American Power Conversion DC User Manual

User Manual For

DC Series MX06 40A Shelf

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DC MX06 40A Shelf

The MX06 40A Shelf is a 19” compatible modular power plant capable of supplying up to 42A at –48V DC (54V). The unit contains a controller that can configure up to 4 x 10.5A rectifiers. Power distribution, Integral LVD contact and alarm signals are all included. Optional mounting brackets are offered to allow the system to be fitted in a 23” rack. Easy subassembly access and replacement allows for convenient and efficient maintenance.

Applications

n Cellular and PCS

n Distributed Networks

n PABX

n Customer premises

n Industrial

n Microwave

n Broadband Wireless

n Fibre

Features

nnnn Integral LVD Contact

nnnn Hot Plugable Fan Cooled Units

nnnn Form C relay signals and visual

alarms

nnnn Single or 3-phase versions available

with a wide Input voltage range

nnnn Battery temperature compensation

of charging voltage

nnnn Overvoltage and reverse voltage

protection

nnnn LED Meter available

nnnn 2400W Output Power

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Contents

SECTION DESCRIPTION PAGE

1 General Information 5

1.1 Introduction 5

1.2 Safety Precautions 5,6

1.3 Types Of Hazard 6

1.4 Inspection Of Goods 7

1.5 APC Worldwide customer support 8

1.6 Warranty Information 9

2 Product Overview + Technical Description 10

2.1 Specification 10

2.2 Display + LED’s 11

2.3 Controller 12

2.4 Alarms 13

2.5 Customer Inputs 16

2.6 Mechanical 19

2.7 Schematic 21

3 System Configuration 23

2.1.1 Rectifier

2.1.2 System AC Input

2.1.3 System Output

2.1.4 Environmental

2.1.5 Approvals

2.3.1 Controller Layout

2.4.1 Available Alarms

2.4.2 Rear Access Alarms

2.4.3 Front Access Alarms

2.4.4 Major and Minor Alarms

2.5.1 Current Limit Programming

2.5.2 Output Voltage Programming

2.5.3 Battery Test Function

2.5.4 Enable Function

2.5.5 Temperature Compensation

2.6.1 Dimensions

2.6.2 Weight

2.6.3 Mounting Options

2.7.1 Positive Earth Configuration

2.7.2 Negative Earth Configuration

10 10 11 11 11

12

13 14 14 15

16 16 17 17 18

19 19 20

21 22

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4 Installation Procedure 24

4.1 AC Primary Supply 24

4.1.1 Single Phase

4.1.3 Single Phase AB Feed

4.1.4 3 Phase Star Supply

4.1.5 3 Phase Delta Supply

4.2 DC Distribution 32

4.2.1 10 GMT Fuses Rear Access

4.2.2 10 GMT Fuses Front Access

4.2.3 4 Circuit Breakers Rear Access

4.2.4 4 Circuit Breakers Front Access

4.2.5 4 Cartridge Fuses Rear Access

4.2.6 4 Cartridge Fuses Front Access

4.3 Cable Routing 37

4.3.1 Input Cables

4.3.2 Output Cables

4.4 External Battery Installation 39

4.4.1 Battery Back-up Function

4.4.2 LVD Function

4.4.3 Installation Procedure

4.4.4 Battery Connection Diagram

4.5 System Output Earthing 40

5 Commissioning the System 41

5.1 General 41

5.2 Powering up the

6 Manual Handling Procedure 42

6.1 General 42

6.2 Preparation 42

6.3 Method 42

7 Fault Finding / Symptoms 43

7.1 Warnings 43

7.2 Fault Symptoms 43

8 Service, Accessories & Spares 44

8.1 Rectifier Replacement 44

8.2 Alarm Module Replacement 44

24,25 26,27 28,29 30,31

32 33 34 35 36 36

37 38

39 39 39 40

MX06 40A Shelf 41

Issue Record

Issue RecordIssue Record

ISSUE DESCRIPTION DATE APPROVED

Rev 01 New document 4th JAN 2002 YES

Rev 02 Update 18th FEB 2002 YES

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1 General Information

1.1 Introduction

DC Power Plants from APC have unique features that make them easy to install, maintain, and upgrade. The rectifier units are modular and truly “hot-pluggable” into the shelf assembly without any separate ac wiring.

All system settings are controlled from the system control unit that provides monitoring and control functions for each component of the system as well as alarm outputs for system diagnosis and maintenance.

The APC international network of sales and service offices and qualified representatives provides sales assistance for proposals, purchases, and after-sales support.

1.2 Safety Precautions

The unit must be installed into an enclosure which conforms to the requirements of EN60950 : 2000, CAN/CSA 22.2 # 60950, UL60950 3 but is not limited to providing external disconnection devices.

The end use equipment must be installed in accordance with the local building code and practices, by proper licensed installation personnel, taking into consideration all cautions and requirements detailed in this manual.

For proper guidance on the selection of any external disconnects and cabling requirements see the CEC and NEC codes or the local electrical code of the country of installation.

Before using the power system, carry out the following:

rd

Edition and be connected to comply with the standard. This includes

1.2.1 READ AND FOLLOW THE SAFETY PROCEDURES.

1.2.2 REFER TO THE FOLLOWING DOCUMENTS. ALL PROCEDURES MUST BE CARRIED OUT IN ACCORDANCE WITH THE INSTRUCTIONS THEREIN.

• EN60950 : 2000, CAN/CSA 22.2 # 60950, UL60950.

• MANUFACTURER’S INSTRUCTIONS

• MATERIAL SAFETY DATA SHEET (MSDS) FOR THE BATTERY

(If batteries are supplied with the system)

• HEALTH AND SAFETY AT W ORK ACT, 1974 (UK)

• OCCUPATIONAL SAFETY & HEALTH STANDARDS (OHSA) (USA)

• ELECTRICITY AT WORK ACT, 1989 (UK)

• NFPA 70 NATIONAL ELECTRICAL CODE (USA)

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•

• CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH (COSHH) REGS

• MANUAL HANDLING REGULATIONS, 1993 (See Section 6)

CEC Code C22.1-98 ( Canada )

1.2.3 BECOME FAMILIAR WITH THE HAZARDS ASSOCIATED WITH THE POWER

SYSTEM AS DETAILED IN PARA 2.

1.2.4 CAUTION - BEFORE INSTALLING RECTIFIERS (POWER SUPPLIES) INTO AN UNPOPULATED SYSTEM SEE INSTALLATION INSTRUCTIONS IN SECTION 4.

1.3 Types of Hazards

The following hazards are present in the power system:

• ELECTRICAL VOLTAGE

• ELECTRICAL ENERGY

• HEAVY MASS

POTENTIALLY LETHAL VOLTAGES AND SOURCES OF HIGH ENERGY ARE PRESENT WITHIN THE POWER SYSTEM. EXTREME CAUTION MUST BE OBSERVED AT ALL TIMES. ACCESS TO THE INTERIOR OF THE SYSTEM FOR INSTALLATION, COMMISSIONING, MAINTENANCE AND REMOVAL AND REPLACEMENT PURPOSES IS LIMITED TO FULLY TRAINED SERVICE PERSONNEL ONLY. THIS SHOULD BE DONE WITH ALL POWER SOURCES DISCONNECTED EXCEPT WHEN ABSOLUTELY NECESSARY.

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1.4 Inspection upon Receipt of Goods

1.4.1 General

APC has taken precautions in packing the power equipment for shipment to ensure its safe arrival; however, the entire shipment including any boxes or crates should be inspected upon receipt for evidence of damage that may have occurred during transit.

1.4.2 Visible External Damage

It is the responsibility of the person receiving the shipment to inventory and inspect all materials against the bill of lading or waybill provided IMMEDIATELY upon taking delivery while the carrier representative is still on site. Please be sure that all items are accounted for, including the correct number of pallets and the quantity of accessory and/or component boxes. Also, note any visible external damage that may have occurred during transit.

If damage has occurred or the quantity of items is not correct, then:

1) Make a descriptive notation on the delivery receipt before signing.

2) File a damage or shortage report with the carrier that delivered the shipment.

1.4.3 Concealed Damage

It is the customer’s responsibility to unpack the power system and equipment received from APC and check for concealed damage. Within 15 days of receipt, check the materials received against the detailed packing list to verify that the quantity and condition are complete and satisfactory. Again, note any damage to the internal packing material and/or material shortages. If damage or shortage is noted, then:

3) Request an inspection by the carrier

4) File a concealed damage claim; and/or

5) File a material shortage claim with your APC representative.

DELAY IN NOTIFYING THE CARRIER MAY RESULT IN LOSS OF RIGHT TO REIMBURSEMENT FOR DAMAGES OR LOSS.

If you are unsure about the appearance of a part while conducting the materials inventory and inspection, refer to the manual or contact the Customer Service Department of APC.

Should you have any questions concerning potential damages or should you experience a lack of cooperation from your carrier, please contact your APC representative, or call APC

.

1.4.4 Return of Damaged Goods

Should equipment be damaged and require return to APC for repair, the APC service representative will provide instructions along with a valid returned material authorization (RMA) number to facilitate return of the damaged goods to the APC repair center.

It is important that the steps outlined in Section 1.4.2 and also Section 4 and 5 are followed carefully. Your APC representative will assist you, if required, in obtaining proper disposition of an initial delivery return issue; however, a valid RMA number must be obtained before returning any equipment to APC.

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1.5 APC Worldwide Customer Support

Customer support for this or any other American Power Conversion (APC) product is available at no charge in any of the following ways:

l Visit the APC web site to find answers to frequently asked questions (FAQs), to access documents

in the APC Knowledge Base, and to submit customer support requests.

http://www.apc.com (Corporate Headquarters) Connect by links to APC web pages for specific countries and regions, each of which provides customer support information.

http://www.apc.com/support/

Submit customer support requests.

l Contact an APC Customer Support centre by telephone or email.

Regional Centres:

APC Headquarters (US and Canada)

Latin America

Europe, Middle East, Africa

l Local, country-specific centers: go to http://www.apc.com/support/contact for contact information.

(1) (800) 800 4272 (toll free)

apctech@apcc.com

(1) (401) 789 5735 (United States)

apctchla@apcc.com

(353) 91 702020 (Ireland)

apceurtech@apc.com

Contact the APC representative or other distributor from whom you purchased your APC product for information on how to obtain local customer support.

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1.6 Warranty Information

1.6.1 Limited Warranty

American Power Conversion (APC) warrants the DC MX06 40A Shelf to be free from defects in materials and workmanship for a period of two years from the date of purchase. It’s obligation under this warranty is limited to repairing or replacing, at it’s own sole option, any such defective products. This warranty does not apply to equipment that has been damaged by accident, negligence, or misapplication or has been altered or modified in any way. This warranty applies only to the original purchaser.

1.6.2 Warranty Limitations

Except as provided herein, American Power Conversion makes no warranties, express or implied, including warranties of merchantability and fitness for a particular purpose.

Some jurisdictions do not permit limitation or exclusion of implied warranties; therefore, the aforesaid limitation(s) or exclusion(s) may not apply to the purchaser.

Except as provided above, in no event will APC be liable for direct, indirect, special, incidental, or consequential damages arising out of the use of this product, even if advised of the possibility of such damage.

Specifically, APC is not liable for any costs, such as lost profits or revenue, loss of equipment, loss of use of equipment, loss of software, loss of data, costs of substitutes, claims by third parties, or otherwise. This warranty gives you specific legal rights and you may also have other rights, which vary from state to state.

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2 Product Overview and Technical Description

2.1 Specification

2.1.1 Rectifier

Parameter (per rectifier) 1TWF0500H54**

Approved Input Rating 115V or 230Vac

I/p Operating Range 103.5V to 264V

RMS Input Current

“ “ “

Approved Input Frequency

range

Turn-on Surge < 10A

Turn-on Time < 2 Seconds

Internal Fuse 7 amp 250V time lag

Power Factor 99 % typical, 90 % min

Output Voltage (Nominal) 54.5V dc

O/p Current (Rated) 10.5A @ 230V, 0-50°C

Current Limit 105 % of rated

Over Volts Protection 59.5V dc ± 0.5V

Power O/p (Rated) 500W @ 115V

Efficiency 83 % typical

Cooling Fan Cooled, front to rear

Ambient Temp -40 to 50°C (de-rate above 50°C)

Note :- See TWF0500 Rectifier datasheet for further or more detailed information

2.1.2 System AC Input

Input Voltage (Single phase)

(3 Phase Star)

(3 Phase Delta)

RMS Current (max) single phase

RMS Current (max) 3 phase star

RMS Current (max) 3 phase delta

Frequency

Efficiency

Harmonic Distortion

90 - 264Vac (Live to Neutral)

26A @ 115V ±10%, 14.5A @ 230V ±10% (total)

45 – 65 Hz 83% Typical Complies with EN61000-3-2

6.5A max @115V

3.6A max @230V 45 – 65Hz

9A @ 230V, 50-65°C

9A @ 115V, 0-50°C

8A @ 115V, 50-65°C

600W @ 230V

208Vac, 380Vac, 400Vac or 415Vac (phase to phase) 208Vac only (phase to phase)

13A @ 208Vac, 7.2A @ 415Vac (per phase)

9.5A @ 208Vac (per phase)

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V

t

y

r

G

r

Y

2.1.3 System Output

Output Voltage Nominal

oltage Adjustment Range

Current Rating

Temperature Coefficien

Current Limi

Reverse Quiescent Curren

Regulation

Over voltage

2.1.4 Environmental

Temperature Range

Humidity

2.1.5 Safety Approvals

54.5Vdc 44 V – 57 V (Below 42V LVD contact opens) 42 A @ 230Vac, 36 A @ 115Vac, 28A @ 100Vac

-76mV/°C ±10% (over range 0°C - 50°C) 100% - 110% of Rated Current Less than 100mA, Typically 50mA 250mV max for any line or load condition

59.5V ± 0.5V (reset by interruption of AC Input)

-25°C to 50°C operating range 85% non condensing

Approved to the following

CE marked to the European Low Voltage

Directive 73/23/EEC amended by 93/68/EEC complies with BS EN60950:2000

Certified to CAN/CSA 22.2#950-00 (NRTL/C UL1950 3rd Edition)

2.2 Display + LED’s

3½ Digit LED Displa

“Volts”

“Amps”

4 LED Rectifie

Single LED Rectifie

Alarm Card LED’s

Switchable between “Volts” and “Amps” System Output Voltage Total Output Load Current

Load Current = Rectifier Current – Batt Charge Current

Input Healthy Output Healthy Current Limit Red Overvoltage Red

Rectifier Fail Red

Input Fail Red Distribution Trip Red Major Fault Red Minor Fault

reen reen

ellow

NB/ LED’s are lit when description is true.

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2.3 Controller

2.3.1 Alarm Card Layout

SK11

32

P5P4P3

SW2SW5

12

112 1

P2

SK10

1

11

SK7SK2SK3

1

SK1

Part Reference Function Adjustment

P1

Output Volts Adjust Via Front Panel

P2

LVD Disconnect Volts Adjust Factory Pre-set

P3

Meter Current Calibration Factory Pre-set

P4

Meter Reading Zero Adjust Factory Pre-set

P5

Meter Volts Calibration Factory Pre-set

SK1 SK2 SK3 SK4 SK5 SK7

SK10 SK11

SW1 SW2 SW3 SW5 SW6

LED Meter

Link Pins 1+2 (27V), 2+3 (54V) (Temp Compensation) Factory Pre-set Link Pins 1+2 (27V), 2+3 (54V) (LVD Coil) Factory Pre-set Link Pins 1+2 (27V), 2+3 (54V) (LVD Circuit) Factory Pre-set Optional front panel access to signals N/A Link Pins 1+2 (27V), 2+3 (54V) (Voltage Programming) Factory Pre-set Link Pins 1+2 (27V), 2+3 (54V) (Meter Current) Factory Pre-set Link Pins 1+2 (Temp Comp), 2+3 (Non Comp) Factory Pre-set

Main 64 Pin Connector N/A Battery connection (LVD) “ON”, “AUTO” or “OFF” Via Front Panel Selects any of 11 alarms to give a “MAJOR” alarm Remove Controller Battery Test function (press and hold for test) Via Front Panel Selects any of 11 alarms to give a “MINOR” alarm Remove Controller Selects “Volts” or “Amps” reading for LED meter Via Front Panel Optional 3½ digit LED Display N/A

1

SK4

P1

1

SK5

LED Meter

SW6

SW1

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2.4 Alarms

2.4.1 Available Alarms

To monitor the system status a selection of alarm outputs are available. Dependant upon the rectifiers fitted either 4 front panel LED’s or a single LED give visual notification of a system fault. There is also a range of open collector transistor alarm outputs, which can be accessed at the rear of the shelf or on a front panel connector (selected models). Finally there are 2 sets of relay contacts that can be configured to represent 1 or more alarms selected by the user.

Below is a list of the available alarms along with their function and pin number.

Note/ Alarms marked with a * are not available if system is fitted with single LED rectifiers.

Alarm / User

Outputs

Bus Voltage Low System volts dropped to LVD set level +10%, LVD imminent SK14-2 SK4-25 * Fan Fail One or more of the Rectifier fans have stopped SK14-3 SK4-24 2+ Rectifiers Fail 2 or more rectifiers giving output less than 31Vdc SK14-4 SK4-5 Rectifier Fail 1 Rectifier giving output less than 31Vdc SK14-5 SK4-6 Distribution Trip 1 or more fuse blown or breaker tripped SK14-6 SK4-2 AC Fail 1 or more of the AC input feeds failed SK14-7 SK4-1 * Over Current 1 or more rectifiers in current limit state SK14-8 SK4-23 * Over Voltage 1 or more rectifiers tripped due to excessive o/p voltage

(interrupt AC input or remove rectifier and refit to reset)

* Over Temperature 1 or more rectifiers tripped due to excessive internal

temperatures (resets itself when cooled down) Signal Common Use to reference all alarms to SK17-1 SK4-17 Current Share Use for paralleling purposes only SK17-3 SK4-16 Current Analogue Analogue voltage representing load current (1V = 5A ± 5%) SK17-4 SK4-19 5V Auxiliary Low current capability 5V supply for use with current limit

programming. Major Failure ‘Minor’ relay contact (closed for alarm) SK18-1 SK4-11 “ “ ‘Minor’ relay contact (Common) SK18-2 SK4-10 “ “ ‘Minor’ relay contact (open for alarm) SK18-3 SK4-12 Minor Failure ‘Major’ relay contact (closed for alarm) SK18-4 SK4-8 “ “ ‘Major’ relay contact (Common) SK18-5 SK4-7 “ “ ‘Major’ relay contact (open for alarm) SK18-6 SK4-9

Description Rear

Access

SK14-9 SK4-22

SK14-10 SK4-21

SK17-5 SK4-15

Warning!

max voltage rating of 60Vdc and a current sink capability of 20mA

All alarm outputs other than the relay contacts are open collector transistors. Each output has a

Front

Access

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2.4.2 Rear Access Alarms

To access the alarm outputs first ensure batteries are disconnected from the system by setting battery connection switch to “OFF” via controller front panel (see section 2.3) and by turning the external battery breaker off. The input mains supply must then be turned off by operating the local isolator or disconnection device. Remove the rear cover to leave the view as shown below. Labelled are the 3 signal output connectors SK14, SK17 and SK18 and also the temperature compensation connector SK19, where a thermistor is wired.

To use a particular alarm signal simply strip the ends of your alarm cables and enter into connectors by pushing down on respective lever, push in alarm cable and release lever to clamp cable. Cables should be routed through one of the knockout panels in the side of the shelf.

2.4.3 Front Access Alarms

SK19

SK14

SK17

SK18

1

2 3 4

1

2 3 4

DISTRIBUTI ON

Knockout

panels

The front access alarms are available from a 25 way ‘D’ connector socket (SK4) mounted in the controller front panel.

Alarms socket SK4

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2.4.4 Major and Minor Alarms

In an MX06 40A Shelf, 9 of the available alarms can be set to show as a “Minor” or “Major” alarm. As standard the alarm outputs are open collector transistor outputs available from the connectors as detailed in the 2 previous sections. If an alarm is selected as a Minor or Major alarm it also lights the corresponding “Major” or “Minor” front panel LED and the “Major” or “Minor” relay contacts also change over. More than one alarm can be selected at once and each alarm can be selected as both Major and Minor if required.

The relay contacts are rated as follows:

AC Rating - 0.5A @ 125Vac DC Rating - 1A @ 24Vdc Max VDC - 0.6A @ 110Vdc

Alarm Description Major alarm

selection

Over Temperature 1 or more rectifiers tripped due to excessive

internal temperatures (Resets itself when cooled down)

Over Volts 1 or more rectifiers tripped due to excessive

o/p voltage (interrupt AC input or remove

rectifier and refit to reset) Over Current 1 or more rectifiers in current limit state SW2-3 SW5-3 Fan Fail One or more of the Rectifier fans have

stopped Bus Voltage Low System volts below 48V LVD imminent SW2-5 SW5-5 A.C Fail 1 or more of the AC input feeds failed SW2-6 SW5-6 Fuse Fail 1 or more fuse blown or breaker tripped SW2-7 SW5-7 2 or more Rectifier Fail 2 or more rectifiers giving output < 31Vdc SW2-10 SW5-10 Rectifier Fail 1 Rectifier giving output less than 31V dc SW2-11 SW5-11

SW2-1 SW 5-1

SW2-2 SW 5-2

SW2-4 SW 5-4

See sections 2.3 for info on SW2 and SW5 location and relay contact pin-outs.

Minor alarm selection

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2.5 Customer Inputs

2.5.1 Current Limit Programming

Input Description Controller

Type Current Limit Program

5V aux

Connect a DC voltage to this pin (referenced to signal common or –Ve output) to reduce the system output current limit point. Current limit is programmed down 1A per 1.5V program voltage. Max program voltage 7.5V. 5V aux can be used to program down current limit level by linking to program pin.

Rear Access

Front Access

Rear Access Front Access

The system output current limit can also be set to either the standard “High” (100%) level or “Low” (70%) level by using SK13.

For “High” current limit level link pins 1 and 2 (default setting) For “Low” current limit level link pins 2 and 3

Selecting “Low” current limit level will program down each rectifiers current limit level to roughly 70% of the default level. (See section 2.1.1 for default levels). This is the same as connecting the 5V aux pin to the current limit program pin as detailed above.

Note/ using both programming methods together will not double the effect

Connector

SK17-2 SK4-20

SK17-5 SK4-15

SK13

2.5.2 Output Voltage Programming

Input Description Controller

type

Voltage

Programming

Connect a DC voltage to this pin (referenced to signal common or –Ve output) to adjust the system output voltage.

This pin floats at 2.5V nominal with respect to negative output (O/P @ 54.5V) Applying a DC voltage adjusts the output by –1V/V. (For 1V swing on program pin the output voltage changes by –1V)

The programming voltage range is 0V – 14V, giving a max adjustment range of 57V to 43V.

Note: See section 2.4 for SK4, SK17 location photo

Rear Access

Front Access

Connector

SK17-7 SK4-18

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2.5.3 Battery Test Function

Input Description Location

Battery Test

Front panel momentary push button. Push and hold drops output volts to 45Vdc. This is below battery float voltage and is used to check the batteries can supply the system load.

2.5.4 Enable Function

Input Description Location

Enable

Back-plane circuit board mounted 3-way Molex header. Link pins 1 and 2 with supplied link for “local” enable of rectifier outputs. Link pins 2 and 3 for “remote” enable.

If “remote” enable SK17-1 and SK17-6 must be linked to enable rectifier outputs.

System is set to “Local Enable” as standard

SK17

SK22

Note: Prior to accessing and making connections ensure batteries are disconnected from the system by setting battery connection switch to “OFF” via controller / alarm card front panel (see section 2.3) and by turning the external battery breaker off.

The AC input supply must then be turned off by operating the local isolator or disconnection device.

Push button mounted on

controller front panel.

SK22 (mounted on back-

plane board).

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2.5.5 Temperature Compensation

Input Description Socket Pin

Temp Compensation

This function allows a temperature probe to be used to automatically adjust the output voltage of the system. This ensures the charging voltage stays within the battery manufacturers recommended limits. To connect thermistor, simply enter striped wires into SK19 and screw to clamp (polarity not important). Check controller configuration link as explained below.

Note: See page 14 for SK19 location photo

MX06 40A Calculated Temperature Compensation (54V)

59.00

Voltage (V)

58.00

57.00

56.00

55.00

54.00

Output Voltage max

Output Voltage nom

Output Voltage min

Minimum Battery Voltage

Maximum Battery Voltage

53.00

52.00

-10.00 0.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00

Temperature (°C)

ALARM CARD

System Controller

SK19 1 - 2

Link fitted on top 2 pins for Temp Comp

Link fitted on bottom 2 pins for no compensation (fixed o/p Volts)

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2.6 Mechanical

2.6.1 Dimensions

Dimension A B C D E F Length 482.6mm

(19in)

132.5mm

(5.22in, 3U)

283.6mm (11.17in)

82.5mm (3.25in)

138.5mm (5.45in)

438.2mm (17.25in)

2.6.2 Weight

Item Measured Shelf + Dist + Controller Single Rectifier Full System

Weight (Kg) 7.65 1.75 14.70

Weight (lbs) 16.85 3.85 32.35

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2.6.3 Mounting Options

The MX06 40A Shelf has 3 positions for mounting ears. If mounting ears were ordered with the system they will be fitted in the front position as standard. The 2 alternative mounting positions are shown below. The end user can simply unscrew the ears and re-fit in the desired position.

Ensure all screws are re-tightened sufficiently.

Mounting Ears

Optional Mounting Positions

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2.7 Schematic

2.7.1 Positive Earth Configured

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2.7.2 Negative Earth Configured

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3 System Configuration

The MX06 40A shelf is designed to meet a wide range of customer requirements/applications. A number of versions and options are available including various distribution types, alternative input supply configurations, 19 and 23 inch mounting versions, temperature probes etc.

Contact APC for details.

Alternatively the following pre configured systems are available:

DCM00K02W481

Rear access 40A system with 4 x 10A circuit breaker output distribution, includes alarm card with LED display option, 19” mounting brackets, single phase – single feed input, 3 rectifier blanking panels and a non temperature compensated output voltage of 54.5Vdc. Probe for temperature compensation supplied.

DCM00K02W482

Front access 40A system with 4 x 10A circuit breaker output distribution, includes front access alarm card with LED display option, 19” mounting brackets, single phase – single feed input, 3 rectifier blanking panels and a non temperature compensated output voltage of 54.5Vdc. Probe for temperature compensation supplied.

DCM00K02W483

Rear access 40A system with 10 way GMT fuse output distribution, includes a selection of GMT output fuses, alarm card with LED display option, 19” mounting brackets, single phase – single feed input, 3 rectifier blanking panels and a non temperature compensated output voltage of 54.5Vdc. Probe for temperature compensation supplied.

DCM00K02W484

Front access 40A system with 10 way GMT fuse output distribution, includes a selection of GMT output fuses, front access alarm card with LED display option, 19” mounting brackets, single phase – single feed input, 3 rectifier blanking panels and a non temperature compensated output voltage of 54.5Vdc. Probe for temperature compensation supplied.

User Manual 990-9178A DC MX06 40A Shelf Page 23 of 44 18

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AC3AC4A

A

4 Installation Procedure

4.1 AC Primary Supply

4.1.1 Single Phase

The MX06 40A Shelf can be used on a Single Phase AC supply. The system can be connected to a 230V or 115V supply.

Maximum input current is 26A at 115Vac and 15A at 230Vac. Choose AC Input cabling rated accordingly and colour coded as required for country/state concerned.

4.1.1.1 Rear Access Connection

To connect the input supply to the MX06 40A Shelf proceed as follows:

• The AC input current to the system should also be limited by an appropriate device in the event of a short circuit as defined in EN60950 to protect the internal wiring of the end use equipment.

• Ensure that the AC supply intended for connection is isolated, locked off and under single operator control. Remove the rear cover to leave the view as shown below.

• There are 3 pairs of AC Input connectors: AC1 (Live), AC2 (Neutral)

AC3 (Live), AC4 (Neutral) AC5 (Live), AC6 (Neutral)

• Connection can be made to any of the 3 pairs but for optimised EMC performance use AC5 (Live), AC6 (Neutral) and the nearest safety earth stud. Access to this should be through the top left knockout tab. If an alternative knockout is to be used ensure additional insulation is used where cabling passes over secondary parts. NB/ Earth connection should be made first.

• Connect the cables terminated with M4 ring crimps using the M4 x 8 screws supplied in the accessory kit.

Top Left

AC5

Safety Earth

AC6

• Cables should be routed as close to the top of the shelf using the supplied routing clips (see section 4.3 for further routing details).

• Refer to section 5 entitled “Commissioning the system” before applying AC power.

Safety Earth

C2

C1

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4.1.1.2 Front Access Connection

To connect the input supply to the MX06 40A Shelf proceed as follows:

• The same protection devices and cable parameters are required for front access connection as explained for “single-phase rear access” previously.

• Ensure that the AC supply intended for connection is isolated, locked off and under single operator control.

• Strip the ends of the AC Input cables to be connected to the Input terminal block.

• By unscrewing the 2 front panel screws the AC Input connection drawer can be opened as

shown below. The AC Input cable is fed through the gland and screwed into the terminal block visible.

• Connect as follows: Safety earth to position marked with earth symbol (connect first)

Live to AC1 Neutral to AC2

• The alarm card adjacent to the AC Input drawer may need to be removed for easier access

• A strain relief bush can be fitted instead of the standard cable gland shown. Contact factory

Terminal Block

Cable Gland

to the terminal block screws.

for details.

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4.1.2 Single Phase, AB Feed

The MX06 40A Shelf can be used on a Single Phase AB Feed system. This means that 2 separate supply’s can be used, each powering 2 of the 4 rectifiers fitted. The system can be connected to a 230V or 115V supply.

The maximum input current per feed is 7.5A at 230V and 13A at 115V. Choose AC Input cabling rated accordingly and colour coded as required for country/state concerned.

4.1.2.1 Rear Access Connection

• The AC input current to the system should also be limited by an appropriate device in the event of a short circuit as defined in EN60950 to protect the internal wiring of the end use equipment. The device(s) should be rated according to the input current as stated above.

• Ensure that the AC supply intended for connection is isolated, locked off and under single operator control. Remove the rear cover to leave the view as shown below

• The main circuit board should have been configured for single phase AB feed use, by removing LK3 and LK4. This is normally factory configured.

• First the two safety earth connections should be connected to the studs labelled below.

• Feed A should be wired to: AC1 (Live) and AC2 (Neutral)

• Feed B should be wired to: AC5 (Live), AC6 (Neutral)

• Connect the cables terminated with M4 ring crimps using the M4 x 8 screws supplied in the

accessory kit.

Top Left

AC5

Feed B

Earth

AC6

LK4

LK3

Feed A

AC3 AC4 AC2

LK2

Earth

AC1

LK1

• Cables should exit through the top left knockout tab. If an alternative knockout is to be used ensure additional insulation is used where cabling passes over secondary parts. Cables should be routed as close to the top of the shelf using the supplied routing clips (see section

4.3 for further routing details).

• Refer to section 5 entitled “Commissioning the system” before applying AC power.

User Manual 990-9178A DC MX06 40A Shelf Page 26 of 44 18

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4.1.2.2 Front Access Connection

To connect the input supply to the MX06 40A Shelf proceed as follows:

• Ensure that the AC supply intended for connection is isolated, locked off and under single operator control.

• The main circuit board should have been configured for an AB Feed by removing LK3 and LK4. This is normally factory configured.

• Strip the ends of the AC Input cables to be connected to the input terminal block.

• By unscrewing the 2 front panel screws the AC Input connection drawer can be opened as

shown below. The AC Input cable is fed through the gland and screwed into the terminal block visible.

• Connect as follows: Safety earth to position marked with earth symbol (connect first)

Feed A Live to AC1 Feed A Neutral to AC2 Feed B Live to AC3

Feed B Neutral to AC4

• The alarm card adjacent to the AC Input drawer may need to be removed for easier access

• A strain relief bush can be fitted instead of the standard cable gland shown. Contact factory

Terminal Block

Cable Gland

to the terminal block screws.

for details.

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4.1.3 3 Phase Star Supply

The MX06 40A Shelf can be used on any of the following supplies: 415V, 400V, 380V or 208V phase to phase.

The maximum input current is 13A per phase on a 208Vac phase to phase supply and 7.2A per phase on a 380Vac, 400Vac or 415Vac supply. Choose AC Input cabling rated accordingly and colour coded as required for country/state concerned.

4.1.3.1 Rear access connection

To connect the input supply to the MX06 40A Shelf proceed as follows:

• The AC input current to the system should also be limited by an appropriate device in the event of a short circuit as defined in EN60950 to protect the internal wiring of the end use equipment. The device(s) should be rated accordingly.

• Ensure that the AC supply intended for connection is isolated, locked off and under single operator control. Remove the rear cover to leave the view as shown below

• The main circuit board should have been configured for 3-phase star use by removal of LK2 and LK3. This is normally factory configured.

• First the safety earth connection should be connected to one of the studs labelled below

• Connect inputs: Phase 1 to AC1, Phase 2 to AC3, Phase 3 to AC5, Neutral to AC2, 4 or 6

(neutral is required as system is a star configuration)

• Connect the cables terminated with M4 ring crimps using the M4 x 8 screws supplied in the accessory kit.

Top Left

Phase 3

AC5

• Cables should exit through the top left knockout tab. If an alternative knockout is to be used ensure additional insulation is used where cabling passes over secondary parts. Cables should be routed as close to the top of the shelf using the supplied routing clips (see section

4.3 for further routing details.

• Refer to section 5 entitled “Commissioning the system” before applying AC power.

Safety Earth

AC6

LK3

Phase 2

AC3

AC4 AC2

LK2

Safety

Phase 1

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4.1.3.2 Front access connection