American Power Conversion MX06 50, MX06 100 User Manual
-48 VDC POWER SYSTEMS
MX06 50
MX06 100
User’s Manual
(Document # 990-9131B)
Table of Contents
1 Safety First! 1
1.1. WARNING SYMBOLS .........................................................................................................1
1.2. GENERAL PRECAUTIONS: ..................................................................................................1
2 Introduction 2
2.1. GENERAL INFORMATION....................................................................................................2
2.2. HOW TO USE THIS MANUAL ..............................................................................................4
3 Installation 5
3.1. UNPACKING EQUIPMENT ...................................................................................................5
3.2. MECHANICAL INSTALLATION ..............................................................................................5
Room / Location......................................................................................................................5
Mounting.................................................................................................................................5
Ventilation...............................................................................................................................6
3.3. AC POWER CONNECTIONS ...............................................................................................6
3.4. BATTERY CONNECTIONS ...................................................................................................7
Planning the Battery installation..............................................................................................7
Connecting the Battery Cables ...............................................................................................7
Battery LVD Connection .........................................................................................................8
Multiple Battery Strings...........................................................................................................8
Battery Temperature Probe Installation ................................................................................10
3.5. DC SYSTEM GROUNDING ...............................................................................................10
3.6. LOAD PROTECTION INSTALLATION....................................................................................11
Circuit Breaker Installation....................................................................................................11
GMT Fuse Installation...........................................................................................................11
3.7. LOAD CONNECTIONS ......................................................................................................12
Cable Size Considerations ...................................................................................................12
Circuit Breaker Protected Load Connections (30 or 60 Amps) .............................................12
GMT Fuse protected Load Connections ...............................................................................13
3.8. I
Relay Output Connections....................................................................................................13
External Alarm Input Connections ........................................................................................14
3.9. R
3.10. INITIAL POWER-UP AND CHECKOUT .................................................................................15
3.11. B
4 Technical Description 17
4.1. RECTIFIER MANAGEMENT................................................................................................17
AC Input Power.....................................................................................................................17
DC Output Power..................................................................................................................17
System Output Capacity .......................................................................................................17
Rectifier alarms reporting......................................................................................................17
4.2. SYSTEM MANAGEMENT ...................................................................................................18
Control Functions..................................................................................................................18
Alarm Functions....................................................................................................................18
Displays ................................................................................................................................18
NPUT / OUTPUT CONNECTIONS.......................................................................................13
ECTIFIER MODULE INSTALLATION...................................................................................15
ATTERY AND LOAD POWER UP.......................................................................................16
MX06 Power Plant User’s Manual Page ii
User Outputs.........................................................................................................................18
User Inputs ...........................................................................................................................19
4.3. LOAD MANAGEMENT .......................................................................................................19
4.4. BATTERY MANAGEMENT .................................................................................................19
Battery Charging...................................................................................................................19
Battery Temperature Compensation.....................................................................................19
Battery Low Voltage Disconnect ...........................................................................................20
5 Operation 21
5.1. DESCRIPTION.................................................................................................................21
5.2. MX06 OPERATION .........................................................................................................21
MX06 Voltage Adjustments ..................................................................................................21
MX06 External Alarm Input Configuration.............................................................................22
5.3. MX06-50 CONFIGURATION SETTINGS .............................................................................22
MX06-50 Rectifier Configuration...........................................................................................23
MX06-50 Programmable Alarms...........................................................................................23
MX06-50 Temperature Probe Selection ...............................................................................24
5.4. MX06-100 CONFIGURATION SETTINGS ...........................................................................24
MX06-100 Rectifier Configuration.........................................................................................24
MX06-100 Programmable Alarms.........................................................................................25
MX06-100 Temperature Probe Selection .............................................................................25
6 Specifications 26
6.1. AC INPUT ......................................................................................................................26
TWF0500H5401 Rectifier .....................................................................................................26
MX06 50 Power System .......................................................................................................26
MX06 100 Power System .....................................................................................................27
6.2. DC OUTPUT ..................................................................................................................27
TWF0500H5401 Rectifier .....................................................................................................27
MX06 50 Power System .......................................................................................................28
MX06 100 Power System .....................................................................................................28
6.3. CONTROLS AND INDICATORS ...........................................................................................29
TWF0500H5401 Rectifier .....................................................................................................29
MX06 Controller....................................................................................................................29
6.4. MECHANICAL .................................................................................................................29
TWF0500H5401 Rectifier .....................................................................................................29
Magnum VS 50 Power System.............................................................................................30
Magnum VS 100 Power System...........................................................................................30
6.5. ENVIRONMENTAL ............................................................................................................30
6.6. COMPLIANCE .................................................................................................................31
7 APC Worldwide Customer Support 32
8 Limited Product Warranty 33
MX06 Power Plant User’s Manual Page iii
Revision History
Revision Date By
Preliminary 15 FEB, 2000 SCG
PML-0216A 07 APR, 2000 SCG
PML-0216B 05 MAY, 2000 SCG
PML-0216C 26 JUN, 2000 DRD
PML-0216D 27 OCT, 2000 DRD
990-9131 Rev01 19 JAN, 2001 DRD
990-9131A Rev02 21 NOV, 2001 DRD / JF
990-9193A Rev03 15 FEB, 2002 JF
990-9131B Rev04 30 JUN, 2003 BT
Table of Figures
FIGURE 2.1-1 MX06 50 DC POWER PLANT ............................................................................................2
FIGURE 2.1-2 MX06 100 BLOCK DIAGRAM...........................................................................................3
FIGURE 3.3-1 AC INPUT WIRING KITS...................................................................................................6
FIGURE 3.4-1 BATTERY CABLE CONNECTION LOCATIONS............................................................8
FIGURE 3.4-2 MOTORIZED CIRCUIT BREAKER...................................................................................8
FIGURE 3.4-3 BATTERY WIRING DIAGRAM ........................................................................................9
FIGURE 3.4-4 BATTERY TEMPERATURE PROBE INSTALLATION ................................................10
FIGURE 3.6-1 GMT FUSE TEMPERATURE DE-RATING CHART......................................................11
FIGURE 3.6-2 GMT FUSES AVAILABLE FROM APC ..........................................................................11
FIGURE 3.7-1 CONNECTIONS TO CIRCUIT BREAKERS....................................................................12
FIGURE 3.7-2 CONNECTIONS TO GMT FUSES....................................................................................13
FIGURE 3.8-1 OUTPUT RELAY CONNECTIONS..................................................................................14
FIGURE 3.8-2 EXTERNAL USER INPUT CONNECTIONS...................................................................14
FIGURE 5.2-1 USER ALARM SETTINGS ...............................................................................................22
FIGURE 5.3-1 MX06-50 CONTROLLER LAYOUT ................................................................................22
FIGURE 5.3-2 MX06-50 JUMPER PROGRAMMING. ............................................................................23
FIGURE 5.3-3 MX06-50 ALARM JUMPERS ...........................................................................................23
FIGURE 5.4-1 MX06-100 CONTROLLER LAYOUT ..............................................................................24
FIGURE 5.4-2 MX06-100 JUMPER PROGRAMMING ...........................................................................25
FIGURE 5.4-3 MX06-100 ALARM JUMPERS .........................................................................................25
MX06 Power Plant User’s Manual Page iv
1 Safety First!
It is very important to follow all safety procedures when unpacking, installing and operating any
sort of power equipment.
1.1. Warning Symbols
CAUTION: An indication that special care is required to
prevent injury, equipment damage or misuse
WARNING: An indication of an electrical hazard that may
1.2. General Precautions:
cause serious personal injury or death, catastrophic equipment
damage or site destruction.
WARNING: Hazardous AC voltage levels are present inside
the power system. Keep the rear cover in place when the
system is operational or energized
WARNING: Hazardous energy levels are present on bare
conductors in the -48VDC distribution connection area of the
plant. Accidental shorting of distribution conductors can cause
Specific CAUTION and WARNING will be placed in manual where appropriate.
arcing and high currents that can cause serious burns or other
physical harm. It is recommended that:
• Remove any jewelry, rings or watches while working on
this equipment.
• Use insulated wrenches, screwdrivers, cutters, pliers
and other tools.
WARNING: Ensure that all of the DC and external AC circuit
breakers are in the OFF position prior to connecting service to
the power plant. Confirm that all voltages have been removed
including any battery sources before proceeding
.
MX06 Power Plant User’s Manual Page 1
2 Introduction
2.1. General Information
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. The MX06 50 has 1 shelf, holding five rectifiers for a maximum
of 52.5 Amps. The MX06 100 has 2 shelves, holding ten rectifiers for a maximum of 105 Amps.
The controller provides monitoring and control functions for each component of the system.
The APC MX06 is a modular stand-alone -48 Volts DC power plant. It is configurable in such a
manner that it will support most typical applications within the specified current ranges (10-100
Amperes) without special application engineering or assistance. DC output distribution is
included for circuit breakers or GMT style fuses or in the 100 Amp versions, a combination of
both. Available circuit breakers are 30 Amps or 60 Amps. GMT fuses can be 1/4 to15 Amps. A
low voltage disconnect (LVD) is provided to disconnect the battery after deep discharge. A 50
Amp power system is shown in Figure 2.1-1. A block diagram of a typical 100 Amp power
system with fuses is shown in Figure 2.1-2.
Figure 2.1-1 MX06 50 DC Power Plant
MX06 Power Plant User’s Manual Page 2
J3
USER
ALARM
INPUTS
J2
ALARM
RELAY
OUTPUTS
J5
MOTORIZED
BREAKER
CONTROLS
J4
TEMPERATURE
PROBE
UFA1
1
UFA2
2
3
UFA3
4
UFA4
5
-BAT
6
-BAT
7
8
-BAT
9
-BAT
10
MAJ NC
1
MAJ COM
2
MAJ NO
3
MIN NC
4
MIN COM
5
MIN NO
6
VLV NC
7
VLV COM
8
VLV NO
9
YELLOW
1
BROWN
2
BLACK
3
ORANGE
4
RED
5
BLUE
6
1
TMP
2
-BAT
3
+12 PWR
4
Control Circuit
-BAT
PC Board
+BAT
CONTROL BUS
DC
AC
M
PortSPort
Control
AC
TRM7 TRM8
L1 L2/N
DC
GND
TRM9
Main Power Distribution Backplane
BATTERY (–)
(orange)
(black)
BATTERY (+)
Visual Alarm
DC
Control
AC
Control
DC
AC
GND
TRM6
TRM4 TRM5
L1 L2/N
Control
AC
TRM1 TRM2
L1 L2/N
DC
GND
TRM3
Control
One to 12 outputs
Load
Distribution
Module
CONTROL BUS
AC
M
PortSPort
DC
Control
AC
TRM7 TRM8
L1 L2/N
DC
GND
TRM9
Second Power Distribution Backplane
BATTERY (–)
(orange)
(black)
BATTERY (+)
Visual Alarm
DC
Control
AC
Control
DC
AC
GND
TRM6
TRM4 TRM5
L1 L2/N
Control
AC
TRM1 TRM2
L1 L2/N
DC
GND
TRM3
Control
One to 12 outputs
Load
Distribution
Module
MX06 Power Plant User’s Manual Page 3
Figure 2.1-2 MX06 100 Block Diagram
2.2. How to Use This Manual
Each section of this manual can be read in any order and provides a complete explanation of
the subject described by the title. However, the sequence of the sections is designed to provide
a typical step-by-step process for successful use of the equipment.
Safety First!
Introduction
Installation
Operation
Technical
Description
Specifications
APC Worldwide
Customer Support
Limited Product
Warranty
Safety symbol description and general precautions.
Brief system preview and explanation of manual usage.
How to unpack, install and commission the equipment for initial
use.
Specifics of controls settings and indicators used to operate the
unit.
Theory of operation of the power equipment.
Power plant and rectifier specifications.
How to contact APC for customer support.
Equipment warranty terms and conditions.
MX06 Power Plant User’s Manual Page 4
3 Installation
3.1. Unpacking Equipment
Remove equipment from packing material and inspect for shipping damage or missing items. It
is important to report damage or material shortages to the shipping carrier while a
representative is on site.
If concealed damage or material shortages are found at a later time, contact the shipper to
make arrangements for inspection and claim filing. Refer to Section 7 in the event it is
necessary to return equipment to APC.
CAUTION: Appropriate lifting techniques and safety equipment should be
used to remove equipment from packing.
PLEASE RECYCLE: The shipping materials can be recycled. Please save
them for later use or dispose accordingly.
3.2. Mechanical Installation
Room / Location
NOTE: The APC DC power plant is to be installed in a room, vault, or similar enclosure that is
accessible only to qualified persons in accordance with the regulatory authority having
jurisdiction.
Prior to installation, drawings, floor loading requirements, external alarm points, AC service
entrance, and grounding schemes should all be checked and confirmed. If batteries are to be
mounted in a room separate from the power plant, careful attention should be paid to battery
cable voltage drop effects. Environmental operating temperatures and ventilation/cooling
considerations should also be noted, not just for the power system but also for all other
equipment that may reside in the power room area.
Mounting
The MX06 provides brackets to mount on a standard EIA 19-inch or 23-inch rack. Install the
power system using hardware designed for the rack.
MX06 Power Plant User’s Manual Page 5
Ventilation
The rectifier modules for this system have fans that provide front-to-rear airflow for internal
cooling. The power system housing should be mounted such that there is free airflow to the
front and back of the unit. [Refer to Section 6.5 for environmental characteristics.] Free airflow
should be ensured so that the power system can provide full power at a given ambient
temperature without de-rating.
3.3. AC Power Connections
WARNING: Ensure that all of the external DC and AC circuit breakers are in
the OFF position prior to connecting service to the power plant. Confirm that
all voltages have been removed including any battery sources before
proceeding. Keep the rear cover in place when the system is operational or
energized.
The DC power system requires the supply of 90/115/208/220/240 VAC single-phase, 50/60 Hz
power. One AC input on the power system backplane supplies power to the first rectifier in each
shelf. Two inputs supply power to the second and third pair of rectifiers and the fourth and fifth
pair in each shelf. This scheme allows a variety of wiring options. Provided the input wiring is
not overloaded, one, two or all three inputs on each shelf can be jumpered together. The
ambient temperature and number of wires in a conduit must be considered in accordance with
all applicable regulatory agencies.
Various AC input cable kits are available from APC. These cables are 12 feet (3.7m) long and
have a power plug installed on each cable. When ordered with the power system, these cables
will be installed with strain reliefs provided to mount the 3-conductor jacketed cables. Each kit
will supply power to the entire power system. Use the chart in Figure 3.3-1 to determine the
suggested cable kits.
Part Num. AWG Cable Qty Plug Num. Plug Style Voltage Power System
0M-91156 12 2 NEMA 5-20P Non-locking 115 Magnum VS 50
0M-91154 12 2 NEMA L5-20P Locking 115 Magnum VS 50
0M-91158 10 1 NEMA 5-50P Non-locking 115 Magnum VS 50
0M-1150 12 2 NEMA L6-20P Locking 230 Magnum VS 50
0M-91160 10 1 NEMA 6-30P Non-locking 230 Magnum VS 50
0M-91159 10 1 NEMA L6-30P Locking 230 Magnum VS 50
0M-91137 12 4 NEMA 5-20P Non-locking 115 Magnum VS 100
0M-91141 12 4 NEMA L5-20P Locking 115 Magnum VS 100
0M-91138 10 2 NEMA 5-50P Non-locking 115 Magnum VS 100
0M-1149 12 4 NEMA L6-20P Locking 230 Magnum VS 100
0M-91135 10 2 NEMA 6-30P Non-locking 230 Magnum VS 100
0M-91136 10 2 NEMA L6-30P Locking 230 Magnum VS 100
Figure 3.3-1 AC Input Wiring Kits
MX06 Power Plant User’s Manual Page 6
3.4. Battery Connections
WARNING: Hazardous energy levels are present on bare conductors in
the -48VDC distribution connection area of the plant. Accidental shorting of
distribution conductors can cause arcing and high currents that can cause
serious burns or other physical harm. It is recommended that:
Planning the Battery installation
The battery cable(s) should be sized to limit the voltage drop from the DC power plant to the
battery during charging per system design requirements. The cable(s) must also carry the full
load current during battery operation. If assistance is required to determine the necessary
cables for the application, contact your sales representative or APC (Refer to Chapter 7 for APC
Customer Support information.
An external fuse or circuit breaker (various options are available from APC) is recommended in
the negative line (located at the battery end) to protect the cables from the battery to the DC
power plant. The power plant can monitor auxiliary contacts from this breaker.
Connecting the Battery Cables
• Remove any jewelry, rings or watches while working on this
equipment.
• Use insulated wrenches, screwdrivers, cutters, pliers and other tools.
WARNING: Make certain that the battery polarity is correct when making
connections to the DC power plant. Incorrect connection could cause
The battery cable connections are located at the rear of the unit as shown in Figure 3.4-1. The
battery positive and battery negative buses each provide a pair of #10-32 studs on 5/8” centers
for connecting two-hole battery cable lugs. A ring size of 0.221 in (5.6 mm) may also be used.
Connect the battery cables as applicable using #10-32 nuts. Cover all battery connections with
heat shrink after assembly.
severe equipment damage.
MX06 Power Plant User’s Manual Page 7
Negative Battery
Connection
(Orange)
Positive Battery
Connection
(Black)
Figure 3.4-1 Battery Cable Connection Locations
Battery LVD Connection
The MX06 provides control for a motorized circuit breaker on the –48 V battery string. This
motorized circuit breaker is mounted on the back of the MX06. Figure 10 shows the power,
control, and monitoring connections. The motorized breaker connects in the negative battery
cable.
Figure 3.4-2 Motorized Circuit Breaker
Multiple Battery Strings
A number of battery strings can be connected to the MX06 using a split bus bar assembly as
shown in Figure 3.4-3. Each battery tray has a provision for a manual battery disconnect. This
allows service to be performed on individual strings without affecting the rest of the system.
MX06 Power Plant User’s Manual Page 8
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