Magnum XS 450 -48 Vdc Power System User’s Manual
Table of Contents 1 SAFETY FIRST! ................................................................................................................. 1 1.1. 1.2. 2 WARNING SYMBOLS ..................................................................................................... 1 GENERAL PRECAUTIONS:.............................................................................................. 1 INTRODUCTION ................................................................................................
Relay Output Connections................................................................................................ 27 External Alarm Input Connections .................................................................................... 28 4 COMMISSIONING ............................................................................................................ 29 4.1 PRE-COMMISSIONING INSPECTION .................................................................................... 29 Environment......
System Temperature Test ................................................................................................ 38 Battery Current Test ......................................................................................................... 38 Battery Temperature Test................................................................................................. 38 LVD Test ...........................................................................................................................
Revision History Revision 990-1557 Revision 1 990-1557A Revision 2 Date 20 Oct, 2003 30 MAR 2004 By JPF BET Description Initial Release Update to include Battery Cabinet Table of Figures FIGURE 2.1-1 MAGNUM XS 450 POWER PLANT ............................................................................ 2 FIGURE 2.1-2 POWER SYSTEM BLOCK DIAGRAM ....................................................................... 3 FIGURE 3.2-1 DOOR CLEARANCE DIMENSIONS ..................................................
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 shelf assemblies are also modular and can be added when system capacity needs to be expanded.
Figure 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.
Figure 3.
Mounting The unit is self-supporting, but designed to be bolted to the floor of the housing structure. Figure 3.2-2 shows the footprint of the box frame and the mounting points with dimensions. Systems with multiple box frames are bolted together with each frame touching, side by side. The side panels where two frames touch are removed so that cables can pass between the frames. A kit with the necessary hardware to bolt two cabinets together (0M-3441) is available from APC. Figure 3.
3.3. 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. The Magnum XS 450 Power System requires the supply of a nominal 230 Vac single-phase, or three-phase 415/230 V, 50/60 Hz power to the ac input terminal block connections. However, it will operate off of voltages in the range of 176 – 293 V.
powered from the terminal block labeled L2. The right rectifier in each shelf is powered from the terminal block labeled L3. AC Line 1 AC Line 2 AC Line 3 L1 L2 L3 AC AC AC AC AC Neutral Neut. AC Earth Ground DC DC DC DC DC E AC AC AC AC DC DC DC DC Figure 3.
Wire Size (AWG) 350 kcmil – 2 Cu Wire Size (AWG) 2/0 – 6 Cu Wire Size (AWG) 4/0 – 6 Cu Neutral Input Wire Size (mm2) Max Torque (in-lb) 185 – 35 Cu 275 L1, L2, and L3 Input Wire Size (mm2) Max Torque (in-lb) 70-16 Cu 125 Earth Ground Input Wire Size (mm2) Max Torque (in-lb 95 – 16 Cu 275 Max Torque (N-m) 31.75 Max Torque (N-m) 13.5 Max Torque (N-m) 31 Figure 3.
AC Line 1 L AC Neutral 1 N AC Line 2 L AC Neutral 2 N AC Line 3 L AC Neutral 3 N AC Line 4 L AC Neutral 4 N AC Line 5 AC Neutral 5 L N AC Line 6 L AC Neutral 6 N AC Line 7 L AC Neutral 7 N AC Line 8 L AC Neutral 8 N AC Line 9 L AC Neutral 9 N AC AC AC AC AC AC AC AC AC DC DC DC DC DC DC DC DC DC Earth Ground GND G1 Figure 3.3-4 AC Input Entry with Individual Rectifier Entry (shown with single pole circuit breaker option) 3.4.
Rectifier Shelf Serial Communications Program the binary address of each rectifier in the shelf using S1 on the rectifier interface card. These are located at the back of each rectifier slot. All switches ON will give an address of zero (rectifier 1).
Rectifier Module Installation WARNING: Rectifier dc output circuits would be damaged if battery were installed incorrectly. Before rectifier installation, ensure proper battery polarity. Rectifier modules are hot-swappable. The rectifier modules are generally shipped in separate containers. Remove the rectifier from its shipping container. Using a flat blade screwdriver, loosen the pawl latch (counter-clockwise) on the rectifier, until the latch is recessed inside the rectifier.
Merlin Gerin 28 Circuit Breaker Module Installation 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.
Merlin Gerin 12 Circuit Breaker Module Installation 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.
Figure 3.5-2 12 Circuit Breakers Module CIRCUIT BREAKER RATING ORDERING NUMBER Merlin Gerin C60HC 4 A Merlin Gerin C60HC 10 A 0M-3318 Merlin Gerin C60HC 20 A 0M-3315 Merlin Gerin C60HC 32A 0M-3316 Merlin Gerin C60HC 40A 0M-3317 Merlin Gerin C60HC 50A 0M-3319 Merlin Gerin C60HC 63A 0M-3311 Merlin Gerin C120HC 80A 0M-3314 0M-3313 Merlin Gerin C120HC 100A 0M-3312 Merlin Gerin C120HC 125A 0M-3310 Table 3.
dc bus. Use M8 hardware to secure the buses together. Use M5 hardware to secure the front lip to the power system frame. Use M6 hardware to secure the rear of the module to the power system frame. Figure 3.5-3 NH2 Fuse Module Connect the LVD power wiring to the power bus observing proper polarity. Connect the LVD control cable to the customer interface card.
Hooking the load cables to a module used as a battery return will cause erroneous battery current readings. The dc load cable(s) should be sized to limit the voltage drop from the Magnum XS 450 Power System 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.
Installing circuit breakers in a 28 Circuit Breaker Module on the DIN rail Figure 3.7-2 Merlin Gerin 28 CB Module Installation Detail Install the Merlin Gerin Circuit Breaker (CB) to the mounting DIN Rail on the 0M-2186 or 0M2579 circuit breaker module with the DIN rail lock positioned toward the main bus. The C60 style CBs should be installed from left to right on the main bus and the C120 style CBs should be installed from right to left on the main bus for the best use of the main bus positions.
C60 28 26 25 23 22 20 19 17 16 14 C120 0 1 2 3 4 5 6 7 8 9 Total 28 27 27 26 26 25 25 24 24 23 C60 13 11 10 8 7 5 4 2 1 0 C120 10 11 12 13 14 15 16 17 18 19 Total 23 22 22 21 21 20 20 19 19 19 Table 3.7-1 Circuit Breaker Mix Table Installing circuit breakers in a 12 CB Module on the DIN rail Install the C60 style Merlin Gerin Circuit Breaker to the mounting DIN Rail on the 0M-2188 or 0M-2189 module with the DIN rail lock positioned toward the bus finger.
Figure 3.7-4 CB Alarm Interface Board (28 circuit breaker module) Figure 3.
Installing a fuse in the NH2 Fuse Module Insert the fuse into the fuse module until the tangs on each end of the fuse bottom out in the socket. Mounting holes for Fuse Alarm Cable Figure 3.7-6 NH2 Fuse Connections DC Load Return Module Installation The modules that are attached to the Return bus are designed to provide a convenient means of attaching the dc return cables. The battery return module has a shunt installed and the load return modules do not. Table 3.
Figure 3.7-7 Large Load and Small Load Return Module DC Load Return cable connections The battery return module has a shunt installed and the load return modules do not. The small return has 40 pairs of M5 threaded holes on 1.59 cm (5/8 in.) centers. One set of M8 threaded holes on 2.54 mm (1 in.) and 4.45 mm (1.75 in.) centers is also provided on the small return module. The large return has 6 pairs of M8 threaded holes on 2.54 mm (1 in.) and 4.45 mm (1.75 in.) centers 3.
Connect the LVD power wiring to the power bus observing proper polarity. Connect the LVD control cable to the customer interface bus. The alarm signal of each individual Battery Disconnect Switch is connected to the blade terminals of the switch (C and N/C). The other end of the alarm cable is connected to the J2 terminal block (User Inputs) located on the Customer Interface Board.
Battery Return Module Installation The battery return module is typically installed in the top return module position. To install the battery return module, loosen the 4 M5 X 8 Phillips head screws on the back of the unit. The slots will allow the module to be aligned precisely. Position the module in an open return position in the unit. Align the holes in the return module with the holes in the return bus and insert 2 M8 X 20 cap screws with lock washers and flat washers.
positioning the probe on the selected battery cell. Remove the adhesive protection strip from the probe body and press the adhesive side of the probe on the battery cell cover. Figure 3.8-3 Typical location of Battery Temperature Probe 3.9 DC System Grounding The Positive connection (load return bus) for the power plant must be connected to the principal ground point of the building where installed. Do not connect the Battery Return Bus to the principal ground point of the building.
is possible by DB-9 cable on the Console Port of the module and via RJ-45 (Ethernet) cable on the 10/100 Base-T port on the Network Management Card. “Smart” Cable DB9 Connection The DB9 connector on the top left hand side of the unit uses the special RS-232 cable (APC part number 940-0024C) to allow local access through a Terminal Emulation program like HyperTerminal™ or Procomm™ (**). This port is labeled as “Console”.
External Alarm Input Connections Four external alarm inputs with assignable priority levels are available. These alarm inputs respond to external dry contact closures between normally open (N/O) and common (C) or contact openings between normally closed (N/C) and C. External Alarm Source (non-alarm state) OPEN CLOSED Connect To Input Alarm Terminals NO-C NC-C Table 3.10-2 External Alarm Input Definition Wago Connectors are located on the customer interface card mounted in the top right side of the unit.
4 Commissioning 4.1 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. Ensure that there is no sign of damage to the dc system. Disable installed alarms before servicing the unit. This will allow the unit to be serviced without creating false alarms. Electrical Installation 1. 2. 3. 4. Ensure that the dc wiring is properly installed, sized, terminated and identified.
10. Check the torque of all battery inter- cell connector in accordance with the battery manufacturer’s specifications. 4.2 Commissioning Initial Set-up 1. Remove all rectifiers. 2. Disconnect battery by removing a link in each string or opening the battery disconnects. 3. Check that battery voltage does not appear on the system bus. 4. Disconnect all loads. AC Power Up WARNING: The dc power plant is supplied from a nominal high voltage ac voltage source.
1. Monitor battery current and verify that it is +/- 0.1 A. 2. Set battery maximum recharge setting by determining the entire battery string capacity and dividing by 10 hours. This setting will recharge the battery in 10 hours. 3. Enter this value in the Max Batt Rech screen. 4. Monitor the battery current while closing the battery disconnects or installing open battery links. Arcing can occur during this connection. 5. The voltage may drop if the maximum battery recharge current is exceeded. 6.
3. Verify that the system voltage is above the float voltage if the battery temperature is below 25 degrees C and below the float voltage if the battery temperature is above 25 degrees C. 4.3 Final Inspection: 1. Verify that the interior and exterior of the system is clean and free from debris. 2. Ensure all wires connected and bolts are properly tightened. 3.
5 Operation 5.1 Technical Description The Magnum XS 450 Power System is designed to supply safe –54 Vdc primary power through the use of up to nine rectifier modules. If installed with an internal battery string, it will supply backup power as well. The controller will monitor and control all system parameters including alarms, system voltage, and system current. Modular dc output distribution supporting loads ranging from 4 amperes to 400 amperes is available. 5.
5.3 DC Distribution DC Distribution Module The main function of the dc distribution module is to provide a means of connecting and protecting cables that will be connected to power dc loads. The dc distribution modules also interface with the main controller to monitor the status of breakers and fuses protecting the dc loads. LVD contactors and control boards are incorporated into the various dc distribution modules.
5.5 Customer Interface Board Alarm Outputs (Output Relays) There are eight alarm output relays designated Relay 1 through Relay 6, Minor, and Major, respectively. These alarms reside on the controller and are connected to the external monitoring system via the customer interface board. Refer to the specific controller user’s manual for more information. External Alarm Inputs (Input Relays) The controller can monitor any external device that uses a switch or relay to output status information.
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. Contact monitoring personnel or disable system alarms before servicing the unit.
2. Check the mechanical integrity of the battery framing, racking, or cabinet. Tighten where necessary. 3. If there is a battery disconnect device fitted, ensure that it is properly connected and protected. 4. Check the general appearance and cleanliness of the battery. Clean if necessary. Use only approved cleaning materials. 5. Visually inspect each cell for the following, and clean and neutralize if necessary. Document discrepancies on Site form accordingly. a. Cracks. b. Case leaks. c. Post-seal leaks.
5. After the fan has completely stopped spinning, insert a plastic pen or plastic screwdriver into the fan blade of one of the rectifiers and reinsert both rectifiers 6. Verify that you get the fan fail alarm on controller and the customer remote alarm panel. 7. Remove the fan fail device. System Temperature Test Verify that the system temperature is correct. Battery Current Test 1. 2. 3. 4. Measure the battery current with a clamp-on meter. Verify that the battery current is below 5 A.
Battery Preventive Maintenance Procedure The purpose of the preventive maintenance is to ensure that the battery is in good, working condition. The observations, measurements, and tests performed are designed to determine the “state of health” of the battery. It will also allow for the prediction of future performance and preempt possible failure. 1. Measure the float charge voltage. a. At the power bay bus. b. At the battery. c. Reset voltage if necessary. 2.
7 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. 7.
7.
8 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.
9 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 XS 450 Power System 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.
