American Power Conversion MX28B User Manual

DC POWER PLANT

PRODUCT MANUAL

MODEL MX28B

Doc # PML-0209

Revision Level: A

American Power Conversion
11035 Switzer Avenue
Dallas, TX 75238
214-342-5000 December, 1999

REVISION HISTORY

Revision Date By Description

A 12/16/99 BGL Initial release.

ii MX28B

TABLE OF CONTENTS

1. GENERAL INFORMATION .................................................................................................................1

1.1 INTRODUCTION...................................................................................................................................1

1.2 PRECAUTIONS....................................................................................................................................1

1.3 INSPECTION UPON RECEIPT OF GOODS ...............................................................................................1

1.3.1 General....................................................................................................................................1

1.3.2 Visible External Damage.........................................................................................................1

1.3.3 Concealed Damage.................................................................................................................2

1.3.4 Return of Damaged Goods .....................................................................................................2

2. CUSTOMER SERVICE AND SUPPORT.............................................................................................3

3. WARRANTY PROVISIONS................................................................................................................. 4

3.1 GENERAL PROVISIONS........................................................................................................................4

3.1.1 Warranty Returns....................................................................................................................4

3.1.2 Warranty Repair or Replacement............................................................................................4

3.2 EXCLUSIONS AND LIMITATIONS............................................................................................................ 4

4. PRODUCT OVERVIEW AND TECHNICAL DESCRIPTION...............................................................6

4.1 DESCRIPTION.....................................................................................................................................6

4.2 POWER OUTPUT CAPACITY.................................................................................................................8

4.3 RECTIFIERS........................................................................................................................................8

4.4 CONTROL UNIT ..................................................................................................................................8

4.5 AC INPUT POWER..............................................................................................................................9

4.6 BATTERY CONNECTIONS .....................................................................................................................9

4.7 DC DISTRIBUTION............................................................................................................................ 10

4.8 MOUNTING.......................................................................................................................................10

4.9 ENVIRONMENTAL..............................................................................................................................10

4.10 MECHANICAL....................................................................................................................................11

4.11 COMPLIANCE....................................................................................................................................11

5. INSTALLATION PROCEDURES.......................................................................................................12

5.1 PREPARATION..................................................................................................................................12

5.1.1 Recommended Tools............................................................................................................12

5.1.2 Recommended Test Equipment............................................................................................12

5.1.3 Equipment Inspection............................................................................................................12

5.1.4 Safety Precautions................................................................................................................12

5.1.5 Room/Locations ....................................................................................................................12

5.1.6 Mounting................................................................................................................................ 13

5.1.7 Ventilation.............................................................................................................................. 13

5.2 AC SERVICE AND GROUND CONNECTIONS........................................................................................13

5.3 BATTERY CONNECTIONS...................................................................................................................13

5.3.1 Battery Disconnect................................................................................................................13

5.3.2 Cable Sizing Considerations.................................................................................................13

5.3.3 Connecting the Cables..........................................................................................................14

5.4 DC SYSTEM GROUNDING...........................................................................................................14

5.5 RECTIFIER INSTALLATION..................................................................................................................14

5.6 ALARM CONNECTIONS...................................................................................................................... 14

5.6.1 External Alarm Inputs............................................................................................................14

5.6.2 Alarm Outputs .......................................................................................................................15

5.7 CONNECTING THE LOADS .................................................................................................................16

MX28B iii

5.7.1 DC Circuit Breakers and Fuses.............................................................................................16

5.7.2 Installation of Circuit Breakers and Fuses.............................................................................17

5.7.2.1 Plug-in Circuit Breakers .................................................................................................................. 17

5.7.2.2 GMT Fuses.....................................................................................................................................18

5.7.3 Load Connections .................................................................................................................18

5.7.3.1 Circuit Breakers ..............................................................................................................................18

5.7.3.2 GMT Fuses.....................................................................................................................................19

5.8 BATTERY TEMPERATURE PROBE INSTALLATION .................................................................................19

5.9 POWER-UP AND CHECKOUT..............................................................................................................19

5.9.1 Apply AC Power....................................................................................................................19

5.9.2 System Parameters Verification/Adjustment.........................................................................20

5.9.3 Full System Power Up...........................................................................................................20

6. SETUP, ADJUSTMENTS, AND OPERATION.................................................................................. 21

6.1 USER INTERFACE .............................................................................................................................21

6.2 EXTERNAL ALARM INPUTS.................................................................................................................21

6.3 ALARM OUTPUT RELAYS................................................................................................................... 22

6.4 PARAMETER LOCATIONS, DESCRIPTIONS, AND DEFAULT VALUES.......................................................22

iv MX28B

1. GENERAL INFORMATION

1.1 Introduction

DC Power Systems 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 made from the system control unit that provides monitoring and
control functions for each component of the system as well as alarm listings 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.

APC provides nationwide 24-hour, 7-day service response by dialing:

[phone]

This service will answer your call, gather specific service information, and have a qualified
APC service representative contact you as quickly as possible (refer to section on customer
service and support).

1.2 Precautions
It is extremely important to read, understand, and strictly follow the instructions in

sections on installation and setup. Also, please note the special SAFETY
PRECAUTIONS outlined in Section 5.1.4 before beginning actual installation of the
power system.

If any precautions are not clearly understood, or local conditions are not covered, contact
the nearest APC representative or APC at [phone] for clarification.

Also, refer to all applicable federal, state, and local regulations, and industry guidelines for
correct installation of this power system.

1.3 Inspection upon Receipt of Goods

1.3.1 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.

1.3.2 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.

MX28B 1

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.

1.3.3 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:

1) Request an inspection by the carrier;

2) File a concealed damage claim; and/or

3) 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.

1.3.4 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 1.3.2 and Section 1.3.3 above 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.

2 MX28B

2. CUSTOMER SERVICE AND SUPPORT

APC manufactures a line power plants and provides customers with complete product and
systems support and service. APC has an international network of factory trained service
technicians. The service organization is on call 24 hours a day, 365 days a year.

If there is a problem with the power system, contact APC at

[phone]

Units returned for repair can be turned around within 24 to 48 hours of receipt at the
factory location. Shipment should be sent pre-paid. The unit will be returned pre­paid provided it was received that way.

An RMA must be obtained for all equipment returned to APC. It is important that correct
procedures be followed in filing an RMA, including providing an accurate written description
of the problem. An accurate written problem description will help ensure that the unit will be
properly repaired.

If a unit is returned and a “No Fault Found” results, APC reserves the right to bill the
customer for labor and assess a service charge to cover extra costs incurred.

MX28B 3

3. WARRANTY PROVISIONS

3.1 General Provisions

APC warrants the power equipment and components it manufactures or sells against
defective materials and workmanship for a period of TWO (2) YEARS from the date of
shipment.

3.1.1 Warranty Returns

If initial physical inspection results in identification of a material or workmanship flaw(s) that
could impair product performance as defined by Advance Power’s electrical and physical
specification in effect at the time of shipment, and if this flaw(s) is not due to transportation
damage or installation abuse, contact Advance Power, Inc. or call the 24-hour emergency
number, [phone], to request assistance.

You will be provided either a) an RMA number with instructions for return of the equipment
or component(s) to the Advance Power, Inc. factory service center, FOB destination, freight
pre-paid, for examination, or b) for non-returnable systems and equipment, notice to wait
until an Advance Power, Inc. authorized service representative arrives at the site to inspect
the equipment. Repaired or advance replacement modules or circuit components will
normally be available within 24 to 48 hours of receipt of equipment or RMA.

3.1.2 Warranty Repair or Replacement

If, during the warranty period, the supplied equipment is found to be physically or electrically
faulty due to defective materials or workmanship on the part of Advance Power, Inc., the
defective product(s) or component(s) will be repaired or replaced at the sole option of
Advance Power, Inc. without charge to the user for replacement materials or repair labor.
(The procedure outlined above for contacting Advance Power, Inc. must be followed.)
Costs incurred for replacement installation including, but not limited to, installation
equipment, travel expenses of an Advance Power, Inc. representative(s), and costs of
installation material transportation expenses are not the responsibility of Advance Power,
Inc. Any replacement product(s) or component(s) shall only complete the remaining unused
portion of the original warranty of the replaced product(s) or component(s).

3.2 Exclusions and Limitations

1. This warranty applies only to the original US domestic purchaser (user) and is not
transferable internationally, except with expressed written consent from Advance
Power, Inc. headquarters in Dallas, Texas.

2. Advance Power, Inc. reserves the right to void the warranty if identification marks or
serial numbers have been removed or tampered with, or the defect is determined to
have been caused by misuse, neglect, improper installation, environmental
conditions, non-authorized repair, alteration, or accident.

3. This warranty does not cover physical damage due to the acts of nature or man
that stress the equipment or component(s) beyond design limits and exert
undesirable influence aside from normal wear and tear.

4 MX28B

4. Advance Power, Inc. assumes no responsibility for any work accomplished or
expenses incurred except with expressed written consent from Advance Power,
Inc.

5. Advance Power, Inc. shall not be liable to the user (purchaser) or any third party for
indirect, incidental, or consequential damages such as, but not limited to, loss of
use, loss of profits, costs associated with removal/installation of a defective
product(s) or component(s) arising out of the sale or relating to the use of this
product, and the user (purchaser) assumes responsibility for all personal injury and
property damage resulting from the handling, possession, or use of the product. In
no event shall the liability of Advance Power, Inc. for any and all claims, including
claims of breach of warranty or negligence, exceed the purchase price of the
product that gave rise to the claim.

The above warranty is in lieu of all other remedies, including actions for contract or
negligence.

All other warranties, expressed or implied, including but not limited to the implied
warranties of merchantability and fitness for a particular purpose, are hereby
excluded.

MX28B 5

4. PRODUCT OVERVIEW AND TECHNICAL DESCRIPTION

4.1 Description

The Advance Power, Inc. Model MX28B is a modular stand-alone -48V dc power plant. It is
configurable in such a manner that it will support most typical applications within the
specified current ranges (either 200 or 400 amperes) without special application
engineering or assistance. Distribution is included for up to 24 plug-in circuit breakers.
These circuit breakers can be 1 to 100 amps, with 60-100 amp breakers requiring two
positions and a circuit breaker adapter kit. An optional low voltage disconnect (LVD) can be
provided on either the battery or the load side. A 400 amp MX28B is shown in Figure

4.1-1. A block diagram is shown in Figure 4.1–2.

Figure 4.1-1. 400 Amp MX28B

6 MX28B

Figure 4.1-2. MX28B BLOCK DIAGRAM

MX28B 7

4.2 Power Output Capacity

The power plant has two basic configurations:
The first supplies a maximum of 200 amps or 150 amps with N+1 redundancy. The housing

for this configuration provides space for one rectifier shelf that can hold up to four rectifiers,
a control unit, and one tier of up to 24 distribution circuit breakers.

The second supplies a maximum of 400 amps or 350 amps with N+1 redundancy. The
housing for this configuration provides space for two rectifier shelves that can hold up to
four rectifiers each, a control unit, and one tier of up to 24 distribution circuit breakers.

The difference between the 200 and 400 amp units are the side plates and an additional
rectifier shelf; all other parts are the same for both configurations.

4.3 Rectifiers

The rectifiers are Advance Power, Inc. Model MRF28H54BV with specifications as follows:

• Input Voltage: 176-264V ac (230V ac nominal) @ 45-66 Hz

• Input Current per Rectifier: 13.9 Amps @ 230V ac

• Apparent Power Factor: 99% Typical, 98% Minimum

• Output Voltage: 54.5V dc

• Overvoltage Protection: Set at 59.5V dc

• Output Current per Rectifier: 50 Amps Minimum Continuous

• Power Output per Rectifier: 2800W Continuous, Vin > 198V ac

• Efficiency: 91% Typical

• Cooling: Fan cooled, front to rear airflow

• Ambient Temperature: -25°C to 65°C Operational

4.4 Control Unit

The microprocessor-based power system control unit is 1U high (1.75”) and provides
control and monitoring functions. Features implemented are:

• 32-character alphanumeric display

• LED alarm and status indicators

• Standard voltage and battery charging control

• Battery temperature compensation (optional)

• Monitoring of up to two shelves of four rectifiers each

• Individual alarm monitoring of 24 breakers

• Eight alarm / annunciation relays (Major, Minor, and six user defined) with form C

contact outputs

• Four external alarm inputs (either N.O. or N.C. contacts)

8 MX28B