MX06 50 MX06 100 -48 VDC POWER SYSTEMS User’s Manual (Document # 990-9131B)
Table of Contents 1 Safety First! 1 1.1. WARNING SYMBOLS .........................................................................................................1 1.2. GENERAL PRECAUTIONS: ..................................................................................................1 2 Introduction 2 2.1. GENERAL INFORMATION ....................................................................................................2 2.2. HOW TO USE THIS MANUAL .................................................
User Outputs.........................................................................................................................18 User Inputs ...........................................................................................................................19 4.3. LOAD MANAGEMENT .......................................................................................................19 4.4. BATTERY MANAGEMENT .......................................................................................
Revision History Revision Preliminary PML-0216A PML-0216B PML-0216C PML-0216D 990-9131 Rev01 990-9131A Rev02 990-9193A Rev03 990-9131B Rev04 Date 15 FEB, 2000 07 APR, 2000 05 MAY, 2000 26 JUN, 2000 27 OCT, 2000 19 JAN, 2001 21 NOV, 2001 15 FEB, 2002 30 JUN, 2003 By SCG SCG SCG DRD DRD DRD DRD / JF JF BT Table of Figures FIGURE 2.1-1 MX06 50 DC POWER PLANT ............................................................................................2 FIGURE 2.1-2 MX06 100 BLOCK DIAGRAM......................
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, 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. 1.2. General Precautions: WARNING: Hazardous AC voltage levels are present inside the power system.
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 MX06 50 has 1 shelf, holding five rectifiers for a maximum of 52.5 Amps. The MX06 100 has 2 shelves, holding ten rectifiers for a maximum of 105 Amps. The controller provides monitoring and control functions for each component of the system.
J4 TEMPERATURE PROBE +BAT YELLOW BROWN BLACK ORANGE RED BLUE 1 TMP 2 -BAT 3 +12 PWR 4 CONTROL BUS Visual Alarm DC AC DC AC DC AC DC AC DC AC Control MAJ NC MAJ COM MAJ NO MIN NC MIN COM MIN NO VLV NC VLV COM VLV NO (black) BATTERY (+) Control 1 2 3 4 5 6 BATTERY (–) (orange) -BAT -BAT Control J5 MOTORIZED BREAKER CONTROLS UFA3 UFA4 -BAT -BAT Main Power Distribution Backplane -BAT Control J2 ALARM RELAY OUTPUTS 1 2 3 4 5 6 7 8 9 UFA1 UFA2 Control J3 USER ALARM INPUTS 1 2 3 4 5 6 7
2.2. How to Use This Manual Each section of this manual can be read in any order and provides 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! Safety symbol description and general precautions. Introduction Brief system preview and explanation of manual usage. Installation How to unpack, install and commission the equipment for initial use.
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 Section 7 in the event it is necessary to return equipment to APC.
Ventilation The rectifier modules for this system have fans that provide front-to-rear airflow for internal cooling. The power system housing should be mounted such that there is free airflow to the front and back of the unit. [Refer to Section 6.5 for environmental characteristics.] Free airflow should be ensured so that the power system can provide full power at a given ambient temperature without de-rating. 3.3.
3.4. Battery Connections WARNING: Hazardous energy levels are present on bare conductors in 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: • Remove any jewelry, rings or watches while working on this equipment. • Use insulated wrenches, screwdrivers, cutters, pliers and other tools.
Negative Battery Connection (Orange) Positive Battery Connection (Black) Figure 3.4-1 Battery Cable Connection Locations Battery LVD Connection The MX06 provides control for a motorized circuit breaker on the –48 V battery string. This motorized circuit breaker is mounted on the back of the MX06. Figure 10 shows the power, control, and monitoring connections. The motorized breaker connects in the negative battery cable. Figure 3.
MX06 Yellow Battery LVD Orange Breaker Side CM NO NC Battery (-) Yellow Brown Motor Side Black Orange 1 2 3 4 5 6 J5 1 2 3 4 5 6 Batt Alm Brown Black Orange +BAT Blue Red Blue Black Battery (+) System Ground Orange Split Bus Bar -48 Volts Return Orange Black Battery Tray 3 CM NO NC + Battery String 3 Battery 3 Disconnect Battery Tray 2 CM NO NC + Battery String 2 Battery 2 Disconnect Battery Tray 1 CM NO NC + Battery String 1 Battery 1 Disconnect Figure 3.
Battery Temperature Probe Installation The 15 Ft (4.5m) temperature probe is used to monitor the battery string temperature. To get the most representative temperature measurement, the probe should be placed in contact with a battery cell that is centrally located. The probe should be placed directly in contact with the cell (not the frame surrounding the cell). Generally, the cell cover can be used; be careful not to allow the probe body to touch the terminals.
3.6. Load Protection Installation Circuit Breaker Installation Standard circuit breaker output boards are available with two 30 Amp breakers or one 60 Amp breaker. Output boards are installed at the factory and are not field replaceable units. Contact APC if the output configuration is not suitable for your needs. Other breaker sizes are not available. GMT Fuse Installation Fuse holders that accommodate GMT fuses are located on the front panel on the left side of the unit.
3.7. Load Connections Cable Size Considerations The DC load cable(s) should be sized to limit the voltage drop from the DC power plant to the loads per system design requirements. The cable(s) must also carry the full load current during battery operation. During battery operation the voltage will be lower and for constant power loads, the current will typically be higher. If assistance is required to determine the necessary cables for the application, contact your sales representative or APC.
GMT Fuse protected Load Connections Connections for ¼ to 15 Amp DC loads require a ring terminal with a 0.170 in (4.3 mm) clearance hole and are located at the rear of the unit. Load Connections should be made as shown in Figure 3.7-2. -54 V J2 J3 J5 J4 F2 F3 F6 F1 F4 F5 F8 F9 F12 F7 F10 F11 54 V Rtn Figure 3.7-2 Connections to GMT Fuses 3.8. Input / Output Connections Relay Output Connections There are three output relays available that provide outputs via Form “C” relay contacts.
RELAY OUTPUT MAJOR MINOR VERY LOW V NC C NO NC C NO NC C NO J2 CONNECTOR DESIGNATIONS 1 2 3 4 5 6 7 8 9 OUTPUT RELAY NOTES Figure 3.8-1 Output Relay Connections External Alarm Input Connections Four user-defined alarm inputs are provided on connector J3. Each alarm input can be individually programmed for alarm priority (MAJOR or MINOR) and input contact configuration (Normally Open or Normally Closed).
3.9. Rectifier Module Installation WARNING: Rectifier DC output circuits will be damaged if battery is installed incorrectly. Before rectifier installation, ensure proper battery polarity and that the battery is isolated from the rest of the system The rectifier modules are generally shipped in separate containers. Follow the procedure below to install a rectifier module. Rectifiers may be installed even when the system is energized.
5) Use a Digital voltmeter to measure the system voltage using the “RTN” (+) and ”-NEG V” (-) test points on the front panel. The voltage is set at the factory for –54.0 V dc. Use the “V ADJ” potentiometer to set the voltage to the desired level. 3.11.Battery and Load Power up After the initial checkout has been performed, the following steps are followed to complete the system power up procedure. 1) Turn on the external circuit breaker from the battery to the power plant.
4 Technical Description The various MX06 models are modular stand-alone –48 V dc power plants. Each can be configured to support most typical applications within their specified current capacity without special application engineering or assistance. Output distribution is provided through the use of up to 12 plug-in GMT-type fuses per shelf or up to two circuit breakers per shelf.
4.2. System Management A single plug-in circuit card provides the control, display and user interface functions for the MX06. Features include the following: Control Functions a) The Control Module is “hot-pluggable”. b) The plant voltage can be adjusted through the use of a front panel accessible potentiometer. The power plant will operate without the Control Module at a factory preset voltage of approximately 54.5 VDC.
User Inputs t) Temperature Probe: Provides input for battery voltage temperature compensation. This feature operates only when the probe is attached. u) User Alarm Inputs: Four inputs are provided for user alarm inputs. The inputs are designed for isolated contacts tied from the alarm input to a corresponding “-BAT” pin on the same connector. The input can be defined as “Normally Open” or “Normally Closed” through dipswitch settings on Control Board (Factory default: Normally open). 4.3.
Battery Low Voltage Disconnect In order to prevent damage to the battery due to deep discharge, the DC power system has hardware support for a battery Low Voltage Disconnect (LVD). A battery LVD has the loads attached to the rectifiers and the battery is disconnected from the system. The MX06 provides control for a motorized circuit breaker on the –48 V battery string. This motorized circuit breaker is mounted on the back of the MX06. Figure 10 shows the power, control, and monitoring connections.
5 Operation 5.1. Description The MX06 is designed for years of operation with no user input. The power system is pre-set at the factory with all parameters needed for normal operation. The front panel LEDs and the alarm output relays, indicate the general health of the unit. Voltage adjustments or changes to switch settings on the system Controller Board are only required under the follow conditions: Rectifiers are added or removed from the original configuration shipped from the factory.
MX06 External Alarm Input Configuration The MX06-50 and the MX06-100 alarm input circuitry is the same for both controllers. Refer to board layouts in the preceding sections to identify switch 1. The four User Input Alarms can be programmed for either a MAJOR or MINOR alarm upon activation and can be configured for either a Normally Open (NO) or a Normally Closed (NC) input contact from the alarm source. Set dipswitch S1 to program the User Input Alarms. Refer to Figure 5.2-1 for details.
MX06-50 Rectifier Configuration The system Controller Board must know if a rectifier is present for each of the five slots. This is done by the properly setting the dipswitch S2 (“RECT PRESENT”) on the Controller Board. If a rectifier is not present in a given slot, the corresponding switch position must be set to the “ON” condition. The ON direction is labeled on the body of the dipswitch. Figure 5.3-1 locates switch S2 on the PC board. Figure 14 shows one style of dipswitch that may be on the board.
MX06-50 Temperature Probe Selection Temperature compensation can be configured for either a Fahrenheit or Celsius probe by the use of configuration jumpers on pin header J4 shown in Figure 5.3-1. The MX06-50 is factory set for Fahrenheit operation, with jumpers on all position of J4. 5.4. MX06-100 Configuration Settings The control card for the MX06-50 is different than the control card for the MX06-100 due to increased number of rectifiers in the MX06-100.
MX06-100 Programmable Alarms The GMT alarm, and the battery circuit breaker alarm can each be programmed to either MAJOR or MINOR alarm priority. A three-pin jumper header is used for each alarm in the manner shown in Figure 13. Figure 12 locates the jumpers on the PC board. If no jumper is in place, then no alarm will be reported. Do not touch any jumpers, other than J6 and J9, as they are factory set for the configuration that you order. 1 2 3 1 MAJOR 2 3 MINOR Figure 5.
6 Specifications The overall system specifications can vary, depending upon the number of rectifier modules. Note that some specification items are provided on a “per rectifier” basis and must be combined or totaled for a given system configuration. 6.1. AC Input TWF0500H5401 Rectifier Nominal Input Voltage 90, 115, 208, 230 VAC Input Voltage Range 85 – 264 VAC AC Frequency Range 47 – 63 Hz Apparent Power Factor 99% Typical, 98% Minimum Input Current (per Rectifier) 5.5 Amps @ 115Volts AC 3.
MX06 100 Power System Nominal Input Voltage 90, 115, 208, 230 VAC Input Voltage Range 85 – 264 VAC AC Frequency Range 47 – 63 Hz Apparent Power Factor 99% Typical, 98% Minimum Input Current 55 Amps @ 115 Volts AC 37 Amps @ 230 Volts AC 6.2. DC Output TWF0500H5401 Rectifier Output Voltage (factory set) 54.5 VDC Operating Voltage Range 44 – 58 VDC Efficiency 85% Typical Over Voltage Protection 59.5VoltsDC Output Current per Rectifier 9.0 Amps Minimum Continuous at 115 VAC Input 10.
MX06 50 Power System Output Voltage (factory programmed) 54.0 VDC Operating Voltage Range 47 – 57 VDC Rated Output Current 52.5 A Efficiency 85% Typical Over Voltage Protection 59.5 Volts DC Output Current 45 Amps Minimum Continuous at 115 VAC Input 52.5 Amps Minimum Continuous at 230 VAC Input. Current Limit 46.5 Amps Maximum at 115 VAC Input 55.0 Amps Maximum at 230 VAC Input. Power Output @ 54.
6.3. Controls and Indicators TWF0500H5401 Rectifier FAIL LED DC output voltage below (-) 39.5 Volts DC or above (-) 59.5 Volts DC. MX06 Controller Voltage Good LED (Green) On when voltage is between 50 and 57 Volts. Major (Red) On when Major Relay is energized Minor (Yellow) On when Minor Relay is energized Low V LED 1 (Yellow) On when voltage is below 50 Volts DC. Very Low V LED (Red) On when voltage is below 44 Volts DC. 6.4. Mechanical TWF0500H5401 Rectifier Dimensions 5 in (12.
Magnum VS 50 Power System Dimensions 5-1/4 in (13.3 cm) high x 17-1/4 in (43.8 cm) wide x 12.5 in (32 cm) deep Weight 12 lbs. (5.5 Kg) Color Grey Front, Yellow zinc sides and back Mounting 19” Rack Mounting (23” Optional) Magnum VS 100 Power System Dimensions 10-1/2 in (26.6 cm) high x 17-1/4 in (43.8 cm) wide x 12.5 in (32 cm) deep Weight 24 lbs. (11 Kg) Color Grey Front, Yellow zinc sides and back Mounting 19” Rack Mounting (23” Optional) 6.5.
6.6.
7 APC Worldwide Customer Support Customer Support for this or any other APC product is available at no charge. You can contact APC Customer Support in any of the following ways: • Use an APC web page to find answers to frequently asked questions (FAQs), to access documents in the APC Knowledge Base, and to submit customer support requests. o http://www.apc.com Connect by links to APC web pages for specific countries and regions, each of which provides customer support information. o http://www.apc.
8 Limited Product Warranty The limited warranty provided by American Power Conversion Corporation ("APC") in this Statement of Limited Factory Warranty applies only to Products Buyer purchases for your commercial or industrial use in the ordinary course of Buyer's business. APC PRODUCTS COVERED ("Product or Products"): MX06 50 MX06 100 Terms of Warranty: APC warrants that the Product shall be free from defects in materials and workmanship, for a period of two (2) years from the date of shipment.
