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
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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 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
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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
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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