complete
Return the faulty SM45, in its anti-static bag, with a copy of the Equipment Incident Report
on page 91.
Replacing the Real-time Clock Battery

x Only service personnel should replace the real-time clock battery.
x There is a risk of explosion if the used battery is replaced by an incorrect type.
x Dispose of the used battery according to the battery manufacturer's instructions.
A 3.6 V lithium battery provides power to the real-time clock when the SM45 is not powered
from a DC power system. The real-time clock battery may need to be replaced because of its
life span (approximately 11 years).
The battery can be replaced with a Tadiran TL-5902/s, or equivalent, ½ AA non-rechargeable
lithium battery.
81
Monitoring and Replacing Transient Protective Devices

For information on transient protection devices refer to Input Transient Protection on page
17.
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.
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.
x 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.
x For remote sites with difficult access – Replace all the MOVs during scheduled
maintenance visits, whether they have failed or not.

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.
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 93.
82
Appendix A
Alarm Descriptions
4
A p p e n d i x A
AC Fail All rectifiers are reporting loss of AC power.

AC Frequency* The frequency of the AC supply is outside the configurable AC frequency
band, defined as: Nominal AC Frequency ± AC Frequency Threshold
AC Phase1 (or 2 or 3)*
83
High Load The bus voltage is higher than the safe range for the load and/or battery.
In Discharge The batteries are discharging.
Load Fuse Fail A load fuse has blown or a load MCB has operated.
Low Aux Temp The auxiliary temperature sensor is at a temperature below the low
temperature set point.
Low Batt Temp The battery temperature sensor is at a temperature below the low
temperature set point. This alarm indicates a risk to the standby power
system battery as lower temperatures reduce the battery capacity.
Low Float The float voltage is below its normal range.
Low Load The bus voltage is lower than the safe range for the load and/or battery.
LVD1 (or LVD2)
LVD1 (or LVD2) has disconnected the battery or load.
Disconnect**
LVD1 (or LVD2) Fail** LVD1 (or LVD2) is faulty.
LVD1 (or LVD2) Manual** The selector switch of LVD1 (or LVD2) is set to OPEN or CLOSED.
MOV Fail One or more MOV cartridges have failed and must be replaced.
Multiple Rect Fail Multiple rectifiers are faulty or their AC power has been removed without
causing partial or total AC failure.
No Load The total rectifier current is less than 2% of the maximum system output
current or is less than 2A.
Partial AC Fail More than 20% of rectifiers are reporting loss of AC power or loss of a phase.
Rect(s) Comms Lost Normally this alarm indicates that one or more rectifiers have been removed
during routine maintenance. However, faulty rectifier communications or
losing the rectifier communications bus can also trigger this alarm. If
removing multiple rectifiers triggers this alarm, you can reset it from the
keypad before it triggers an external alarm.
Rect Current Limit Rectifier(s) in current limit.
Rectifier Fail A rectifier is faulty or its AC power has been removed without causing
partial or total AC failure. Removal of some types of rectifiers (for example
R2048) during routine maintenance will cause a Rectifier Fail alarm. Rectifier
Fail alarm can be reset from the keypad before it triggers an external alarm.
Rect Over-Temp Rectifier(s) operating in temperature turndown mode, because of high
ambient temperature or low AC supply voltage.
Sensor Fail The current, temperature or voltage sensing system is faulty.
SiteSure Missing An external input or output is mapped in the configuration file but the
SiteSure equipment is not operational or not installed. See Interfacing the
SM45 with SiteSure on page 58 for details.
System Overload The power system is operating close to its maximum capacity and more
rectifiers are needed. The System Overload threshold is configurable.
* These alarms only occur if the external AC metering option is fitted. See details on page 60.
** Refer to the Control Function Descriptions on page 85 for further information on these control
functions.
84
Appendix B
Control Functions
4
A p p e n d i x B
Active Voltage Control

Active Voltage Control maintains a constant float voltage under varying load current by
monitoring the bus voltage and adjusting the rectifier output voltage to compensate for any
voltage drop.
Enable Active Voltage Control to prevent undercharging the batteries during high load
demand.
NOT
Battery Current Limit (BCL)

Battery Current Limit automatically limits the battery charge current within a configured
range (a percentage of the C10 rating of the battery) by varying the system voltage.
Enable Battery Current Limit to:
x Prevent overcharging of the batteries in under-loaded systems
x Minimize water loss in VRLA batteries
BCL Engine Run Limit limits the battery charge current to a preset value, when the power
system is powered by a standby engine/alternator during an extended AC power outage. A
smaller engine/alternator set can therefore be used without excessively pulling down the
alternator voltage.

Battery Test
Battery Test is a preventative maintenance tool that monitors the discharge capabilities to
ensure that the condition of the battery has not deteriorated over time. A battery test must be
performed during installation to characterize the battery strings.
The SM45 supervisory module temporarily reduces the output voltage of the rectifiers just
below the bus voltage for a set duration. The battery now supplies power to the load. A
battery test passes if the battery capacity remains above a predetermined level for the
duration of the test.
NOT
85
Current Share
Current Share ensures that the total output power of the power system is evenly shared
between all rectifiers.
Equalize
Equalize automatically charges batteries at a higher voltage after they have been fully
charged to ensure that all individual cell voltages are the same, that electrolyte is distributed
evenly and that sulfate crystal buildup on the plates is reduced.

Fast Charge
Fast Charge automatically increases the float voltage of the power system to recharge the
batteries as quickly as possible after an AC power outage.
Enable Fast Charge if the site experiences frequent AC power outages.
NOT

Load-based Rectifier Shutdown

Load-based Rectifier Shutdown (LBRS) automatically shuts down rectifiers when the total
load current is significantly less than the total rectifier capacity.
This raises the average load on the remaining rectifiers which will then operate at a higher
efficiency. This results in a decrease in total power consumption.

86
Control Functions
Low Voltage Disconnect (LVD)

Powerware Low Voltage Disconnects (LVD) can be connected either as load or battery
disconnect and have two purposes:
x to protect a VRLA battery from deep discharge and premature failure, and/or
x to reduce the load on a battery under discharge so that high priority equipment operates
for a longer time after an AC failure.
Powerware LVDs are normally wired as battery disconnect.
The SM45 supervisory module has two independent LVD control channels (LVD1 and
LVD2) with three modes of operation:
1 Normal Mode: In this mode and are disabled and
LVD1 is configured to disconnect at a higher disconnect voltage than LVD2.
2 LVD2 Slave Mode: In this mode LVD2 Slave Mode is enabled and LVD2 will mirror the
operation of LVD1.
3 AC Timer Mode: When AC Timer is enabled, the LVD will disconnect either after the
AC Timer Disconnect Delay, or the bus voltage drops to the Disconnect Voltage,
whichever happens first. Both LVD1 and LVD2 can be set to AC Timer mode if required.

Relay Test
Simulates an alarm at the SM45 by changing the state of a relay between active and inactive.
Use the Relay Test function to test reception of alarms at a remote location. See details on
page 44.
Temperature Compensation
As the ambient temperature of a battery drops (or rises) the voltage required to maintain full
charge increases (or decreases). Temperature Compensation automatically varies the float
voltage to cancel the effects of changing temperature.
Enable Temperature Compensation for optimum battery life and battery capacity over a
wider temperature range.
NOT
87
88
Contact Arrangement One changeover contact per relay

Maximum Switching Voltage 60V DC or 30V AC
Maximum Switching Current 500mA
Maximum Continuous Current 500mA
Maximum Power Rating 30W or 15VA
Maximum Wire Size 1.5mm2
Isolation Relay connections are isolated to 500V DC
from all other circuitry, earth and system
common.
Input Impedance 47kΩ pull-up resistor to +5V. (Referenced

to supervisory module 0V.)
Maximum Wire Size 1.5 mm2
Rated AC Input Voltage Range 185 – 275V
Maximum AC Input Current 6A / 12A

Rated Output Power 750W / 1500W
Rated Output Current 31A @ 24V / 31A @ 48 V
Preset Voltage 27V / 54.5V
Rectifier AC Fuses (internal) 15A
Rated AC Input Voltage Range 90 – 275V
RMS
Maximum AC Input Current 10A

Rated Output Power 720W
Rated Output Current 15A @ 48V
Preset Voltage 54.5V
Rectifier AC Fuses (internal) 15A
Comprehensive supervisory module and rectifier product data sheets are available. Refer to
Worldwide Support on page 93.
90
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: __________
91
INFORMATION continued (fault details, circumstances, consequences, actions)
SG/03 ISS04
92
SM45 LCD Display Menu Structure

Access Power Solutions Installation Guide: (SM45 Controlled)

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Issue: IPN 997-00012-38D

This guide does not cover the following:

Reporting Problems with this Guide

Powerware DC Product Marketing Communications

For Further Information and Technical Assistance

About This Guide

Chapter 5 SM45 Operations

APS3 Series DC Power Systems 2

APS6 Series DC Power Systems 3

APS12/18/24 Series DC Power Systems 4

Access Power Rectifiers 5

SM45 Supervisory Module 6

I/O Interface Boards 6

Low Voltage Disconnect Option 8

APS3 Series DC Power Systems

APS6 Series DC Power Systems

APS12/18/24 Series DC Power Systems

Access Power Rectifiers

SM45 Supervisory Module

Low Voltage Disconnect Option

APS3 Power System LVD

APS6 Power System LVD

Auto Normal automatic operation Controlled by the Closed: Green/No alarm

Mounting the APS DC Power System 16

Input Transient Protection 17

Connecting the APS DC Power System to the AC Supply 20

High AC Voltage Protection 27

Connecting the DC Load and Battery Cables 28

Connecting the DC Output to Earth 32

Installing the Batteries 33

Mounting the Battery Temperature Sensor 34

Installing External Alarm and Digital Inputs Cabling 34

Mounting the APS DC Power System

Input Transient Protection

Primary Transient Protection

Secondary Transient Protection

Tertiary Transient Protection

x Label the switchboard.

High AC Voltage Protection

Connecting the DC Load and Battery Cables

Connecting the DC Output to Earth

Retaining the Factory-installed AC-DC Earth Link

Installing the Batteries

Battery Installation Practices

Unpacking and Inspecting the Batteries

Interconnecting the Batteries

Mounting the Battery Temperature Sensor

Installing External Alarm and Digital Inputs Cabling

Step 1 - Remove the top cover (if fitted)

Slide forward and lift.

Step 2 - Access the alarm relay and digital input terminations

Alarm relay and digital input terminations are located:

Step 3 - Terminate the cabling

Step 4 - Check the cabling

Inserting the Rectifiers 38

Configuring the DC Power System 40

Testing Alarms at a Remote Location 44

Applying DC Power to the Load 45

Inserting the Rectifiers

Step 1 - Unpack the rectifiers

Step 3 - Push in the rectifier

x Keep fingers clear to avoid injury, as in following diagram.