MX28B400 +24 Vdc Power System With Network Management User’s Manual
Table of Contents 1 SAFETY FIRST! .....................................................................................................................1 1.1. 1.2. 2 INTRODUCTION ....................................................................................................................2 2.1. 2.2. 3 WARNING SYMBOLS .........................................................................................................1 GENERAL PRECAUTIONS: .......................................................
Rectifier alarms reporting......................................................................................................20 4.3. SYSTEM MANAGEMENT ...................................................................................................21 System Output Capacity .......................................................................................................21 System Voltage Control ........................................................................................................
Revision History Revision 990-1809 Rev 1 Date 02 MAR, 2004 By BET Description Preliminary Release Table of Figures FIGURE 2.1-1 MX28B-400 +24 VDC POWER PLANT .............................................................................2 FIGURE 2.1-2 MX28B-400 +24 VDC SYSTEM WIRING DIAGRAM WITH BATTERY LVD .............3 FIGURE 3.4-1 BATTERY CABLE CONNECTION LOCATIONS............................................................7 FIGURE 3.4-2 BATTERY TEMPERATURE PROBE INSTALLATION .........................
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.
2 Introduction 2.1. General Information 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.
Figure 2.
2.2. 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! Safety symbol description and general precautions. Introduction Brief system preview and explanation of manual usage.
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 MX28B housing should mounted such that there is free airflow to the front, top, and bottom 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 without de-rating. 3.3.
3.4. Battery Connections WARNING: Hazardous energy levels are present on bare conductors in the +24Vdc 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: • Any jewelry, rings or watches be removed while working on this equipment. • Handles of all wrenches, screwdrivers, cutters and pliers should be insulated.
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.
3.5. DC SYSTEM GROUNDING The return bus for the power plant must be connected to the Central Office Ground. The left end of the return bus provides a pair of threaded 3/8-16 holes on 1-inch (25.4 m) centers for connection of a two-hole lugged cable to the Master Station Ground. Details for this connection should be provided in the site electrical grounding plans. Figure 3.
3.6. DC Power Output Over-Current Protection DC Circuit Breakers A standard 24-position plug-in circuit breaker tier provides +24 Vdc distribution. Various circuit breaker sizes from 1 to 100 amps are available, with 60-100 amp breakers requiring two positions and a circuit breaker adapter kit. The breaker tier is connected at its center to the +24 Vdc bus, and each side has a current capacity of 300A. It is therefore necessary to balance the load on the power plant to avoid overloading the output bus.
BREAKER RATING 1A PART NUMBER ADAPTOR SIZE FFA-0014 None 3A FFA-0015 None 5A FFA-0016 None 10 A FFA-0017 None 20 A FFA-0018 None 30 A FFA-0019 None 40 A FFA-0020 None 50 A FFA-0025 None 60 A FFA-0021-1 #10 studs on 5/8” centers 60 A FFA-0021-2 #10 studs on ¾” centers 60 A FFA-0021-3 ¼” studs on 1” centers 70 A FFA-0022-1 #10 studs on 5/8” centers 70 A FFA-0022-2 #10 studs on ¾” centers 70 A FFA-0022-3 ¼” studs on 1” centers 80 A FFA-0023-1 #10 studs on 5/8” cent
Plug-in Circuit Breaker Installation CAUTION During circuit breaker installation, carefully align the breaker alarm terminals with the alarm terminal board to avoid breaker terminal damage. 1) Remove the circuit breaker cover panel and the plastic cover(s) from the desired location(s). 2) 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 3.
Circuit Breaker Connections (1 to 50 Amps) Connections for 1 to 50 amp dc loads require standard two-hole lugs with holes for #10 screws on 5/8” centers and are located directly above the corresponding circuit breaker. The load returns connect to the return bus located just above and rearward of the breaker connection points as seen in Figure 3.
The load returns connect to the return bus located just above and rearward of the breaker connection points as seen in Figure 2.1-1. The return bus provides 24 sets of threaded #10-32 holes on 5/8” centers and four sets of threaded ¼-20 holes on ¾” centers for connection of twohole lugs on load return wires. Load Connections should be made as shown in fFigure 3.6-5. fFigure 3.6-5 Adaptor and lugs for 60-100 Amp breakers GMT Fuse Option The customer interface card shown in Figure 3.
RJ45 Ethernet Connector The optional management card has an RJ-45 connector to support a TCP/IP protocol over a 10BaseT Ethernet Local Area Network (LAN). Relay Output Connections There are eight alarms available that provide outputs via Form “C” relay contacts. The last two of these are preassigned as the Minor and Major relay outputs. The Major relay is energized (NO-O contacts closed) during normal (non-alarm) operating conditions; all the other relays energize when an alarm condition occurs.
RELAY OUTPUT RELAY #1 RELAY #2 RELAY #3 RELAY #4 RELAY #5 RELAY #6 MINOR MAJOR TERMINAL DESIGNATION NO-NC-C J1 NO1-NC1-C1 NO2-NC2-C2 NO3-NC3-C3 NO4-NC4-C4 J2 NO5-NC5-C5 NO6-NC6-C6 NO7-NC7-C7 NO8-NC8-C8 USER ALARM NOTES ________________________ ________________________ ________________________ ________________________ ________________________ ________________________ ________________________ ________________________ Figure 3.7-2 Output Relay Connections 3.8.
3.9. Rectifier Module Installation WARNING: Rectifier output circuits would be damaged if battery were 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 shipped in separate containers. Follow the procedure below to install a rectifier module. 1) Remove the rectifier from its shipping container.
4) Apply ac Power. Turn on the circuit breakers that supply ac power to the rectifiers in the MX28B power plant. The main screen should appear on the control unit display (see Figure 4.6-1). The display on the control unit is a 2-lines by 16-characters display. The cursor cycles below the characters of the active selection on the display. Information shown in the second line of Figure 4.
3.12.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 power plant. Turn on the external circuit breaker from the battery to the power plant. Turn on all the circuit breakers that supply ac power to the rectifiers in the MX28B power plant. Load circuit protection may now be enabled as required.
4 Operation 4.1. Technical Description The MX28B-400 Power System is designed to supply safe +24 Vdc primary power through the use of up to four rectifier modules. In conjunction with an external battery string, it will supply backup power as well. The Power System Control Unit (PSCU) will monitor all MX28B functions and provides battery management including controlled battery recharge with temperature compensation and low voltage disconnect.
4.3. System Management System Output Capacity The MX28B-400 supplies a maximum of 400 amps or 300 amps with N+1 redundancy. The housing for this configuration provides space for two rectifier shelves that can hold up to four rectifiers each, a control unit, and one tier of up to 24 distribution circuit breakers. System Voltage Control The PSCU monitors and adjusts the system voltage. It uses a voltage trim input to the rectifier to precisely control the dc output voltage.
4.4. DC Distribution Distribution is included for up to 24 plug-in circuit breakers. These circuit breakers can be 1 to 100 amps, with 60-100 amp breakers requiring two positions and a circuit breaker adapter kit. When a circuit breaker trips, a normally open switch closes and a CB alarm is reported by the PSCU. To disconnect a load attached to a circuit breaker, move the lever to the down “OFF” position.
Battery/Load Low Voltage Disconnect In order to prevent damage to the battery due to deep discharge, the power system has hardware and software support for a battery or load Low Voltage Disconnect (LVD). A battery LVD has the loads permanently attached to the rectifiers and the battery is disconnected from the system. A load LVD has the battery permanently attached to the rectifiers and the loads are disconnected from the system.
If the user plans to make any changes to system parameters, the first item that should be verified or entered is the appropriate password for the security level required for the parameters to be modified. Security level 2 (enter 2222 on the “PIN” screen) enables modification of all variable system parameters. Security level 1 (enter 1111 on the “PIN” screen) permits modification of some parameters. No security is required for viewing status items and parameter settings.
Parameter Locations, Descriptions, and Default Values PARAMETER NAME/ DESCRIPTION [MENU LOCATION] DISPLAY SCREENS / DEFAULT SETTINGS Address 1 Security Level {1} [SYSTEM/SETUP] Address 2 Security Level {1} [SYSTEM/SETUP] Address 3 Security Level {1} [SYSTEM/SETUP] Alarms Item 1 {Status Only} [ALARMS] • • • Alarms Item 16 [ALARMS] Power plant address or identification first line. Address 1 m+ APC DCNS, Inc. Power plant address or identification second line.
Parameter Locations, Descriptions, and Default Values PARAMETER NAME/ DESCRIPTION [MENU LOCATION] Battery Low Temperature Alarm Security Level {1} [BATT/SET-ALM] Battery Low Temperature Threshold Security Level {1} [BATT/SET-ALM] Battery Low Voltage Alarm Security Level {1} [BATT/SET-ALM] Battery Low Voltage Threshold Security Level {1} [BATT/SET-ALM] Battery Maximum Recharge Current Security Level {1} [BATT/PARAM] Battery Temperature {Status Only} [STATUS] Circuit Breaker 1 Alias Security Level {1} [MOD
Parameter Locations, Descriptions, and Default Values PARAMETER NAME/ DESCRIPTION [MENU LOCATION] Compensation Low Knee Security Level {1} [BATT/COMP] Compensation Method Security Level {1} [BATT/COMP] Compensation Temperature Coefficient Security Level {1} [BATT/COMP] Control Unit Revision {Status Only} [SYSTEM/SETUP] Conv HV Alm Conv HV Thr Conv LV Alm Conv LV Thr Date Security Level {1} [SYSTEM/DATE] Display Type {Status Only} [SYSTEM/SETUP] Fahrenheit Scale Security Level {1} [SYSTEM/SETUP] Firmwa
Parameter Locations, Descriptions, and Default Values PARAMETER NAME/ DESCRIPTION [MENU LOCATION] Fuse 1 Alias Security Level {1} [MODULES/GMT/ALIAS] Fuse 1-8 Alm Security Level {1} [MODULES/GMT/SET-ALM] Hardware Battery Current Alarm Security Level {2} [SYSTEM/SET-ALM] Hardware Battery Temperature Alarm Security Level {2} [SYSTEM/SET-ALM] Hardware LVD Alarm Security Level {2} [SYSTEM/SET-ALM] Hardware System Temperature Alarm Security Level {2} [SYSTEM/SET-ALM] Hardware System Voltage Alarm Security Leve
Parameter Locations, Descriptions, and Default Values PARAMETER NAME/ DESCRIPTION [MENU LOCATION] Lamp Test Security Level {1} [SYSTEM/DIAG] LVD 1 or 2 Option Security Level {1} [MODULES/LVD/SET-ALM] LVD 1 or 2 Reset Security Level {1} [MODULES/LVD/PARAM] LVD 1 or 2 Trip Security Level {1} [MODULES/LVD/PARAM] LVD Alarm Security Level {1} [MODULES/LVD/SET-ALM] Model Programming Security Level {2} [SYSTEM/SETUP] OEM R Gain Security Level {2} [OEM] OEM R Offset Security Level {2} [OEM] OEM S Gain Security Le
Parameter Locations, Descriptions, and Default Values PARAMETER NAME/ DESCRIPTION [MENU LOCATION] Output Relay 1 Alias Security Level {1} [SYSTEM/OUT-RLY/ALIAS] • • • Output Relay 6 Alias {1} [SYSTEM/OUT-RLY/ALIAS] An alternate name (alias) can be assigned to Output Relay 1 if desired. • • • An alternate name (alias) can be assigned to Output Relay 6 if desired.
Parameter Locations, Descriptions, and Default Values PARAMETER NAME/ DESCRIPTION DISPLAY SCREENS / DEFAULT SETTINGS The output relay that is energized or special rectifier alarm group n of N that occurs when a rectifier has been forced into the current limited mode. The status will be “ON” if the rectifier has been forced into its current limited mode. NOTE: This information can be viewed for each rectifier installed by using the horizontal arrow keys.
Parameter Locations, Descriptions, and Default Values PARAMETER NAME/ DESCRIPTION DISPLAY SCREENS / DEFAULT SETTINGS The output relay that is energized or special rectifier alarm group n of N that occurs when the control unit is holding a rectifier in the standby mode. The status will be “ON” if the control unit is holding the rectifier in the standby mode. NOTE: This information can be viewed for each rectifier installed by using the horizontal arrow keys.
Parameter Locations, Descriptions, and Default Values PARAMETER NAME/ DESCRIPTION [MENU LOCATION] System Temperature {Status Only} [STATUS] System Voltage {Status Only} [STATUS] Test Major Relay Security Level {1} [SYSTEM/DIAG] Test Minor Relay Security Level {1} [SYSTEM/DIAG] Test Relay 1 Security Level {1} [SYSTEM/DIAG] • • • Test Relay 6 Security Level {1} [SYSTEM/DIAG] Test Relay Enable Security Level {1} [SYSTEM/DIAG] Time Security Level {1} [SYSTEM/DATE] DISPLAY SCREENS / DEFAULT SETTINGS System
Control Unit Menu Structure The complete menu structure shown in the order in which it is accessed from the control unit display is presented in outline form below. Each indentation to the right represents a menu level below the indicated title.
T o p L e v e l Second Level Third Level • • Conv Cfg Alm • • Conv 1ofN Alm • • Conv 2ofN Alm • • Sys HT Thr • • Sys HT Alm • • Sys LT Thr • • Sys LT Alm • • Hw Sys V Alm • • Hw Cnv V Alm • • Hw Batt C Alm • • Hw Batt T Alm • • Hw Sys T Alm • • Hw LVD1 Alm • • Hw LVD2 Alm • SYS: + LM SETUP DATE PIN 1 • • PIN 2 • • Address 1 • • Address 2 • • Address 3 • • Model • • Fahrenheit • • Cntrl Rev • • FW Version • • Display Type • • • SYS:
T o p L e v e l Second Level Third Level Fourth Level • • • Out-Rly 6 Alm • • • Out-Rly 1 Dly • • • Out-Rly 2 Dly • • • Out-Rly 3 Dly • • • Out-Rly 4 Dly • • • Out-Rly 5 Dly • • • Out-Rly 6 Dly • • SYS:OUT: AP ALIAS + Out-Rly 1 • • • Out-Rly 2 • • • Out-Rly 3 • • • Out-Rly 4 • • • Out-Rly 5 • • • Out-Rly 6 • • • Relay Minor • • • Relay Major • SYS: + LY IN-RLY DIAG SYS:IN-: + RLY-MAP ALIAS In-Rly 1 Alm • • • In-Rly 2 Alm • • • In-Rl
T o p L e v e l Second Level Third Level • • Test Relay 5 • • Test Relay 6 • • Test Min Rly • • Test Maj Rly MX28B400 +24V + EM MODULES BATT MOD: RECT CONV CIR + MOD:REC: + SET-ALM PARAM I Fourth Level Rect CL Alm • • • Rect Stdby Alm • • • Rect FF Alm • • • Rect RFA Alm • • • • • • MOD:REC: + LM PARAM INFO • MOD:REC: AM INFO Rect Fail Safe Rect Fail Comm + Rect # Desc • • • Rect # Curr • • • Rect # CL • • • Rect # Stdby • • • Rect # FF • • • Rec
T o p • L e v e l Second Level Third Level Fourth Level MOD: + NV CIR-BKR FUSE MOD:CIR: + SET-ALM ALIAS Cir Bkr 1 Alm • • • Cir Bkr 2 Alm • • • Cir Bkr 3 Alm • • • • • • • • • • • • • • • Cir Bkr 22 Alm • • • Cir Bkr 23 Alm • • • Cir Bkr 24 Alm • • MOD:CIR: LM ALIAS + Cir Bkr 1 • • • Cir Bkr 2 • • • Cir Bkr 3 • • • • • • • • • • • • • • • Cir Bkr 22 • • • Cir Bkr 23 • • • Cir Bkr 24 • MOD: KR FUSE LVD + MOD:FUS: + SET-ALM ALIAS
T o p L e v e l Second Level Third Level Fourth Level • • • • • • • • • • • • • • • FUSE 14 • • • FUSE 15 • • • FUSE 16 • MOD: MT LVD + MOD:LVD: + SET-ALM PARAM LVD 1 Option • • • LVD 1 Open Alm • • • LVD 2 Option • • • LVD 2 Open Alm • • MOD:LVD: LM PARAM + LVD 1 Trip • • • LVD 1 Reset • • • LVD 2 Trip • • • LVD 2 Reset MX28B400 +24V + ES BATT PIN OEM BAT: + SET-ALM PARAM C Batt Disc Thr • • Batt Disc Alm • • Batt HV Thr • • Batt HV A
T o p L e v e l MX28B400 +24V TT PIN OEM + MX28B400 +24V IN OEM + Second Level Third Level Fourth Level PIN OEM R Offset • OEM R Gain • OEM C Offset • OEM C Gain • OEM S Offset • OEM S Gain Front Panel LED Indicators Major (Red) On when Major Relay is de-energized* Minor (Yellow) On when Minor Relay is energized Normal (Green) On when no alarms are active ALM 1 (Red) On when Output Relay 1 is energized ALM 2 (Red) On when Output Relay 2 is energized ALM 3 (Red) On when Output
4.7. Alarm Outputs (Output Relays) There are eight alarm output relays designated Relay 1 through Relay 6, Minor, and Major, respectively. Various system parameters may be programmed to activate any of these alarm relays when set thresholds are exceeded or specific conditions occur. The first six relays can also be assigned a priority and routed or “mapped” to other output alarm relays. Available assignments are “Ignore”, “Major”, “Minor”, and “Relay 1” ··· “Relay 6”.
5 Remote Monitoring 5.1. Description Remote monitoring and control of the dc power system is accomplished through the use of the optional APC Network Management card. This card is a separate module mounted into the top panel of the system controller module. Complete documentation for the use of the management card accompanies the power system in the form of a small Quick Start Guide and a CD.
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 give system configuration. 6.1. AC Input 1MRF28H27BV Rectifiers Nominal Input Voltage 230 Vac Input Voltage Range 176 – 264 Vac AC Frequency Range 47 – 63 Hz Apparent Power Factor 99% Typical, 98% Minimum Maximum Input Current (per Rectifier) 13.
6.2. DC Output (with either Rectifier) Nominal Output Voltage (factory set) 27.2 Vdc Operating Voltage Range 22 – 29 Vdc Rated Output Current (per Rectifier) 100 A Rated Output Power (per Rectifier) 2800 W (45ºC) Efficiency 91% Typical 6.3. Controls and Indicators Rectifiers Input Healthy LED AC power present. Output Healthy LED DC output voltage within operating range (20 to 29 Vdc). Output Current LED On when rectifier is supplying current.
+I Test Point Rectifier Current can be measured with a voltmeter between COM and +I. Current is 10A/V multiplied by test point voltage. Float / Boost/Equalize Switch Used to Control voltage on systems without a PSCU Float Trim Pot The float pot is used to adjust the default float voltage (27.2 Vdc). Boost/Equalize Trim Pot The boost/equalize pot is used to adjust the default boost equalize voltage (28.8 Vdc).
6.4. Mechanical Dimensions 15.75” high x 23” wide x 17.5” deep Weight Housing 85 lb Rectifier (each) 11 lb Color Dawn Gray Mounting Front or mid-mounting on standard 23-inch rails 6.5. Environmental Ambient Temperature Humidity Altitude (Operating) -45ºC to +55ºC (+65ºC with reduced power output) (Storage) -45ºC to +85ºC (Operating) 0 – 85% RH (non-condensing) (Storage) 0 – 95% RH (non-condensing) (Operating) 3000 m (9840 ft.) (Storage) 10000 m (39370 ft.) 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.
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"): Magnum MX28B400 +24 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.
