American Power Conversion MX28B600 User Manual

DC Power Plant

Product Manual

MX28B600

December 2002 APC DCNS Inc.
11035 Switzer Avenue
Part# 990-0564 Dallas, TX 75238

REVISION HISTORY

Revision Date By Description

07/10/01 JNF Initial release.

10/30/02 BET Changed breaker numbering

TABLE OF CONTENTS

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

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 Cable Sizing Considerations .........................................................................................................14

5.3.2 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 ....................................................................................................................15

5.6.2 Alarm Outputs ..................................................................................................................................16

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

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

MX28B600

5.7.2 Installation of Circuit Breakers and Fuses ................................................................................18

5.7.2.1 Plug-in Circuit Breakers.................................................................................................................. 18

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

5.7.3 Load Connections............................................................................................................................19

5.7.3.1 Circuit Breakers .................................................................................................................................. 19

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

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

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

5.9.1 Apply AC Power ..............................................................................................................................20

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

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

6. SETUP, ADJUSTMENTS, AND OPERATION................................................22

6.1 USER INTERFACE ........................................................................................................................................22

6.2 SNMP INTERFACE .....................................................................................................................................22

6.3 EXTERNAL ALARM INPUTS .......................................................................................................................23

6.4 ALARM OUTPUT RELAYS ..........................................................................................................................23

6.5 PARAMETER LOCATIONS, DESCRIPTIONS, AND DEFAULT VALUES ...................................................23

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MX28B600

1. GENERAL INFORMATION

1.1 Introduction

DC Power Plants from APC DC Network Solutions Inc. (hereafter in this document “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’s international network of sales and service offices and qualified representatives
provides sales assistance for proposals, purchases, and after-sales support.

APC provides nationwide support 8am to 8pm EST. 8pm to 8am Emergencies only by
leaving a message with a paging system 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 call us at 800-800-4APC 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 and all 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 all 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:

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MX28B600

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 of any and all materials. The
customer is responsible to 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, the equipment itself, and/or material or
equipment shortages. If damage or shortage is noted, then:

1) Immediately 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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MX28B600

2. CUSTOMER SERVICE AND SUPPORT

APC manufactures standby power plants and systems, 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 DCNS at

1-800-800-4APC

When you contact APC you should refer to your supplier as DC Network Solutions. Units
returned for repair can usually 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 in a timely manner.

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 recover the costs incurred.

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MX28B600

3. WARRANTY PROVISIONS

3.1 General Provisions

APC DC Network Solutions Inc. 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 at 1-800-800-4APC, 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 returned equipment or repairs and/or equipment adjustments will be
performed by APC service representatives at the site. APC reserves the right to determine the
method for correction of equipment flaw(s).

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 for 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.

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 performed, or expenses incurred, except with
expressed written consent from APC.

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MX28B600

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 all
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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MX28B600

4. PRODUCT OVERVIEW AND TECHNICAL DESCRIPTION

4.1 Description

The MX28B600 is a modular stand-alone -48V DC power plant with a microprocessor-based
control unit. It is configurable in such a manner that it will support most typical applications
within the specified current range of 600 amperes without special application engineering or
assistance. Distribution of two tiers is included for up to 44 plug-in circuit breakers, located in a
24-position panel (breakers labeled 1 to 23) and two 10-position panels (breakers labeled 25-34
and 39-48), all with front access. 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.

Optional load shedding capabilities can also be provided by use of an additional LVD that will
disconnect loads connected to the lower right breaker panel at a user specified voltage.

Figure 4.1-1. MX28B600

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MX28B600-48V

Figure 4.1-2. MX28B600 BLOCK DIAGRAM

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MX28B600-48V

4.2 Power Output Capacity

600 amps maximum, or 550 amps with N+1 redundancy. The housing provides space for three
rectifier shelves that can hold up to four rectifiers each, a control unit, and two tiers of up to 43
distribution circuit breakers.

4.3 Rectifiers

The rectifiers are APC DC Network Solutions, 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

• Over voltage 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

• Hostile/Dusty Environment: Dust filter is optional

4.4 Control Unit

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

• 32-character alphanumeric display

• LED alarm and status indicators

• Standard voltage and battery charging control

• Battery temperature compensation (optional)

• Monitoring of up to three shelves of four rectifiers each

• Individual alarm monitoring of 43 breakers

• Individual alarm monitoring of eight GMT 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 of either a battery or a load LVD

• WEB/SNMP interface card for remote monitoring.

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