Magnum VS 50 Magnum VS 100 -48 Vdc Power Systems User Manual 990-1479E 05/2007
Table of Contents 1 Introduction ............................................................................................................................................................6 1.1. GENERAL INFORMATION ....................................................................................................................................6 2 Installation...................................................................................................................................................
5 6 7 8 System Current Monitor.......................................................................................................................................26 System Status and Alarm Reporting ...................................................................................................................26 4.3. LOAD MANAGEMENT .......................................................................................................................................26 Circuit Breakers .............
MAGNUM VS CONTROLLER ........................................................................................................................................50 8.4. MECHANICAL ..................................................................................................................................................51 TWF0500H54B Rectifier......................................................................................................................................51 Magnum VS 50 Power System....
1 1.1. Introduction General Information The APC Magnum VS is a modular -48 Vdc power plant. The Magnum VS has unique features that make it easy to install, maintain, and upgrade. There are two Magnum VS models; Magnum VS 50 and 100. The Magnum VS 50 is a single shelf system and can support up to 5, 10A rectifiers, for a rated current of 50A. The Magnum VS 100 is a dual shelf system and can support up to 10, 10A rectifiers, for a rated current of 100A.
SKU DCM00K03SGMT Description Magnum VS 50, Basic Controller and Integrated Network Management Card (NMC), One (1) 1TWF0500H54B 10 A Rectifier, and One (1) GMT Distribution Module (8 Fuse Positions) DCM00K03S2X30 Magnum VS 50, Basic Controller and Integrated Network Management Card (NMC), One (1) 1TWF0500H54B 10 A Rectifier, and One (1) Circuit Breaker (CB) Distribution Module (2–30 A Circuit Breakers) DCM00K03S1X60 Magnum VS 50, Basic Controller and Integrated Network Management Card (NMC), One (1) 1TW
Blank Panel ( 0P1838 ) Microprocessor Control Board WEB SNMP Card ( AP9617 ) Magnum VS –48 Vdc User Manual OUT RLY MAJOR MINOR DC OK DB-9 PORT COMM PORT RESET 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 1 2 3 4 COVERED COVERED COVERED CONTROL BUS MAJ NC MAJ C MAJ NO MIN NC MIN C MIN NO USER NC USER C USER NO 1 TMP 2 -BAT 3 +12 PWR 4 ALARM RELAY OUTPUTS BATTERY TEMPERATURE PROBE 1 2 3 4 5 6 7 8 9 USER ALARM INPUTS ALM IN_1 ALM IN_2 ALM IN_3 ALM IN_4 ALM RTN ALM RTN ALM RTN ALM RTN GND GND G
2 2.1. Installation 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 Error! Reference source not found. in the event it is necessary to return equipment to APC.
2.3. 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. AC Connections The Magnum VS DC power system, specifically each rectifier, requires a single phase input AC supply (Range: 85–264 VAC, 47–63 Hz) to operate.
Each phase should be wired for a minimum of 15 A. The rear cover of each Magnum VS shelf in the power system has two 1.125-inch (2.858 cm) diameter holes for electrical conduit. Conduit can be run to each Magnum VS shelf, or, alternatively, strain relief is provided for the direct installation of AC power cables. Please note that the ambient temperature and the number of wires in a conduit must be considered in accordance with national and local wiring code requirements (e.g., NEC).
2.4. Battery Connections WARNING: Hazardous energy levels are present on bare conductors in the DC 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 to: Remove any jewelry, rings, or watches while working on this equipment. • Use insulated wrenches, screwdrivers, cutters, pliers and other tools.
Figure 2.4-1 Battery Cable Connection Locations Battery Temperature Probe Installation The 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.
CEMF Connections Figure 2.5-1 CEMF Connection Locations 2.6. DC System Grounding The positive bus for the power plant should be connected to the Central Office Ground. The Battery Return provides a pair of #10-32 studs on 5/8-inch centers for connection of a two-hole lugged cable to the Central Office Ground. A ring size of 6 mm may also be used. Cover this connection with heat shrink tubing after assembly.
2.7. Load Protection Installation Circuit Breaker Installation Standard circuit breaker output distribution modules are available with two 30-A breakers or one 60-A breaker. Output distribution modules are installed at the factory and are typically not field replaceable units. Contact APC if the output configuration is not suitable for your needs. Other breaker sizes are not readily available.
Circuit Breaker Protected Load Connections (30 or 60 A) The circuit breaker lug landing connection provides a pair of #10-32 studs on 5/8” centers for mounting two-hole lugs. A ring size of 6 mm may also be used. A right angle bus bar with two studs is provided to land the lugs. Load Connections should be made as shown in. Cover connections with heat shrink after assembly. -54 Volt Load Connections Load Returns Figure 2.
Figure 2.8-3 Bottom Shelf GMT Fuse Connections 2.9. Monitoring and Relay Output Connections Front Panel DB9 Connection The front panel DB-9 connector is used to hook up a standard RS-232 cable (such as APC part number 0129-XX. A 0129-6 is included with this manual. ). This will allow local access through a Terminal Emulation program such as HyperTerminal™ or ProComm.
Output Relays (J411) User Inputs (J412) Figure 2.9-1 Interface Connections Output Relay 2-6 Connections Output Relays 2 through 6 are virtual relays and are not available for physical connection by the user. The small size of this unit limits the number of relays that can be placed in the system. These output relays are supported by the controller and reported by the network management card. Any alarm condition can be programmed to map to one of these relays.
RELAY OUTPUT OUT RELAY #1 OUT RELAY #2 OUT RELAY #3 OUT RELAY #4 OUT RELAY #5 OUT RELAY #6 MINOR MAJOR J 411 TERMINAL DESIGNATIONS NO C NC N/A N/A N/A N/A N/A NO C NC NO C NC RELAY ALIAS OUTPUT RELAY NOTES N/A N/A N/A N/A N/A N/A Figure 2.9-2 Output Relay Connections External Alarm Input Connections Four external alarm inputs with assignable relay outputs are available.
2.10. Rectifier Module Installation WARNING: Rectifier output DC circuits will be damaged if the batteries are installed incorrectly. Before installing additional rectifiers, ensure proper battery polarity, and that the battery is isolated from the rest of the system. The Magnum VS system includes one (1), 10A, rectifier module. To install additional rectifier modules (shipped separately), follow the procedure outlined below.
3 Commissioning This section is intended as a guide when powering up a system for the first time. It may not be desirable to perform some steps depending on the particular installation. Refer to the appropriate section for information relating to how these steps should be performed. 3.1. Pre-Commissioning Inspection Environment 1. 2. 3. 4. Ensure the dc system environment is suitable for operation. Ensure that there is sufficient clearance around the system for service.
3.2. Commissioning Initial Set-up 1. 2. 3. 4. Remove all rectifiers. Disconnect battery by removing a link in each string or opening the battery disconnects. Check that battery voltage does not appear on the system bus. Disconnect all loads. AC Power Up WARNING: The dc power plant is supplied from a nominal high voltage ac voltage source. Keep the ac input enclosure cover in place when the system is operational or energized 1. 2. 3. 4.
Rectifier Test: 1. To verify that all rectifiers are reporting correctly to the controller, navigate through the menu and verify that the status for every rectifier in the system is correct. 2. Remove any rectifier and verify that you get a Minor Relay Output for rectifier 1 of n failure. 3. Remove a second rectifier and verify that you get a Major Relay Output for rectifier 2 of n failure. Battery Power Up 1. Monitor battery current and verify that it is +/- 0.1 A. 2.
Output Relay 1: 1. Minor and Major output relays were tested in the rectifier test section. 2. Change the alarm to desired relay output via the controller for any relay output that will be used. All alarm parameters are shipped as either major or minor, but may be changed to output relay 1. 3. Program output relay 1 to desired major or minor alarm to complete programming. 4. Exercise the output relay by causing the alarm to change state. Battery Temperature Compensation 1.
4 Technical Description The Power System is designed to supply safe –54 Vdc primary power through the use of up to 10 rectifier modules. The controller will monitor all functions and provides battery management including controlled battery recharge with temperature compensation and low voltage disconnect. Integrated dc output distribution supports loads ranging from ¼ A all the way to 60 A. The controller can monitor up to 4 discrete external events with voltage free (“dry contact”) user inputs. 4.1.
System Current Monitor The controller monitors individual rectifier currents and displays total system current as a sum of rectifier currents. Load current can be found by adding battery current to system current. Battery Current is positive when the battery is discharging. Sys Current + Batt current = Load Current For example, if the battery is charging the Batt Current reading could be (–) 10 A, Sys Current reading could be 50 A.
GMT Fuses When a GMT fuse trips, a fuse element burns out allowing the indicator to connect DC power to the alarm contact. This turns on the fuse alarm LED on the fuse panel indicating the affected group and the Controller reports a fuse alarm. Each Controller fuse alarm combines alarms from 4 individual fuses: Fuse F1 to F4: Controller Fuse Alarm 1 Fuse F5 to F8: Controller Fuse Alarm 2 Fuse F9 to F12: Controller Fuse Alarm 3 Fuse F13 to F16: Controller Fuse Alarm 4.
Battery Protection An external disconnect should be mounted at the battery string to protect the system from the high energy stored in the battery if a short occurs. The battery LVD will not be energized until a battery string is installed with the proper polarity and the battery disconnect switch is turned on. The battery connections are to be used for the battery only. Do not attach loads to the battery connections or erroneous battery current will be reported.
4.5. Controls and Indicators Controller Module All status monitoring and/or parameter changes are made using a computer connected to the Magnum VS system over an (10/100 Base-T) Ethernet network or directly connected via a serial cable. Refer to Section 5 for additional information. There are five visual indicators (LEDs) on the Controller Module. The Major LED (Red) is on when the Major Relay is de-energized. The Major Relay is energized when there is no alarm.
5 5.1. Operation Description The Magnum VS is designed for years of operation with no user input. The power system is pre-programmed 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. 5.2. Controller Module Jumpers System Voltage J5 The positioning of jumpers on header J5 will determine the operating voltage of the controller card operates. Options include –48 V, +24 V, +48 V, or –24 V systems.
J2 10 1 Display Backlight Power J3 J5 SNMP Interface System Voltage Select J4 Display Interface J12 DB9 - RS232 Port 6 5 J13 1 DC GOOD Vtrim Dropout MINOR MAJOR J1 OUT RLY VR1 J10 "HEARTBEAT" LED Negative Test Jack J11 Display Contrast 1 1 J9 J8 Firmware Change Positive Test Jack Parameter Change Lockout J6 Keypad Interface 1 Figure 5.
Figure 0-1 Magnum VS Controller 5.3. Operation Using the RS-232 Comm Port The front panel DB-9 connector provides a means to connect a PC to the controller locally to set controller parameters and to view status. To connect to this port use a straight through cable such as APC part number 0129-XX. A 0129-6 is included with this manual. .
5.4. Operation Using the 10/100 BaseT Ethernet Port The RJ-45 10/100 Base-T port is primarily intended for connection to an intranet for remote access to the DC power system. However with the use of a crossover cable or a hub, a direct PC to 10/100 Base-T local connection may also be made. After the Management Card is configured and running on your network, you can use several different interfaces to access the Management Card: Web, Telnet, SNMP and FTP.
Figure 5.
PARAMETER NAME/ DESCRIPTION [MENU LOCATION] Battery Max Recharge {Status Only} [System/DC Parameters] Battery Maximum Recharge Current [Batteries/Parameters] Battery Temperature [System/DC Parameters] Battery Temperature Compensation High Knee [Batteries/Parameters] Battery Temperature Compensation Low Knee [Batteries/Parameters] Battery Temperature Compensation Method [Batteries/Parameters] Battery Temperature Compensation Temperature Coefficient [Batteries/Parameters] Circuit Breaker 1 Alias [Distribut
PARAMETER NAME/ DESCRIPTION [MENU LOCATION] Current Limit Alarm Status {Status Only} [Power Modules/Rectifiers] Date [System/Date & Time] Description 1 [System/DC Parameters] Description 2 [System/DC Parameters] Description 3 [System/DC Parameters] Fail Safe [Power Modules/Rectifiers] The status will be “ON” if the rectifier has been forced into its current limited mode. Status Only Internal network management card calendar date. Used as a date stamp in the web card event log.
PARAMETER NAME/ DESCRIPTION [MENU LOCATION] Hardware System Voltage Alarm [Power Modules/Rectifiers] Hardware Temperature Alarm [System/DC Parameters] High Temperature Alarm [System/DC Parameters] High Temperature Threshold [System/DC Parameters] High Voltage alarm [Power Modules/Rectifiers] High Voltage Threshold [Power Modules/Rectifiers] Imbalance Alarm [Power Modules/Rectifiers] Input Relay 1 [I/O/Input] • • • Input Relay 4 [I/O/Input] Input Relay 1-4 Alias [I/O/Input] Input Relay 1-4 Delay [I/O/Inp
PARAMETER NAME/ DESCRIPTION SETTINGS (Default settings in BOLD) System Temperature is ambient temperature measured inside the controller. An alarm will be reported if temperature is lower than the temperature entered. Not the same as battery temperature threshold. Defines the output relay that is energized if the System Voltage is below the System Low Voltage threshold. Not the same as battery voltage alarm. System Voltage is bus voltage measured by the controller.
PARAMETER NAME/ DESCRIPTION [MENU LOCATION] Output Relay 1 Alias [System/Out-Rly/Alias] • • • Output Relay 6 Alias [System/Out-Rly/Alias] Output Relay 1 Delay [I/O/Output] • • • Output Relay 6 Delay [I/O/Output] Rectifier 1-of-N Alarm [Power Modules/Rectifiers] Rectifier 2-of-N Alarm [Power Modules/Rectifiers] Rectifier Configuration Alarm [Power Modules/Rectifiers] Rectifier Current Limit Alarm [Power Modules/Rectifiers] Rectifier Current Output Status {Status Only} [Power Modules/Rectifiers] Rectifie
PARAMETER NAME/ DESCRIPTION [MENU LOCATION] Rectifier Fault Alarm (RFA) Status {Status Only} [Power Modules/Rectifiers] Rectifier RFA Alarm [Power Modules/Rectifiers] Rectifier Standby Alarm [Power Modules/Rectifiers] Rectifier Standby Alarm Status {Status Only} [Power Modules/Rectifiers] Remote Configurable [System/DC Parameters] Store Configuration [Power Modules/Rectifiers] System Current {Status Only} [System/DC Parameters] System Temperature {Status Only} [System/DC Parameters] System Voltage {Statu
5.6. LVD Operation In order to prevent damage to the battery due to deep discharge, the dc power system has a Low Voltage Disconnect (LVD). When the battery voltage reaches the threshold set by the LVD 1 Trip Voltage setting during discharge, the dc power system will activate the LVD contactor to disconnect the battery from the system. The LVD will remain open until ac power is restored to the system and the bus voltage reaches the level defined by the LVD 1 Reset Voltage variable.
6 Preventive Maintenance Preventive Maintenance is typically performed on a quarterly basis. 6.1. Equipment 1. 4-Digit Voltmeter. 2. Clamp-on Ampere Meter. 3. Standard Insulated tools. 6.2. Inspection Environmental Inspection 1. 2. 3. 4. Ensure the dc system environment is suitable for operation. Ensure that there is sufficient clearance around the system for service. Ensure that there is no sign of damage to the dc system.
Battery Visual and Safety Inspection Check that the battery temperature probe is firmly attached to the battery. Check the mechanical integrity of the battery framing, racking, or cabinet. Tighten where necessary. If there is a battery disconnect device fitted, ensure that it is properly connected and protected. 1. Check the general appearance and cleanliness of the battery. Clean if necessary. Use only approved cleaning materials.
Battery Current Test 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Measure the battery current with a clamp-on meter. Verify that the battery current is below 5 A. Verify that the displayed battery current is within + 5 A. Determine the total battery capacity at the site: Cells connected in series make up a string, and the capacity is determined by the capacity of a single cell. Add Ah capacity for all strings connected in parallel. Determine the Max. Batt.
6.4. Final Inspection: 5. Verify that the interior and exterior of the system is clean and free from debris. 6. Ensure all wires connected and bolts are properly tightened. 7. Ensure the following the User, Service, and Calibration parameters are set properly on the controller (default settings are in parenthesis): LVD LVD1 Trip LVD1 Reset Battery Parameters Discharge Threshold Float Voltage Maximum Recharge Compensation Method 8.
7 ALARM/ DESCRIPTION Alarm Summary DEFAULT SETTINGS [MENU LOCATION] Battery Discharge Alarm [Batteries/Parameters] Battery High Temp Alm [Batteries/Parameters] Battery Low Temp Alm [Batteries/Parameters] Battery LV Alm [Batteries/Parameters] Circuit Breaker Alm 1 [Distribution/Breakers] Circuit Breaker Alm 2 [Distribution/Breakers] Circuit Breaker Alm 3 [Distribution/Breakers] Circuit Breaker Alm 4 [Distribution/Breakers] FUSE Alm 1 [Distribution/Fuses] FUSE Alm 2 [Distribution/Fuses] FUSE Alm 3 [Distri
ALARM/ DESCRIPTION DEFAULT SETTINGS [MENU LOCATION] System LT Alm [System/DC Parameters] Low Voltage Alarm [Power Modules/Rectifiers] LVD Alarm [Batteries/LVD] User Output Relay 1 Alarm [I/O/Output] Rectifier 1-of-N Alm [Power Modules/Rectifiers] Rectifier 2-of-N Alm [Power Modules/Rectifiers] Rectifier Current Limit Alarm [Power Modules/Rectifiers] Rectifier Fan Fail Alm [Power Modules/Rectifiers] Rectifier RFA Alarm [Power Modules/Rectifiers] The System Temperature is below the System Low Temperature
8 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. 8.1. AC Input TWF0500H54B Rectifier 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 A @ 115 Vac 3.
8.2. DC Output TWF0500H54B Rectifier Output Voltage (factory set) 54.5 Vdc Operating Voltage Range 44 – 58 Vdc Efficiency 85% Typical Over Voltage Protection 59.5 Vdc Output Current per Rectifier 9.0 A Minimum Continuous at 115 Vac Input 10.5 A Minimum Continuous at 230 Vac Input. Current Limit 9.3 A Maximum at 115 Vac Input 11.0 A Maximum at 230 Vac Input. Power Output per Rectifier @ 54.
Magnum VS 100 Power System Output Voltage (factory programmed) 54.0 Vdc Operating Voltage Range 47 – 56.5 Vdc Rated Output Current 100 A Efficiency 85% Typical Over Voltage Protection 59.5 Vdc Output Current 90 A Minimum Continuous at 115 Vac Input 105 A Minimum Continuous at 230 Vac Input. Current Limit 93 A Maximum at 115 Vac Input 110 A Maximum at 230 Vac Input. Power Output per Rectifier @ 54.5 Vdc 4900 W Continuous at 115 Vac Input 5700 W Continuous at 230 Vac Input 8.3.
8.4. Mechanical TWF0500H54B Rectifier Dimensions (Overall) 5 in (12.7 cm) high x 2.75 in (7 cm) wide x 10.5 in (26.7 cm) deep Dimensions (not including faceplate or connectors) 5 in (12.7 cm) high x 2.5 in (6.3 cm) wide x 9.4 in (24 cm) deep Weight 4 lb (1.8 kg) Color Black front, Yellow zinc sides and back Mounting Hot swappable. Secured with 2.5 mm captive screws Magnum VS 50 Power System Dimensions 5-1/4 in (13.3 cm) high x 17-1/4 in (43.8 cm) wide x 13 in (33 cm) deep Weight 15 lb. (6.
8.6. Compliance NEBS Level 3 (Pending) Safety UL 60950 CE Marked to Low Voltage Directive (EN60950) EMC FCC Part 15 Class A EN55022 Class A, EN55024 EN61000-3-2, EN61000-3-3 8.7. Compliance NEBS Level 3 (Pending) Safety UL 60950 CE Marked to Low Voltage Directive (EN60950) EMC FCC Part 15 Class A EN55022 Class A, EN55024 EN61000-3-2, EN61000-3-3 8.8.
9 APC Worldwide Customer Support Customer Support for this or any other APC product is available at no charge in any of the following ways: Refer to the APC Web site to access documents in the APC Knowledge Base and to submit customer support requests. o www.apc.com (Corporate Headquarters) Connect to localized APC Web sites for specific countries, each of which provides customer support information. o www.apc.com/support Global support searching APC Knowledge Base and using e-support.
10 Limited Product Warranty Two Year Factory Warranty 1 The limited warranty provided by American Power Conversion (APC®) in this Statement of Limited Factory Warranty applies only to Products you purchase for your commercial or industrial use in the ordinary course of your business. Terms of Warranty APC warrants its products to be free from defects in materials and workmanship for a period of two years from the date of purchase.
