DC POWER PLANT PRODUCT MANUAL MODEL MX28B1200/2400+27V APC DC Network Solutions Inc.
MX28B-1200+27V PRODUCT MANUAL Rev 1 Product Structure Component Description Part Number MX28B1200/2400+27V Main Bay 1200 amp frame, 2400 amp carry through, controller. No rectifiers, converters, no distribution 0M-91147 MX28B1200/2400+27V Main Bay 1200 Amp expansion frame, No rectifiers, distribution.
Rev 1 MX28B-1200+27V PRODUCT MANUAL REVISION HISTORY Revision Date By 1 09/12/2001 JNF Description Initial release.
MX28B-1200+27V PRODUCT MANUAL Rev 1 TABLE OF CONTENTS 1 GENERAL INFORMATION ...........................................................................................................1 1.1 1.2 1.3 INTRODUCTION ................................................................................................................................................................. 1 PRECAUTIONS...........................................................................................................................
Rev 1 5.8 MX28B-1200+27V PRODUCT MANUAL CONNECTING THE LOADS ............................................................................................................................................. 20 5.8.1 DC Circuit Breakers...........................................................................................................................................20 5.8.2 Installation of Circuit Breakers...................................................................................................
Rev 1 MX28B-1200+27V PRODUCT MANUAL 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.
MX28B-1200+27V PRODUCT MANUAL 1.3.3 Rev 1 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.
Rev 1 MX28B-1200+27V PRODUCT MANUAL 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.
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.
Rev 1 MX28B-1200+27V PRODUCT MANUAL 4 PRODUCT OVERVIEW AND TECHNICAL 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 specified 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.
MX28B-1200+27V PRODUCT MANUAL USER INFRASTRUCTURE Rev 1 +24V RECTIFIERS -48V LOADS UTILITY AC -48V DC/DC CONVERTERS -48V BUS +24V BUS +24V LOADS BATTERY PLANT BATTERY DISCONNECT LVD (OPTIONAL) MASTER CONTROLLER WEB/SNMP INTERFACE USER INPUT/OUTPUT RETURN BUS BATTERY SHUNT MX28B-1200 +27 Figure 4-2 MX28B1200/2400+27V System Diagram 6 MAIN GND BUS
Rev 1 MX28B-1200+27V PRODUCT MANUAL 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.
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.
Rev 1 MX28B-1200+27V PRODUCT MANUAL 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.
MX28B-1200+27V PRODUCT MANUAL +24V load supply Rev 1 Load Return Bus. Thirty-eight +24V Breakers Seven -48V Breakers For DC to DC converters Figure 4.5 DC Distribution. 4.9 –48 V DC Distribution from Converters (Optional) Up to eight 24V/-48V dc converters can be used to supply power for –48V loads in increments of 10 Amps each. These converters are mounted at to bottom of the unit. Each converter is powered via a circuit breaker located directly below. See figure 4.6 Figure 4.6 DC-to-DC Converters.
Rev 1 MX28B-1200+27V PRODUCT MANUAL 4.10 Environmental • Ambient Temperature: -4°F to 149°F (-20°C to +65°C) operating -40°F to 185°F (-40°C to +85°C) storage • Humidity: 0% to 85% RH non-condensing operating 0% to 95% RH non-condensing storage • Altitude: Up to10,000 feet (3000m) operating Up to 33,000 feet (10,000m) storage 4.11 Mechanical • Weight: Power Frame – 550 to 600 lbs. (250 to 272 kg) Rectifier - 11 lbs. (5 kg.) Converters – 7.2 lbs. (3.3 kg.) • Dimensions Frame: 84” high x 24.
MX28B-1200+27V PRODUCT MANUAL Rev 1 5 INSTALLATION PROCEDURES 5.1 Preparation 5.1.1 5.1.2 Recommended Tools • Standard selection of insulated hand tools. • Proper tools for crimping the selected cable lugs. Recommended Test Equipment • 5.1.3 Digital Multimeter Equipment Inspection Remove equipment from packing material and inspect for shipping damage to verify the safety and operational suitability for the installation site. [Refer to Section 1.3] 5.1.
Rev 1 5.1.5 MX28B-1200+27V PRODUCT MANUAL Room/Locations NOTE: The APC Model MX28B1200/2400+27V DC power plant is to be installed in a room, vault, or similar enclosure that is accessible only to qualified persons in accordance with the NEC or the authority having jurisdiction. Prior to installation, drawings, floor loading requirements, external alarm points, AC service entrance, and grounding schemes should all be checked and confirmed.
MX28B-1200+27V PRODUCT MANUAL 5.1.7 Rev 1 Ventilation The rectifiers have fans that provide front to rear airflow for internal cooling. The MX28B1200 housing should mounted to allow free airflow from the front and out the top of the unit. [Refer to Section 4.10 for environmental characteristics.] 5.2 AC Service and Ground Connections ***** 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.
Rev 1 MX28B-1200+27V PRODUCT MANUAL The AC input enclosure, located at the top rear of the MX28B housing, is provided with three pilot holes in the top for attaching external conduit (Figure 5-4), and three 1-inch conduits exiting the bottom for AC wire. AC wiring passing through the conduit will be routed through the access opening in the AC input enclosure into the wiring area where a safety ground bar and rectifier input terminal blocks are located.
MX28B-1200+27V PRODUCT MANUAL Rev 1 5.3.2 Cable Sizing Considerations The battery cable(s) should be sized sufficiently large to limit the voltage drop from the MX28B DC power plant to the battery during charging per system design requirements. The cable (s) must also carry the full load current during battery operation. If assistance is required to determine the necessary cables for the application, contact your sales representative or APC. 5.3.
Rev 1 MX28B-1200+27V PRODUCT MANUAL 5.5 Rectifier Installation The rectifiers are shipped in separate containers. Follow the procedure below to install a rectifier. 1) Remove the rectifier from its shipping box. 2) Slide the rectifier into the shelf between the guides until fully seated. 3) Fasten the rectifier in place with the rectifier retaining screw included in the shipment. Since all adjustments are made from the system control unit, no rectifier adjustments are necessary.
MX28B-1200+27V PRODUCT MANUAL Rev 1 5.7 Alarm Connections The alarm connections for all rectifiers, breakers, and fuses are factory pre-wired. The MX28B DC power plant, however, permits the user to program the system alarms in various ways. A Printed Circuit (PC) board designated “0P9133” is mounted in the space above the master control unit and provides terminal block connection points for alarm outputs and alarm inputs (Figure 5-7).
Rev 1 5.7.1 MX28B-1200+27V PRODUCT MANUAL External Alarm Inputs Four external alarm inputs with assignable priority levels are availa ble. These alarm inputs respond to external dry contact closures between normally open (NO) and common (C) or contact openings between normally closed (NC) and C (see Table 5-1). External Alarm Source (non-alarm state) Connect To Input Alarm Terminals OPEN CLOSED NO-C NC-C Table 5-1.
MX28B-1200+27V PRODUCT MANUAL ALARM OUTPUT Rev 1 TERMINAL DESIGNATION NO-NC-C USER ALARM NOTES J1 RELAY #1 RELAY #2 RELAY #3 RELAY #4 NO1-NC1-C1 NO2-NC2-C2 NO3-NC3-C3 NO4-NC4-C4 ________________________ ________________________ ________________________ ________________________ J2 RELAY #5 RELAY #6 MINOR MAJOR NO5-NC5-C5 NO6-NC6-C6 NO7-NC7-C7 NO8-NC8-C8 ________________________ ________________________ ________________________ ________________________ Table 5-3. Alarm Output Connections 5.
Rev 1 5.8.2 MX28B-1200+27V PRODUCT MANUAL Installation of Circuit Breakers 1) Remove the metal circuit breaker cover panels. 2) Use diagonal cutters to cut the metal web of the breaker panel “knock-outs” at the desired breaker locations. 3) Install the circuit breaker(s) by snapping the top terminal onto the upper bus bar and rotating the unit down until the second terminal snaps onto the breaker termination post as shown in Figure 5-8.
MX28B-1200+27V PRODUCT MANUAL Rev 1 5.9 Battery Temperature Probe Installation The optional 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.
Rev 1 MX28B-1200+27V PRODUCT MANUAL 5.10.1 Apply AC Power Turn on the circuit breakers that supply AC power to the rectifier shelves in the MX28B DC power plant. Turn on the individual 20 Amp circuit breakers for each rectifier on the shelf. The main screen should appear on the control unit display (see Figure 5-10). The display on the control unit is a 2-line by 16-characters display. The cursor cycles below the characters of the active selection on the display.
MX28B-1200+27V PRODUCT MANUAL Rev 1 5.10.3 Full System Power Up To complete a full system power up, perform the following steps 1) Turn OFF all the circuit breakers that supply AC power to the rectifiers in the MX28B DC power plant. 2) Turn on the external circuit breaker from the battery to the power plant. 3) Turn on all the circuit breakers that supply AC power to the rectifiers in the MX28B DC power plant. 4) Load circuit breakers may now be turned on and inserted as required.
Rev 1 MX28B-1200+27V PRODUCT MANUAL 6 SETUP, ADJUSTMENTS, AND OPERATION 6.1 User Interface The MX28B control unit provides a user interface designed with a hierarchical menu that can be viewed on the 32-character display by “navigating” with the “ï” (left), “ð” (right), “ñ” (up), and “ò” (down) arrow keys located on the front panel. The selected item on the display is identified by the cursor cycling beneath its characters.
MX28B-1200+27V PRODUCT MANUAL Rev 1 The default passwords for level 1 and level 2 are “1111” and “2222”, respectively. There are no alternate passwords or “backdoors” for accessing the system. A forgotten password may require a new master controller board, at customer expense. System control parameters are stored in non-volatile memory and will not be erased when power is removed for the master control unit.
Rev 1 MX28B-1200+27V PRODUCT MANUAL 6.5 Parameter Locations, Descriptions, and Default Values The location, description, and factory programmed default value for each of the MX28B system parameters is found in Table 6-1. The table also shows all of the status and information screens with typical displays. The location of a parameter screen is shown in brackets, for example: [SYSTEM/IN-RLY/RLY-MAP].
MX28B-1200+27V PRODUCT MANUAL Figure 6-2.
Rev 1 MX28B-1200+27V PRODUCT MANUAL (Figure 6-2.
MX28B-1200+27V PRODUCT MANUAL ALIAS In-Rly In-Rly In-Rly In-Rly 1 2 3 4 DIAG Store Cfg Lamp Test Test Relay En Test Relay 1 Test Relay 2 Test Relay 3 Test Relay 4 Test Relay 5 Test Relay 6 Test Min Rly Test Maj Rly MODULES RECT SET-ALM Rect Rect Rect Rect PARAM Rect Rect INFO Rect Rect Rect Rect Rect CL Alm Stdby Alm FF Alm RFA Alm Fail Safe Fail Comm # # # # # Curr CL Stdby FF RFA Conv SET-ALM Conv Conv Conv Conv PARAM Conv Conv INFO Conv Conv Conv Conv Conv 30 CL Alm Stdby Alm FF Alm CFA Alm Fail
Rev 1 MX28B-1200+27V PRODUCT MANUAL (Figure 6-2.
MX28B-1200+27V PRODUCT MANUAL ALIAS FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 LVD SET-ALM LVD1 LVD1 LVD2 LVD2 PARAM LVD1 LVD1 LVD2 LVD2 Option Open Alm Option Open Alm Trip Reset Trip Reset BATT SET-ALM Batt Batt Batt Batt Batt Batt Batt Batt Batt Batt PARAM Batt Batt COMP Comp Comp Comp Comp Disc Thr Disc Alm HV Thr HV Alm LV Thr LV Alm HT Thr HT Alm LT Thr LT Alm Float Max Rech Method TC HKnee Lknee (Figure 6-2.
Rev 1 MX28B-1200+27V PRODUCT MANUAL PIN PIN OEM OEM OEM OEM OEM OEM OEM R R C C S S Offset Gain Offset Gain Offset Gain 33
MX28B-1200+27V PRODUCT MANUAL Rev 1 Table 6-1. Parameter Locations, Descriptions, and Default Values PARAMETER DESCRIPTION DISPLAY SCREENS / DEFAULT SETTINGS SYSTEM SETUP Password Entry PIN Entry [PIN] Screen for entry of the active password (PIN). PIN m+ 0000 Password Setup Level 1 PIN {2} [SYSTEM/SETUP] Password (PIN) that permits security Level 1 parameter changes - limited access.
Rev 1 MX28B-1200+27V PRODUCT MANUAL PARAMETER Display Type [SYSTEM/SETUP] DESCRIPTION DISPLAY SCREENS / DEFAULT SETTINGS Type number for the control unit display. Display Type + 000255 Date {1} [SYSTEM/DATE] Internal system calendar date. Date m+ DEC 16 1999 Time {1} [SYSTEM/DATE] Internal system clock time (24-hour format). Time Date/Time Setup m+ 9:00:25 Alarm Threshold Setup High Voltage Threshold {1} [SYSTEM/SET-ALM] System High voltage alarm threshold. Sys HV Thr m+ 28.
MX28B-1200+27V PRODUCT MANUAL Rev 1 Converter Low Voltage {1} [SYSTEM/SET-ALM] Converter voltage is below the low-voltage threshold. Conv LV Alm m+ Minor System High Temperature {1} [SYSTEM/SET-ALM] The control unit temperature is above the high temperature threshold. Sys HT Alm m+ Minor System Low Temperature {1} [SYSTEM/SET-ALM] The control unit temperature is below the low temperature threshold.
Rev 1 MX28B-1200+27V PRODUCT MANUAL Test Relay Enable {1} [SYSTEM/DIAG] This parameter must be set to “Enable” to permit the eight output relays to be manually tested; otherwise, the state of the relays will be per system conditions. Test Relay En m+ Disable Test Relay 1 {1} [SYSTEM/DIAG] Setting this parameter to “ON” energizes Relay 1 and turns on the “ALM1” LED on the control unit front panel.
MX28B-1200+27V PRODUCT MANUAL Rev 1 (Table 6-1. Parameter Locations, Descriptions, and Default Values) PARAMETER DESCRIPTION DISPLAY SCREENS / DEFAULT SETTINGS Battery Alarms Discharge Alarm {1} [BATT/SET-ALM] An alarm that is ge nerated if the battery discharge current exceeds the programmed battery discharge threshold. Batt Disc Alm m+ Minor High Voltage Alarm {1} [BATT/SET-ALM] An alarm that is generated if the magnitude of the battery voltage rises above the high voltage threshold.
Rev 1 MX28B-1200+27V PRODUCT MANUAL (Table 6-1. Parameter Locations, Descriptions, and Default Values) PARAMETER DESCRIPTION DISPLAY SCREENS / DEFAULT SETTINGS Standby Alarm {1} [MODULES/RECT/SET-ALM] This alarm indicates that the control unit is holding a rectifier in the standby mode. Rect Stdby Almm+ n of N Fan Fail Alarm {1} [MODULES/RECT/SET-ALM] This alarm indicates that a rectifier fan has failed.
MX28B-1200+27V PRODUCT MANUAL • Breaker 72 Alias {1} [MODULES/CIRBKR/ALIAS] Rev 1 • • An alternate name (alias) that can be assigned to a circuit breaker if desired. Cir Bkr 72 +24V An alarm that indicates Circuit Breaker 1 is tripped. Cir Bkr 1 Alm m+ Major m+ Circuit Breaker Alarms Breaker 1 Tripped {1} [MODULES/CIRBKR/SET-ALM] • • • Breaker 72 Tripped {1} [MODULES/CIRBKR/SET-ALM] • • • • • • An alarm that indicates Circuit Breaker 24 is tripped.
Rev 1 MX28B-1200+27V PRODUCT MANUAL Input Relay 4 {1} [SYSTEM/IN-RLY/RLY-MAP] An alarm activated in response to an external contact closure or opening at the Input Relay 4 connection. In-Rly 4 Alm m+ Ignore An alternate name (alias) can be assigned to the relay if desired. Out-Rly 1 Relay 1 OUTPUT RELAY SETUP Output Relay 1 Alias {1} [SYSTEM/OUT-RLY/ALIAS] • • • • • • m+ • • • Output Relay 6 Alias {1} [SYSTEM/OUT-RLY/ALIAS] An alternate name (alias) can be assigned to the relay if desired.
MX28B-1200+27V PRODUCT MANUAL Rev 1 LVD Alarm 42 LVD1 Option {1} [MODULES/LVD/SET-ALM] Set to “Enable” if the unit has an LVD1. LVD1 LVD1 Alarm {1} [MODULES/LVD/SET-ALM] Sets the priority or “mapping” of an LVD1 Alarm. LVD1 Open Alm m+ Minor LVD2 Option {1} [MODULES/LVD/SET-ALM] Set to “Enable” if the unit has an LVD2. LVD2 LVD2 Alarm {1} [MODULES/LVD/SET-ALM] Sets the priority or “mapping” of an LVD2 Alarm.
