American Power Conversion MX28B1200, MX28B2400+27V User Manual

DC POWER PLANT

PRODUCT MANUAL

MODEL MX28B1200/2400+27V

APC DC Network Solutions Inc. 11035 Switzer Avenue Dallas, TX 75238 Part Number 990-9166 800-800-4APC Preliminary release

MX28B-1200+27V PRODUCT MANUAL Rev 1

Product Structure

Component

MX28B1200/2400+27V Main Bay

DC Distribution Options +24V

Small Breakers

LVD Options +24V

Description Part Number

1200 amp frame, 2400 amp carry through, controller. No rectifiers, converters, no distribution

1200 Amp expansion frame, No rectifiers, distribution.

Main and/or extension Bay

38 +27V breakers and 8 –48V volt breakers

Main and/or extension Bay

0M-91147

Available soon

0M-91145

No LVD TBD Battery LVD TBD

Converter Shelf Option

No Converters

TBD

Converter Shelf, Input power breakers, distribution breakers

Provides power to, and distribution from converters

0M-6176

Rectifiers +27V @ 100 Amps each 1MRF28H27BV Converters -50V @ 10 Amps each AAC-0010 Battery Temperature Probe 15 ft. (4.6m) FFA-0013-1 50 ft. (15.2m) FFA-0013-2

*Note: DC-to-DC converters are available in the main frame only.

Rev 1 MX28B-1200+27V PRODUCT MANUAL

REVISION HISTORY

Revision Date By Description

1 09/12/2001 JNF Initial release.

iii

MX28B-1200+27V PRODUCT MANUAL Rev 1

TABLE OF CONTENTS

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

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

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

1.3 INSPECTION UPON RECEIPT OF G OODS..........................................................................................................................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............................................................................................................3

3.1 G ENERAL PROVISIONS..................................................................................................................................................... 3

3.1.1 Warranty Returns..................................................................................................................................................3

3.1.2 Warranty Repair or Replacement .......................................................................................................................3

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

4 PRODUCT OVERVIEW AND TECHNICAL DESCRIPTION.........5

4.1 DESCRIPTION.....................................................................................................................................................................5

4.2 POWER OUTPUT CAPACITY.............................................................................................................................................7

4.3 RECTIFIERS........................................................................................................................................................................7

4.4 CONVERTERS.....................................................................................................................................................................7

4.5 CONTROL UNIT.................................................................................................................................................................8

4.6 AC INPUT POWER.............................................................................................................................................................8

4.7 BATTERY CONNECTIONS..................................................................................................................................................9

4.8 +24V DC DI STRIBUTION................................................................................................................................................. 9

4.9 –48 V DC DISTRIBUTION FROM CONVERTERS (OPTIONAL) ....................................................................................10

4.10 ENVIRONMENTAL...........................................................................................................................................................11

4.11 MECHANICAL..................................................................................................................................................................11

4.12 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...................................................................................................................................................13

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

5.1.7 Ventilation............................................................................................................................................................14

5.2 AC SERVICE AND G ROUND CONNECTIONS................................................................................................................ 14

5.3 BATTERY CONNECTIONS...............................................................................................................................................15

5.3.1 Battery Disconnect ..............................................................................................................................................15

5.3.2 Cable Sizing Considerations.............................................................................................................................16

5.3.3 Connecting the Cables.......................................................................................................................................16

5.4 DC SYSTEM GROUNDING......................................................................................................................................16

5.5 RECTIFIER INSTALLATION.............................................................................................................................................17

5.6 CONVERTER INSTALLATION ..........................................................................................................................................17

5.7 ALARM CONNECTIONS ...................................................................................................................................................18

5.7.1 External Alarm Inputs........................................................................................................................................19

5.7.2 Alarm Outputs......................................................................................................................................................19

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5.8 CONNECTING THE LOADS.............................................................................................................................................20

5.8.1 DC Circuit Breakers...........................................................................................................................................20

5.8.2 Installation of Circuit Breakers........................................................................................................................21

5.8.2.1 24V Circuit Breaker Load Connections ......................................................................................................21

5.8.2.2 –48V Circuit Breaker Load Connections ....................................................................................................21

5.9 BATTERY TEMPERATURE PROBE INSTALLATION......................................................................................................22

5.10 POWER-UP AND CHECKOUT..........................................................................................................................................22

5.10.1 Apply AC Power.............................................................................................................................................23

5.10.2 System Parameters Verification/Adjustment.............................................................................................23

5.10.3 Full System Power Up...................................................................................................................................24

6 SETUP, ADJUSTMENTS, AND OPERATION.....................................................25

6.1 USER INTERFACE ............................................................................................................................................................25

6.2 SNMP INTERFACE..........................................................................................................................................................26

6.3 EXTERNAL ALARM INPUTS...........................................................................................................................................26

6.4 ALARM OUTPUT RELAYS..............................................................................................................................................26

6.5 PARAMETER LOCATIONS, DESCRIPTIONS, AND DEFAULT V ALUES........................................................................27

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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 repr esentative or APC at (800) 800-4172 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.

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.

MX28B-1200+27V PRODUCT MANUAL Rev 1

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.

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 in spect 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).

MX28B-1200+27V PRODUCT MANUAL Rev 1

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

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 TECHNI CAL DESCRIPTION

4.1 Description

The APC Models MX28B1200+27V represents a family of stand-alone +24V DC power plants. Through the use of modular power, a system is configurable in such a manner that it will support most typical applications within the spe cified current range of up to 1200 amps without special application engineering or assistance. The expansion bay, which will increase the output to 2400 Amps, will be available shortly.

The system is capable of supplying 1200 amps of +24V DC power in a sin gle frame with integrated power distribution and an advanced control and monitoring module. Standard distribution for a power bay includes up to 38 plug-in circuit breakers ranging from 1 to 100 amps. An optional +24V to -48V Converter shelf is available to power up to 80 Amps of –48V loads that can be distributed by up to 7 circuit breakers. An optional low voltage disconnect (LVD) can be provided on the battery side. A 1200 amp MX28B+27V with converters is shown in. Figure 4-1. A block diagram is show n in Figure 4–2

Figure 4-1 MX28B-1200/2400+27V

MX28B-1200+27V PRODUCT MANUAL Rev 1

USER INFRASTRUCTURE

UTILITY

BATTERY PLANT

+24V RECTIFIERS

BATTERY DISCONNECT LVD (OPTIONAL)

+24V BUS

MASTER CONTROLLER

-48V DC/DC CONVERTERS

WEB/SNMP

INTERFACE

-48V BUS

USER

INPUT/OUTPUT

-48V

LOADS

+24V LOADS

RETURN BUS

BATTERY SHUNT

MX28B-1200 +27

Figure 4-2 MX28B1200/2400+27V System Diagram

MAIN GND BUS

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4.2 Power Output Capacity

A power frame consists of three rectifier shelves, each shelf accommodating up to four hot-plug, 100 amp rectifiers. A completely configured power frame with 12 rectifiers is rated at 1200 amps. The master control unit provides control and monitoring for the entire system.

The optional converter shelf supports up to eight hot-plug +24/-48V DC/DC converters. Each converter is rated at 10 Amps.

4.3 Rectifiers

APC Model MRF28H27BV 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: 27.2V DC

• Overvoltage Protection: Set at 31.5V DC

• Output Current per Rectifier: 100A Minimum Continuous

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

• Efficiency: 89% Typical

• Cooling: Fan cooled, front to rear airflow

• Ambient Temperature: -25°C to 55°C Operational

4.4 Converters

APC Vector Series with specifications as follows:

• Input Voltage: +20V DC to +30V DC

• Input Current per converter: <30 amps

• Output Voltage: -50VDC (-48V DC to –52V DC)

• Output current per converter: 10 amps

• Power output per converter: 520 Watts

• Efficiency: >85%

• Cooling: Fan cooled, front to rear airflow

• Ambient temperature: -40°C to 55°C Operational

MX28B-1200+27V PRODUCT MANUAL Rev 1

4.5 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 6 shelves of four rectifiers each and up to 8 DC to DC Converters

• Individual alarm monitoring of 72 breakers

• Individual alarm monitoring of 16 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)

• WEB/SNMP Interface Card for remote monitoring

4.6 AC Input Power

Each rectifier shelf requires 208/220/240V ac, single-phase, 50/60 Hz, supplied through an external 80-amp breaker. Three Vertical wire conduits in the left rear of the frame provide routing for AC input power connection of each shelf. The Earth Ground wiring is factory installed to each rectifier shelf. A power entry box with 3 pilot holes is provided at the top and rear of the frame where AC wiring conduit can be run. Refer to Figure 4-3.

AC wire conduits (3)

Figure 4.3 Power Entry Box

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4.7 Battery connections

Battery connections are made at the top rear of the unit. The +24V and Battery Return buses each provide two sets of 3/8” -16 holes on 1 inch or 1 ¾ inch centers for connecting two-hole battery cable lugs. Refer to Figure 4-4.

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.

- +

4.8 +24V DC Distribution

A standard power distribution module can mount up to 38 plug-in circuit breakers providing +24V power for customer loads. Each breaker row is connected at its center to the +24V DC bus, with each column having an ampacity of 300A. Connections for the +24V DC loads are located directly above 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.

The load return cables for each circuit breaker connect to a return bus directly above the top row of circuit breakers. The return bus contains a pattern for 40 two-hole #10-32 lugs on 5/8-inch centers. Figure 4-5 shows the power plant’s DC distribution section.

Figure 4.4 Battery Connections

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