User Manual For DC Series MX06 40A Shelf User Manual 990-9178A DC MX06 40A Shelf Page 1 of 44 th 18 FEB 02
DC MX06 40A Shelf The MX06 40A Shelf is a 19” compatible modular power plant capable of supplying up to 42A at –48V DC (54V). The unit contains a controller that can configure up to 4 x 10.5A rectifiers. Power distribution, Integral LVD contact and alarm signals are all included. Optional mounting brackets are offered to allow the system to be fitted in a 23” rack. Easy subassembly access and replacement allows for convenient and efficient maintenance.
Contents SECTION 1 2 DESCRIPTION General Information 1.1 Introduction 1.2 Safety Precautions 1.3 Types Of Hazard 1.4 Inspection Of Goods 1.5 APC Worldwide customer support 1.6 Warranty Information Product Overview + Technical Description 2.1 Specification 2.2 2.3 2.1.1 Rectifier 2.1.2 System AC Input 2.1.3 System Output 2.1.4 Environmental 2.1.5 Approvals Display + LED’s Controller 2.3.1 2.4 2.5 2.6 2.7 3 User Manual 990-9178A DC MX06 40A Shelf Controller Layout Alarms 2.4.
Installation Procedure 4.1 AC Primary Supply 4.2 4.3 4.1.1 Single Phase 4.1.3 Single Phase AB Feed 4.1.4 3 Phase Star Supply 4.1.5 3 Phase Delta Supply DC Distribution 4.2.1 10 GMT Fuses Rear Access 4.2.2 10 GMT Fuses Front Access 4.2.3 4 Circuit Breakers Rear Access 4.2.4 4 Circuit Breakers Front Access 4.2.5 4 Cartridge Fuses Rear Access 4.2.6 4 Cartridge Fuses Front Access Cable Routing 4.3.1 4.3.2 4.4 5 6 7 8 Input Cables Output Cables External Battery Installation 4.4.
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 controlled from the system control unit that provides monitoring and control functions for each component of the system as well as alarm outputs for system diagnosis and maintenance.
• CEC Code C22.1-98 ( Canada ) • CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH (COSHH) REGS • MANUAL HANDLING REGULATIONS, 1993 (See Section 6) 1.2.3 BECOME FAMILIAR WITH THE HAZARDS ASSOCIATED WITH THE POWER SYSTEM AS DETAILED IN PARA 2. 1.2.4 CAUTION - BEFORE INSTALLING RECTIFIERS (POWER SUPPLIES) INTO AN UNPOPULATED SYSTEM SEE INSTALLATION INSTRUCTIONS IN SECTION 4. 1.
1.4 Inspection upon Receipt of Goods 1.4.1 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. 1.4.
1.5 APC Worldwide Customer Support Customer support for this or any other American Power Conversion (APC) product is available at no charge in any of the following ways: l Visit the APC web site to find answers to frequently asked questions (FAQs), to access documents in the APC Knowledge Base, and to submit customer support requests. http://www.apc.com (Corporate Headquarters) Connect by links to APC web pages for specific countries and regions, each of which provides customer support information.
1.6 Warranty Information 1.6.1 Limited Warranty American Power Conversion (APC) warrants the DC MX06 40A Shelf to be free from defects in materials and workmanship for a period of two years from the date of purchase. It’s obligation under this warranty is limited to repairing or replacing, at it’s own sole option, any such defective products. This warranty does not apply to equipment that has been damaged by accident, negligence, or misapplication or has been altered or modified in any way.
2 Product Overview and Technical Description 2.1 Specification 2.1.1 Rectifier Parameter (per rectifier) 1TWF0500H54** Approved Input Rating I/p Operating Range RMS Input Current “ “ “ Approved Input Frequency range Turn-on Surge Turn-on Time Internal Fuse Power Factor Output Voltage (Nominal) O/p Current (Rated) 115V or 230Vac 103.5V to 264V 6.5A max @115V 3.
2.1.3 System Output Output Voltage Nominal Voltage Adjustment Range Current Rating Temperature Coefficient Current Limit Reverse Quiescent Current Regulation Over voltage 2.1.4 54.5Vdc 44 V – 57 V (Below 42V LVD contact opens) 42 A @ 230Vac, 36 A @ 115Vac, 28A @ 100Vac -76mV/°C ±10% (over range 0°C - 50°C) 100% - 110% of Rated Current Less than 100mA, Typically 50mA 250mV max for any line or load condition 59.5V ± 0.5V (reset by interruption of AC Input) Environmental Temperature Range Humidity 2.1.
2.3 Controller 2.3.
2.4 Alarms 2.4.1 Available Alarms To monitor the system status a selection of alarm outputs are available. Dependant upon the rectifiers fitted either 4 front panel LED’s or a single LED give visual notification of a system fault. There is also a range of open collector transistor alarm outputs, which can be accessed at the rear of the shelf or on a front panel connector (selected models). Finally there are 2 sets of relay contacts that can be configured to represent 1 or more alarms selected by the user.
2.4.2 Rear Access Alarms To access the alarm outputs first ensure batteries are disconnected from the system by setting battery connection switch to “OFF” via controller front panel (see section 2.3) and by turning the external battery breaker off. The input mains supply must then be turned off by operating the local isolator or disconnection device. Remove the rear cover to leave the view as shown below.
2.4.4 Major and Minor Alarms In an MX06 40A Shelf, 9 of the available alarms can be set to show as a “Minor” or “Major” alarm. As standard the alarm outputs are open collector transistor outputs available from the connectors as detailed in the 2 previous sections. If an alarm is selected as a Minor or Major alarm it also lights the corresponding “Major” or “Minor” front panel LED and the “Major” or “Minor” relay contacts also change over.
2.5 Customer Inputs 2.5.1 Current Limit Programming Input Current Limit Program 5V aux Description Connect a DC voltage to this pin (referenced to signal common or –Ve output) to reduce the system output current limit point. Current limit is programmed down 1A per 1.5V program voltage. Max program voltage 7.5V. 5V aux can be used to program down current limit level by linking to program pin.
2.5.3 Battery Test Function Input Description Battery Test 2.5.4 Front panel momentary push button. Push and hold drops output volts to 45Vdc. This is below battery float voltage and is used to check the batteries can supply the system load. Enable Function Input Enable Location Push button mounted on controller front panel. Description Back-plane circuit board mounted 3-way Molex header. Link pins 1 and 2 with supplied link for “local” enable of rectifier outputs.
2.5.5 Temperature Compensation Input Description Socket Pin Temp Compensation This function allows a temperature probe to be used to automatically adjust the output voltage of the system. This ensures the charging voltage stays within the battery manufacturers recommended limits. To connect thermistor, simply enter striped wires into SK19 and screw to clamp (polarity not important). Check controller configuration link as explained below.
2.6 Mechanical 2.6.1 Dimensions Dimension Length 2.6.2 A 482.6mm (19in) B 132.5mm (5.22in, 3U) C 283.6mm (11.17in) D 82.5mm (3.25in) E 138.5mm (5.45in) F 438.2mm (17.25in) Weight Item Measured Shelf + Dist + Controller Single Rectifier Full System Weight (Kg) 7.65 1.75 14.70 Weight (lbs) 16.85 3.85 32.
2.6.3 Mounting Options The MX06 40A Shelf has 3 positions for mounting ears. If mounting ears were ordered with the system they will be fitted in the front position as standard. The 2 alternative mounting positions are shown below. The end user can simply unscrew the ears and re-fit in the desired position. Ensure all screws are re-tightened sufficiently.
2.7 Schematic 2.7.
2.7.
3 System Configuration The MX06 40A shelf is designed to meet a wide range of customer requirements/applications. A number of versions and options are available including various distribution types, alternative input supply configurations, 19 and 23 inch mounting versions, temperature probes etc. Contact APC for details.
4 Installation Procedure 4.1 AC Primary Supply 4.1.1 Single Phase The MX06 40A Shelf can be used on a Single Phase AC supply. The system can be connected to a 230V or 115V supply. Maximum input current is 26A at 115Vac and 15A at 230Vac. Choose AC Input cabling rated accordingly and colour coded as required for country/state concerned. 4.1.1.
4.1.1.2 Front Access Connection To connect the input supply to the MX06 40A Shelf proceed as follows: • The same protection devices and cable parameters are required for front access connection as explained for “single-phase rear access” previously. • Ensure that the AC supply intended for connection is isolated, locked off and under single operator control. • Strip the ends of the AC Input cables to be connected to the Input terminal block.
4.1.2 Single Phase, AB Feed The MX06 40A Shelf can be used on a Single Phase AB Feed system. This means that 2 separate supply’s can be used, each powering 2 of the 4 rectifiers fitted. The system can be connected to a 230V or 115V supply. The maximum input current per feed is 7.5A at 230V and 13A at 115V. Choose AC Input cabling rated accordingly and colour coded as required for country/state concerned. 4.1.2.
4.1.2.2 Front Access Connection To connect the input supply to the MX06 40A Shelf proceed as follows: • Ensure that the AC supply intended for connection is isolated, locked off and under single operator control. • The main circuit board should have been configured for an AB Feed by removing LK3 and LK4. This is normally factory configured. • Strip the ends of the AC Input cables to be connected to the input terminal block.
4.1.3 3 Phase Star Supply The MX06 40A Shelf can be used on any of the following supplies: 415V, 400V, 380V or 208V phase to phase. The maximum input current is 13A per phase on a 208Vac phase to phase supply and 7.2A per phase on a 380Vac, 400Vac or 415Vac supply. Choose AC Input cabling rated accordingly and colour coded as required for country/state concerned. 4.1.3.
4.1.3.2 Front access connection To connect the input supply to the MX06 40A Shelf proceed as follows: • The AC input current to the system should also be limited by an appropriate device in the event of a short circuit as defined in EN60950 to protect the internal wiring of the end use equipment. The device(s) should be rated accordingly. • Ensure that the AC supply intended for connection is isolated, locked off and under single operator control.
4.1.4 3 Phase Delta Supply Warning! The MX06 40A Shelf can only be used on a 208Vac phase to phase supply. In a delta connection system each rectifier input is connected directly across two phases. Due to the maximum voltage rating of the rectifiers being 264Vac this is the maximum phase-to-phase voltage that can be applied. The maximum input current on a 208Vac supply is 9.5A per phase. Choose AC Input cabling rated accordingly.
4.1.4.2 Front access connection To connect the input supply to the MX06 40A Shelf proceed as follows: • The AC input current to the system should also be limited by an appropriate device in the event of a short circuit as defined in EN60950 to protect the internal wiring of the end use equipment. The device(s) should be rated accordingly. • Ensure that the AC supply intended for connection is isolated, locked off and under single operator control.
4.2 DC Distribution The MX06 40A Shelf has a DC distribution module fitted. This module contains the chosen distribution components of either circuit breakers or fuses. It also contains an LVD contact (controlled by the controller) and a current shunt measuring load current. The modules can be configured for either positive or negative earthed output. The output can also be left floating to facilitate external grounding. A tripped output will give an alarm displayed as a front panel LED.
4.2.2 10 GMT Fuses Front Access No. of Outputs : Output Rating : Fuses : Trip Alarm : 10 10A max per output (42A total) GMT-** (Bussmann) YES To connect the cables to the system proceed as follows: • Cables should be rated to at least the same current rating as the corresponding output fuse and be colour coded as to meet all the local installation regulations • Remove the distribution front panel to give easier access to terminal block if required.
4.2.3 4 Circuit Breakers Rear Access No. of Outputs : Output Rating : CONTROLLER DISTRIBUTION Circuit Breakers : 1 2 3 4 Trip Alarm : 4 4 O/P’s up to 20A max 2 O/P’s up to 40A max 1 O/P up to 50A max Series DC Current trip, Medium time delay. YES • Remove the rear cover to give access to the output terminals (shown below).
4.2.4 4 Circuit Breakers Front Access No. of Outputs : Output Rating : Circuit Breakers : Trip Alarm : 4 4 O/P’s up to 20A max 2 O/P’s up to 40A max 1 O/P up to 50A max Series DC Current trip Medium time delay YES To connect the cables to the system proceed as follows: • To connect to the output terminals use M4 ring crimps with cables rated to at least the same current rating as the corresponding output breaker and colour coded as to meet all the local installation regulations.
4.2.5 4 Cartridge Fuses Rear Access No. of Outputs : Output Rating : Fuses : Trip Alarm : 4 4 O/P’s up to 20A max 2 O/P’s up to 25A max 1 O/P up to 25A max Bussmann NITD range YES To connect the cables to the system follow the same procedure as for the “4 Circuit Breaker Rear Access” distribution module (section 4.2.3). 4.2.6 4 Cartridge Fuses Front Access The ratings are the same as for the rear access version above.
4.3 Routing Of Cables 4.3.1 Input cables One or more of the top 3 knockouts (top left hand side knockout and 2 actually in the rear cover) must be used for entry of the input AC cable. This is essential if the input cabling used is not double insulated and recommended as this optimises the EMC performance by ensuring the AC Input cables are as far away from the output wiring as possible.
Supplied cable clips for routing of input cables 4.3.2 Output Cables The output cables may be of quite large diameter and therefore it may be necessary to use more than one knockout hole. The right hand side knockouts should be used to keep the output cables physically as far from the input cables as possible to optimise EMC performance.
4.4 External Battery Installation 4.4.1 Battery Back-up function Battery backup may be achieved by connecting 48V strings of batteries onto the external battery terminals of the distribution module at the rear of the system. This battery string will be connected to the system bus voltage via an internal LVD contact. If for any reason the rectifier outputs are not present, either by component failure or by the loss of AC power then the battery string can supply the load for a limited time. 4.4.
4.4.4 Battery Connection Diagram Earth connection for grounding output Battery Positive Earth Stud Battery Negative 4.5 System Output Earthing The MX06 40A Shelf has its output earthed as default. The output is earthed by the earth cable joining the earth stud to the output earthing bus-bar (as shown in the above picture). The earth link can be removed to leave the output floating but the user must then earth the output at some other point in the system.
5 Commissioning the System 5.1 General All site preparation and equipment installation in the previous chapters must be completed before commissioning. • Ensure that the AC power source isolator is switched OFF. • Switch all MX06 40A Shelf and any external battery circuit breakers to the OFF position. 5.2 Powering up the MX06 40A Shelf • Set the required alarms to show a “Major” or “Minor” alarm. To do this remove the alarm card from the shelf and operate switches SW2 and SW5 (see section 2.3.
6 Manual Handling Procedure 6.1 General 6.1.1 Items within the sub-system present a hazard due to mass. A fully configured system fitted with 4 rectifiers weighs almost 15Kg. 6.1.2 The Manual Handling of Loads Regulations, 1993 require that all persons working on the equipment are familiar with the Regulations, that they take care to minimise risk of injury to themselves and others, that they are properly trained, and that the correct equipment is used. Safety shoes are to be worn. 6.1.
7 Fault Finding / Symptoms The sub-system is designed for maximum reliability and therefore faults during normal operation are unlikely. If faulty operation does occur the source of the failure can usually be readily determined by inspection of the LED meter and the LED’s. 7.1 Warnings POTENTIALLY LETHAL VOLTAGES AND SOURCES OF HIGH ENERGY ARE PRESENT WITHIN THE POWER SYSTEM. EXTREME CAUTION MUST BE OBSERVED AT ALL TIMES.
8 Service, Accessories & Spares 8.1 Rectifier replacement If a faulty rectifier is to be replaced simply unscrew the two front panel fixings on the rectifier front panel and withdraw the rectifier from the shelf. A replacement rectifier can then be inserted directly into the shelf and will start-up automatically. Note – The rectifiers are “hot plugable” and therefore can be replaced without turning the system off. 8.
