American Power Conversion XS 450 -48 User Manual

Magnum XS 450

-48 Vdc Power System User’s Manual

Table of Contents

1 SAFETY FIRST! ................................................................................................................. 1

1.1. W

1.2. G

ARNING SYMBOLS ..................................................................................................... 1

ENERAL PRECAUTIONS

:.............................................................................................. 1

2 INTRODUCTION ................................................................................................................ 2

2.1. G H

OW TO USE THIS MANUAL

ENERAL INFORMATION

................................................................................................ 2

...................................................................................................... 4

3 INSTALLATION.................................................................................................................. 5

3.1. U

3.2. M

NPACKING EQUIPMENT

ECHANICAL INSTALLATION .......................................................................................... 5

............................................................................................... 5

Room / Location.................................................................................................................. 5

Mounting ............................................................................................................................. 7

Ventilation ........................................................................................................................... 7

3.3. AC P

OWER CONNECTIONS

........................................................................................... 8

AC Kit with Three Phase Spreader..................................................................................... 8

AC Kit with Phoenix Terminals Only................................................................................. 10

3.4. R

ECTIFIER SHELF AND MODULE INSTALLATION

............................................................. 11

Rectifier Shelf Serial Communications ............................................................................. 12

Rectifier Shelf Mechanical ................................................................................................ 12

Rectifier AC Input Connections ........................................................................................ 12

Rectifier Module Installation.............................................................................................. 13

3.5. DC D

ISTRIBUTION MODULE INSTALLATION

................................................................... 13

Module Selection .............................................................................................................. 13

Merlin Gerin 28 Circuit Breaker Module Installation ......................................................... 14

Merlin Gerin 12 Circuit Breaker Module Installation ......................................................... 15

NH2 Fuse Module Installation .......................................................................................... 16

3.6 DC C

ABLING GENERAL INSTRUCTIONS

3.7 DC D

ISTRIBUTION INSTALLATION.................................................................................... 18

.............................................................................. 17

Circuit Breaker Installation................................................................................................ 18

Installing circuit breakers in a 28 Circuit Breaker Module on the DIN rail ........................ 19

Installing circuit breakers in a 12 CB Module on the DIN rail ........................................... 20

Installing circuit breaker wiring (both types of circuit breaker modules)........................... 20

Installing a fuse in the NH2 Fuse Module......................................................................... 22

DC Load Return Module Installation................................................................................. 22

DC Load Return cable connections.................................................................................. 23

3.8 B

ATTERY INSTALLATION

................................................................................................. 23

Battery Tray Installation .................................................................................................... 23

Battery Installation ............................................................................................................23

Battery Disconnect Module Installation ............................................................................ 23

Negative Battery Cable Connections................................................................................ 24

Battery Return Module Installation ................................................................................... 25

Positive Battery Cable Connections ................................................................................. 25

Battery Temperature Probe Installation............................................................................ 25

3.9 DC S

3.10 M

ONITORING AND RELAY OUTPUT CONNECTIONS

YSTEM GROUNDING

.............................................................................................. 26

........................................................ 26

Network Management Card.............................................................................................. 26

“Smart” Cable DB9 Connection ........................................................................................ 27

RJ45 Ethernet Connector ................................................................................................. 27

Magnum XS 450 Power System –48 VDC User’s Manual Page ii

Relay Output Connections................................................................................................ 27

External Alarm Input Connections .................................................................................... 28

4 COMMISSIONING............................................................................................................ 29

4.1 P

RE-COMMISSIONING INSPECTION

.................................................................................... 29

Environment...................................................................................................................... 29

Electrical Installation .........................................................................................................29

Battery Visual and Safety Inspection................................................................................ 29

4.2 C

OMMISSIONING

............................................................................................................ 30

Initial Set-up ...................................................................................................................... 30

AC Power Up .................................................................................................................... 30

DC Power Up: ................................................................................................................... 30

Rectifier Test:.................................................................................................................... 30

Battery Power Up.............................................................................................................. 30

LVD Test ........................................................................................................................... 31

Circuit Breaker/ Fuse Test: ............................................................................................... 31

User Inputs........................................................................................................................ 31

Output Relay 1: .................................................................................................................31

Battery Temperature Compensation ................................................................................ 31

4.3 F

INAL INSPECTION

:........................................................................................................ 32

5 OPERATION..................................................................................................................... 33

5.1 T

5.2 R

ECHNICAL DESCRIPTION

ECTIFIER MANAGEMENT .............................................................................................. 33

.............................................................................................. 33

AC Input Power................................................................................................................. 33

DC Output Power.............................................................................................................. 33

Rectifier alarms reporting.................................................................................................. 33

System Voltage Control .................................................................................................... 33

Rectifier Current................................................................................................................ 33

5.3 DC D

ISTRIBUTION

......................................................................................................... 34

DC Distribution Module..................................................................................................... 34

DC Return Module ............................................................................................................ 34

5.4 B

ATTERY MANAGEMENT

................................................................................................ 34

Battery Disconnect Module............................................................................................... 34

Battery Return Module...................................................................................................... 34

Battery Shelves.................................................................................................................34

Battery Cabinet .................................................................................................................34

5.5 C

USTOMER INTERFACE BOARD

...................................................................................... 35

Alarm Outputs (Output Relays) ........................................................................................ 35

External Alarm Inputs (Input Relays)................................................................................ 35

6 PREVENTIVE MAINTENANCE ....................................................................................... 36

6.1 E

6.2 I

QUIPMENT

NSPECTION

.................................................................................................................. 36

Environmental Inspection ................................................................................................. 36

System Visual and Safety Inspection ............................................................................... 36

Battery Visual and Safety Inspection................................................................................ 36

6.3 T

EST ............................................................................................................................ 37

System Voltage Test......................................................................................................... 37

Rectifier Current Test........................................................................................................ 37

Rectifier Current Share Test ............................................................................................. 37

System Current Test......................................................................................................... 37

Rectifier Alarm Test .......................................................................................................... 37

Magnum XS 450 Power System –48 VDC User’s Manual Page iii

System Temperature Test ................................................................................................ 38

Battery Current Test ......................................................................................................... 38

Battery Temperature Test................................................................................................. 38

LVD Test ........................................................................................................................... 38

Battery Preventive Maintenance Procedure..................................................................... 39

6.4 F

INAL INSPECTION

:........................................................................................................ 39

7 SPECIFICATIONS............................................................................................................ 40

7.1 AC I

7.2 M

7.3 E

7.4 C

ECHANICAL

NVIRONMENTAL........................................................................................................... 40

OMPLIANCE

DCPM28HN54SH0 R

NPUT

................................................................................................................. 40

................................................................................................................. 41

ECTIFIER

..................................................................... 40

8 APC WORLDWIDE CUSTOMER SUPPORT .................................................................. 42

9 LIMITED PRODUCT WARRANTY .................................................................................. 43

Reproduction in whole or in part without permission is prohibited. APC and the APC

logo are trademarks or registered trademarks of American Power Conversion

Corporation. All other trademarks, product names, and corporate names are the

property of their respective owners and are used for informational purposes only

Magnum XS 450 Power System –48 VDC User’s Manual Page iv

Revision History

Revision Date By Description

990-1557 Revision 1 20 Oct, 2003 JPF Initial Release

990-1557A Revision 2 30 MAR 2004 BET Update to include Battery Cabinet

Table of Figures

FIGURE 2.1-1 MAGNUM XS 450 POWER PLANT ............................................................................2

FIGURE 2.1-2 POWER SYSTEM BLOCK DIAGRAM ....................................................................... 3

FIGURE 3.2-1 DOOR CLEARANCE DIMENSIONS ........................................................................... 6

FIGURE 3.2-2 FLOOR MOUNTING DIMENSIONS ...........................................................................7

FIGURE 3.3-1 AC KIT WITH THREE PHASE SPREADER (SHOWN WITH SINGLE POLE

BREAKERS) ................................................................................................................................... 9

FIGURE 3.3-2

FIGURE 3.3-3 RECOMMENDED TORQUES FOR TERMINAL BLOCK CONNECTIONS .......... 10

FIGURE 3.3-4 AC INPUT ENTRY WITH INDIVIDUAL RECTIFIER ENTRY (SHOWN WITH

SINGLE POLE CIRCUIT BREAKER OPTION)......................................................................... 11

FIGURE 3.4-1 RECTIFIER SWITCH SETTINGS .............................................................................. 12

FIGURE 3.4-2

FIGURE 3.5-1 28 CIRCUIT BREAKER MODULE ........................................................................... 14

FIGURE 3.5-2 12 CIRCUIT BREAKERS MODULE ......................................................................... 16

FIGURE 3.5-3 NH2 FUSE MODULE ..................................................................................................17

FIGURE 3.7-1 MERLIN GERIN CIRCUIT BREAKER...................................................................... 18

FIGURE 3.7-2 MERLIN GERIN 28 CB MODULE INSTALLATION DETAIL ...............................19

FIGURE 3.7-3 MERLIN GERIN 12 CB MODULE INSTALLATION DETAIL ...............................20

FIGURE 3.7-4 CB ALARM INTERFACE BOARD (28 CIRCUIT BREAKER MODULE).............. 21

FIGURE 3.7-5 CB ALARM EXPANSION BOARD (12 CIRCUIT BREAKER MODULE) ............. 21

FIGURE 3.7-6 NH2 FUSE CONNECTIONS ....................................................................................... 22

FIGURE 3.7-7 LARGE LOAD AND SMALL LOAD RETURN MODULE ...................................... 23

FIGURE 3.8-1 BATTERY CABLE CONNECTIONS ......................................................................... 24

FIGURE 3.8-2 BATTERY RETURN MODULE ................................................................................. 25

FIGURE 3.8-3 TYPICAL LOCATION OF BATTERY TEMPERATURE PROBE ........................... 26

FIGURE 3.10-1 NETWORK MANAGEMENT CARD ....................................................................... 26

RECOMMENDED TORQUES ON INPUT CONNECTORS..................................... 10

RECOMMENDED TORQUES ON RECTIFIER CONNECTORS ............................ 12

Magnum XS 450 Power System –48 VDC User’s Manual Page v

1 Safety First!

It is very important to follow all safety procedures when unpacking, installing and operating any sort of power equipment.

1.1. Warning Symbols

CAUTION: An indication that special care is required to prevent injury,

1.2. General Precautions:

equipment damage or misuse

WARNING: An indication of an electrical hazard that may cause serious personal injury or death, catastrophic equipment damage or site destruction.

WARNING: Hazardous ac voltage levels are present inside the power system. Keep the ac input cover in place when the system is operational or energized.

WARNING

the -48Vdc distribution connection area of the plant. Accidental shorting of distribution conductors can cause arcing and high currents that can cause serious burns or other physical harm. It is recommended that:

Specific CAUTION and WARNING will be placed in manual where appropriate.

• Remove any jewelry, rings or watches while working on this

• Use insulated wrenches, screwdrivers, cutters, pliers and other

WARNING: Ensure that all of the dc and external ac circuit breakers are in the OFF position prior to connecting service to the power plant. Confirm that all voltages have been removed including any battery sources before proceeding

: Hazardous energy levels are present on bare conductors in

equipment.

tools.

Magnum XS 450 Power System –48 VDC User’s Manual Page 1

2 Introduction

2.1. General Information

DC Power Plants from APC have unique features that make them easy to install, maintain, and upgrade. The rectifier units are modular and truly “hot-pluggable” into the shelf assembly without any separate ac wiring. The shelf assemblies are also modular and can be added when system capacity needs to be expanded. All system settings are made from the system controller that provides monitoring and control functions for each component of the system as well as alarm listings for system diagnosis and maintenance.

The APC Magnum XS 450 Power System 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 range without special application engineering or assistance. A wide variety of dc output distribution and battery disconnect modules are supported. An optional low voltage disconnect (LVD) can be provided on either the battery or the load side. A 450ampere system is shown in Figure 2.1-1. A block diagram of a typical configuration of the power system is shown in Figure 2.1-2

Figure 2.1-1 Magnum XS 450 Power Plant

Magnum XS 450 Power System –48 VDC User’s Manual Page 2

Magnum XS 450 Power System –48 VDC User’s Manual Page 3

Figure 2.1-2 Power System Block Diagram

How to Use This Manual

Each section of this manual can be read in any order and should provide a complete explanation of the subject described by the title. However, the sequence of the sections is designed to provide a typical step-by-step process for successful use of the equipment.

Safety First!

Introduction

Installation

Commissioning

Operation

Preventative

Maintenance

Specifications

APC Worldwide

Customer Support

Safety symbol description and general precautions.

Brief system preview and explanation of manual usage.

How to unpack and install the equipment.

The procedure for commissioning the equipment for initial use

Specifics of controls settings and indicators used to operate the

unit.

Procedures for performing preventative maintenance on the

equipment.

Power plant and rectifier specifications.

How to contact APC for customer support.

Warranty

Equipment warranty terms and conditions.

Magnum XS 450 Power System –48 VDC User’s Manual Page 4

3 Installation

3.1. Unpacking Equipment

Remove equipment from packing material and inspect for shipping damage or missing items. It is important to report damage or material shortages to the shipping carrier while a representative is on site.

If concealed damage or material shortages are found at a later time, contact the shipper to make arrangements for inspection and claim filing. Refer to necessary to return equipment to APC.

Section 7

in the event it is

CAUTION

used to remove equipment from packing.

PLEASE RECYCLE: The shipping materials can be recycled. Please save them for later use or dispose accordingly.

: Appropriate lifting techniques and safety equipment should be

3.2. Mechanical Installation

Room / Location

NOTE:

enclosure that is accessible only to qualified persons in accordance with the local regulatory authority.

Prior to installation, drawings, floor loading requirements, external alarm points, ac service entrance, and grounding schemes should all be checked and confirmed. If batteries are to be mounted in a room separate from the power plant, careful attention should be paid to battery cable voltage drop effects. Environmental operating temperatures and ventilation/cooling considerations should also be noted, not just for the power system but also for all other equipment that may reside in the power room area.

The power system has a door on the front that can be hinged to swing either way. The power system has two doors on the rear that swing out. The doors have spring loaded hinge pins so that they can be removed for servicing. Dimensions are shown in Figure 3.2-1. The sides have panels that are mounted flush with the frame. A key-lock on the top of the panels holds the panels in place.

The APC Magnum XS 450 Power System is to be installed in a room, vault, or similar

Magnum XS 450 Power System –48 VDC User’s Manual Page 5

Figure 3.2-1 Door Clearance Dimensions

Magnum XS 450 Power System –48 VDC User’s Manual Page 6

Mounting

The unit is self-supporting, but designed to be bolted to the floor of the housing structure. Figure 3.2-2 shows the footprint of the box frame and the mounting points with dimensions.

Systems with multiple box frames are bolted together with each frame touching, side by side. The side panels where two frames touch are removed so that cables can pass between the frames. A kit with the necessary hardware to bolt two cabinets together (0M-3441) is available from APC.

Figure 3.2-2 Floor Mounting Dimensions

Ventilation

The rectifier modules for this system have fans that provide front-to-rear airflow for internal cooling. The Magnum XS 450 Power System frame should be mounted such that there is free airflow to the front and rear of the unit. [Refer to

Section 7.3

for environmental characteristics.] Free airflow should be ensured so that the power system can provide full power at ambient temperature without de-rating.

Magnum XS 450 Power System –48 VDC User’s Manual Page 7

3.3. AC Power Connections

WARNING

: Ensure that all of the external dc and ac circuit breakers are in the OFF position prior to connecting service to the power plant. Confirm that all voltages have been removed including any battery sources before proceeding

The Magnum XS 450 Power System requires the supply of a nominal 230 Vac single-phase, or three-phase 415/230 V, 50/60 Hz power to the ac input terminal block connections. However, it will operate off of voltages in the range of 176 – 293 V. The maximum possible dc Current Output of the rectifiers is less than the typical value of 50A per rectifier at ac input voltages in the range of 176 to 195 Vac. As the ac input voltage decreases, the maximum dc Output current follows a de-rating curve. For further details on the de-rating curve, please refer to the specification sheet for the DCPM28HN54SH0 Rectifier available from APC Customer service in your area or your local APC distributor.

The ac input enclosure is located at the top of the Magnum XS 450 Power System housing. AC wiring, from the ac input terminal block connections to the hot-pluggable ac input connector for each rectifier, is factory installed. An ac branch circuit breaker of 50 A is recommended for each phase if using the three phase set-up. An ac branch circuit breaker of 20A is recommended for each single-phase connection.

WARNING: Hazardous ac voltage levels are present inside the power system. Keep the ac input cover in place when the system is operational or energized.

AC Kit with Three Phase Spreader

A terminal block for connection of ac input power and “Earth Ground” is provided. The terminal block is labeled as E, NEUT, L1, L2 and L3. At the front of the ac input enclosure, either single pole or two pole circuit breakers are provided for each rectifier. The single pole option breaks the “hot” wire going to each individual circuit breaker. The two-pole breaker option simultaneously breaks both the “hot” wire and the Neutral wire.

The top of the ac input enclosure is provided with four pilot holes for easy alignment of the desired conduit entry holes. A duct is provided so that the ac input connections can be routed up through the unit from the bottom. Two 31.75 mm (1-1/4 inch) conduit entry holes are provided in the bottom of the cabinet.

When a single three phase ac input line is run to each system, a large line spreader strip is provided for connection of the ac Input. The suggested wire size for the Neutral and Ground lines are 35 mm 16 mm

(#6 AWG) rated at 90°C or higher; however, the ambient temperature and number of

(#2 AWG) rated at 90°C or higher The suggested wire size for the lines is

wires in a conduit must also be considered in accordance with all applicable code requirements.

If the ac input power is provided from a three-phase distribution panel. The left rectifier in each shelf is powered from the terminal block labeled L1. The middle rectifier in each shelf is

Magnum XS 450 Power System –48 VDC User’s Manual Page 8

powered from the terminal block labeled L2. The right rectifier in each shelf is powered from the terminal block labeled L3.

AC Line 1

AC Line 2

AC Line 3

AC Neutral

Earth Ground

Neut.

Figure 3.3-1 AC Kit with Three Phase Spreader (shown with single pole breakers)

Magnum XS 450 Power System –48 VDC User’s Manual Page 9

Neutral Input

Wire Size (AWG) Wire Size (mm2) Max Torque (in-lb) Max Torque (N-m) 350 kcmil – 2 Cu 185 – 35 Cu 275 31.75

L1, L2, and L3 Input

Wire Size (AWG) Wire Size (mm2) Max Torque (in-lb) Max Torque (N-m)

2/0 – 6 Cu 70-16 Cu 125 13.5

Earth Ground Input

Wire Size (AWG) Wire Size (mm2) Max Torque (in-lb Max Torque (N-m)

4/0 – 6 Cu 95 – 16 Cu 275 31

Figure 3.3-2 Recommended Torques on Input Connectors

AC Kit with Phoenix Terminals Only

A terminal strip for ac input power connection and a separate “Earth Ground” bar for connection of the safety ground wire(s) is provided. The terminal block is labeled as L and N for each rectifier with the terminal block for rectifier one being the leftmost. At the front of the ac input enclosure, optional single pole or two pole circuit breakers may be provided for each rectifier. The single pole option breaks the “hot” wire going to each individual circuit breaker. The two-pole breaker option simultaneously breaks both the “hot” wire and the Neutral wire. The system may also have no circuit breakers.

Individual ac input lines are run for each rectifier. The suggested wire size is 6 mm

(#10 AWG) rated at 90°C or higher, however, the ambient temperature and number of wires in a conduit must also be considered in accordance with all applicable code requirements.

Wire Size (AWG) Wire Size (mm

) Max Torque (in-lb) Max Torque (N-m)

6 - 10 Cu 16 –6 16 1.8

Figure 3.3-3 Recommended Torques for Terminal Block Connections

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