APC MX28B-1200, MX28B-2400 User Manual
DC POWER PLANT
PRODUCT MANUAL
MODEL MX28B-1200/2400
APC DC Network Solutions Inc. Division
11035 Switzer Avenue
Dallas, TX 75238 Part Number PML-0218
800-800-4APC Revision (B)
MX28B-1200 PRODUCT MANUAL Revision B
ii MX28B-1200/2400
Revision B MX28B-1200 PRODUCT MANUAL
REVISION HISTORY
Revision Date By Description
Preliminary 05/19/2000 SCG Preliminary release.
A 06/30/2000 SCG Various corrections and typos.
B 01-16-01 JNF Replaced Advance with APC. Changed 1-800
number. Added ESD caution
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TABLE OF CONTENTS
1. GENERAL INFORMATION........................................................................................................................... 1
NTRODUCTION................................................................................................................................................ 1
1.1 I
1.2 P
RECAUTIONS.................................................................................................................................................. 1
1.3 I
NSPECTION 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 ........................................................................................................................... 5
3.1 G
ENERAL PROVISIONS..................................................................................................................................... 5
3.1.1 Warranty Returns .................................................................................................................................. 5
3.1.2 Warranty Repair or Replacement.......................................................................................................... 5
3.2 E
XCLUSIONS AND LIMITATIONS ...................................................................................................................... 5
4. PRODUCT OVERVIEW AND TECHNICAL DESCRIPTION................................................................... 7
4.1 D
4.2 P
4.3 R
4.4 C
4.5 AC I
4.6 B
4.7 DC D
4.8 E
4.9 M
4.10 C
ESCRIPTION................................................................................................................................................... 7
OWER OUTPUT CAPACITY ............................................................................................................................. 9
ECTIFIERS...................................................................................................................................................... 9
ONTROL UNIT................................................................................................................................................ 9
NPUT POWER.......................................................................................................................................... 10
ATTERY CONNECTIONS................................................................................................................................ 10
ISTRIBUT ION ......................................................................................................................................... 10
NVIRONMENTAL .......................................................................................................................................... 11
ECHANICAL ................................................................................................................................................ 11
OMPLIANCE ........................................................................................... ERROR! BOOKMARK NOT DEFINED.
5. INSTALLATION PROCEDURES ................................................................................................................ 13
5.1 P
REPARATION................................................................................................................................................ 13
5.1.1 Recommended Tools............................................................................................................................ 13
5.1.2 Recommended Test Equipment............................................................................................................ 13
5.1.3 Equipment Inspection.......................................................................................................................... 13
5.1.4 Safety Precautions............................................................................................................................... 13
5.1.5 Room/Locations................................................................................................................................... 14
5.1.6 Mounting ............................................................................................................................................. 14
5.1.7 Ventilation........................................................................................................................................... 15
5.2 AC S
5.3 B
ERVICE AND GROUND CONNECTIONS.................................................................................................... 15
ATTERY CONNECTIONS ............................................................................................................................... 17
5.3.1 Battery Disconnect .............................................................................................................................. 17
5.3.2 Cable Sizing Considerations ............................................................................................................... 17
5.3.3 Connecting the Cables ........................................................................................................................ 17
5.4 DC SYSTEM GROUNDING....................................................................................................................... 17
5.5 R
5.6 M
ECTIFIER INSTALLATION ............................................................................................................................. 18
ULTIPLE FRAME ASSEMBLY ....................................................................................................................... 18
5.6.1 Power Bus Connections ...................................................................................................................... 18
5.6.2 Control Wiring .................................................................................................................................... 19
5.7 A
LARM CONNECTIONS .................................................................................................................................. 23
5.7.1 External Alarm Inputs ......................................................................................................................... 24
5.7.2 Alarm Outputs ..................................................................................................................................... 24
5.8 C
ONNECTING THE LOADS.............................................................................................................................. 25
5.8.1 DC Circuit Breakers and Fuses .......................................................................................................... 25
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5.8.2 Installation of Circuit Breakers and Fuses ......................................................................................... 26
5.8.2.1 Plug-in Circuit Breakers ..................................................................................................................................26
5.8.2.2 Circuit Breaker Load Connections...................................................................................................................27
5.8.2.3 Power Distribution Fuse Load Connections ..................................................................................................... 27
5.9 BATTERY TEMPERATURE PROBE INSTALLATION........................................................................................... 28
OWER-UP AND CHECKOUT .......................................................................................................................... 28
5.10 P
5.10.1 Apply AC Power.................................................................................................................................. 28
5.10.2 System Parameters Verification/Adjustment ....................................................................................... 29
5.10.3 Full System Power Up......................................................................................................................... 29
6. SETUP, ADJUSTMENTS, AND OPERATION ........................................................................................... 31
6.1 U
6.2 E
6.3 A
6.4 P
SER INTERFACE ........................................................................................................................................... 31
XTERNAL ALARM INPUTS ............................................................................................................................ 32
LARM OUTPUT RELAYS .............................................................................................................................. 32
ARAMETER LOCATIONS, DESCRIPTIONS, AND DEFAULT VALUES................................................................ 32
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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 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:
(800) 800-4APC
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 (214) 342-5000 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
carrier representative is STILL ON SITE
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.
. Please be sure that all items are accounted for,
upon taking delivery while the
If damage has occurred or the quantity of items is not correct, then:
1) Make a descriptive notation on the delivery receipt before signing.
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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.
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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
(800) 800-4APC
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 pre-paid
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.
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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 APC’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 APC or call the 24-hour emergency number, (800) 800-4APC, to
request assistance.
You will be provided either a) an RMA number with instructions for return of the equipment or
component(s) to the APC factory service center, FOB destination, freight pre-paid, for
examination, or b) for non-returnable systems and equipment, notice to wait until an APC
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 APC, the defective product(s) or
component(s) will be repaired or replaced at the sole option of APC without charge to the user
for replacement materials or repair labor. (The procedure outlined above for contacting APC
must be followed.) Costs incurred for replacement installation including, but not limited to,
installation equipment, travel expenses of an APC representative(s), and costs of installation
material transportation expenses are not the responsibility of APC 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 APC facility in
Dallas, Texas.
2. APC 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. APC assumes no responsibility for any work accomplished or expenses incurred except with
expressed written consent from APC
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5. APC 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 APC 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.
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4. PRODUCT OVERVIEW AND TECHNICAL DESCRIPTION
4.1 Description
The APC Models MX28B-1200/2400 represents a family of stand-alone -48V dc power plants.
Through the use of modular power and distribution box frames, a system is configurable in such
a manner that it will support most typical applications within the specified current range of up to
3600 amps without special application engineering or assistance.
The system is designed to start as a base unit capable of supplying 1200 amps of –48V dc power
in a single box frame with integrated power distribution breakers and an advanced control and
monitoring module. Standard distribution for a power bay includes up to 48 plug-in circuit
breakers (1 to 100 amps), or large panel-mounted circuit breakers (250 to 700 amps).
Expansion of the base unit is accomplished by adding power frames and distribution frames on
either side of the base unit The distribution box frames come with a variety of circuit breaker
and fuse options. Power expansion of the 1200 amp plant to a 2400 amp plant only requires the
addition of splice plates to the existing bus structure.
An optional low voltage disconnect (LVD) can be provided on either the battery or the load side
in each power bay. Systems incorporating power distribution frames need an external LVD unit
A 1200 amp MX28B is shown in. Figure 4-1. A block diagram is shown in Figure 4–2.
Figure 4-1 MX28B-1200
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Figure 4-2 MX28B-1200 System Diagram
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4.2 Power Output Capacity
A single power box frame consists of six rectifier shelves, each shelf accommodating up to four
hot-plug, 50 amp rectifiers. A completely configured power frame with 24 rectifiers is rated at
1200 amps. Each additional power frame will add up to 1200 amps for a maximum total of
2400 amps using 48 rectifiers. A single master control unit in the first power frame provides
control and monitoring for the entire system.
4.3 Rectifiers
The rectifiers are APC 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 (2 lines by 16 characters)
•= LED alarm and status indicators
•= Standard voltage and battery charging control
•= Battery temperature compensation (optional temperature probe)
•= Monitoring of up to 18 shelves of four rectifiers each
•= Individual alarm monitoring of 72 breakers
•= Individual alarm monitoring of ten power distribution fuses
•= 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)
•= Control for two independent Low Voltage Disconnects (LVD’s)
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MX28B-1200 PRODUCT MANUAL Revision B
+
)
4.5 AC Input Power
Each rectifier requires 208/220/240V ac, singlephase, 50/60 Hz, supplied through an external 20amp two-pole breaker. A vertical wire channel at
the rear of the box frame provides terminal strips
for ac input power connection of each shelf.
Separate “Earth Ground” terminal bars are
provided for the connection of the safety ground
wires. A power entry box is provided at the top
and rear of the box frame where AC wiring
conduit can be attached. Refer to Figure 4-3.
4.6 Battery connections
-
Battery connections are made at the top rear of the
unit. The -48V and Battery Return buses each
provide four sets of threaded 3/8”-16 holes on 1
inch or 1 ¾ inch centers for connecting two-hole
battery cable lugs. Refer to Figure 4-3.
A battery disconnect breaker is required external
to this equipment. The power plant can monitor
auxiliary contacts from this breaker. Battery
temperature compensation is available. APC’s
master control unit, in conjunction with the
optional temperature monitor sensor cable, is used
to implement this function.
4.7 DC Distribution
A standard power distribution module within the power
box frame contains two 24-position plug-in circuit
breaker columns, providing -48V power for customer
loads. Each breaker column is connected at its center to
the -48V dc bus, with each side having an ampacity of
300A. Connections for the -48V dc loads are located
directly to the side of the corresponding breaker. A
typical load connection would utilize a #6 AWG wire
with a two-hole lug on 5/8-inch centers, attached with
standard #10-32 mounting screws.
Battery
Connections
AC entry and
vertical wiring
channel
Figure 4-3 Power Entry Box and Battery
Connections
Circuit Breaker Positions (-
The load return cables for each circuit breaker section
connect to a return bus directly opposite the circuit
breakers. These return buses contain patterns for 28
two-hole #10-32 lugs on 5/8-inch centers, and 14 twohole ¼”-20 lugs on a double-pattern of either 5/8-inch
or 1-inch centers. Figure 4-4 shows the power plant’s dc
Load Returns (+) and
Facility Main Ground Bus
Figure 4-4 DC Distribution
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Revision B MX28B-1200 PRODUCT MANUAL
distribution section with the front cover removed.
Alternate circuit breaker configurations are available in order for the power frames to provide
support for larger individual load connections. Six circuit breakers in the 100 amp to 400 amp
range or four circuit breakers in the 225 to 700 amp range in a panel-mount arrangement can be
specified instead of the distribution module with 48 plug-in breakers.
Optional power distribution box frames can be added to a power system to support additional
circuit breakers or telecom fuses. Auxiliary alarm contacts from circuit breakers can be brought
back to the control unit through the use of an alarm extension printed circuit board in each bay.
Ten fuses outputs can also be directly monitored by the control unit.
4.8 Environmental
•= Ambient Temperature: -20°C to +65°C operating
-40°C to +85°C storage
•= Humidity: 0% to 85% RH non-condensing operating
0% to 95% RH non-condensing storage
•= Altitude: Up to 3000m, operating
Up to 10,000m, storage
4.9 Mechanical
•= Weight: Base Power Frame – 400 to 600 lbs. (181 to 272 kg)
•= Dimensions Box Frame: 84” high x 26” wide x 26” deep
•= Color: Dawn Gray (fronts)
4.10 Compliance
•= Safety UL 1950
Extension Power Frame – 400 to 600 lbs. (181 to 272 kg)
Rectifier - 11 lbs. (5 kg.)
(2134 mm x 660 mm x 660 mm)
MX28B-1200/2400 11
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