User Manual For DC Series MX06 60A Shelf User Manual 990-9189A DC MX06 60A Shelf Page 1 of 30 th 18 FEB 02
DC MX06 60A Shelf The DC Series MX06 60A Shelf is a 19” compatible modular power plant capable of supplying up to 63A at –48V DC (54V). The unit contains a simple alarms/control card that can configure up to 6 x 10.5A rectifiers and offers voltage control and basic alarms. Optional mounting brackets are offered to allow the system to be fitted in a 23” rack. Easy sub-assembly access and replacement allows for convenient and efficient maintenance.
Contents SECTION 1 2 DESCRIPTION General Information 1.1 Introduction 1.2 Safety Precautions 1.3 Types Of Hazard 1.4 Inspection Of Goods 1.5 APC Worldwide customer support 1.6 Warranty Information Product Overview + Technical Description 2.1 Specification 2.2 2.3 2.4 2.5 3 User Manual 990-9189A DC MX06 60A Shelf 2.1.1 Rectifier 2.1.2 System AC Input 2.1.3 System Output 2.1.4 Environmental 2.1.5 Approvals LED’s 2.2.1 4 LED Rectifier 2.2.2 Single LED Rectifier Alarms/Customer Inputs 2.
Installation Procedure 4.1 AC Primary Input 4.2 4.3 4.4 5 6 7 8 4.1.1 Single Phase 4.1.2 Single Phase, AB Feed 4.1.4 3 Phase Star 4.1.5 3 Phase Delta System Output Connection System Earthing 4.2.1 Output Earth 4.2.2 Alarms Earth Cable Routing 4.4.1 Input Cables 4.4.2 Output Cables Commissioning the System 5.1 General 5.2 Powering up the MX06 60A Shelf Manual Handling Procedure 6.1 General 6.2 Preparation 6.3 Method Fault Finding / Symptoms 7.1 Warnings 7.
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 controlled from the system control unit that provides monitoring and control functions for each component of the system as well as alarm outputs for system diagnosis and maintenance.
• CEC Code C22.1-98 ( Canada ) • CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH (COSHH) REGS • MANUAL HANDLING REGULATIONS, 1993 (See Section 6) 1.2.3 BECOME FAMILIAR WITH THE HAZARDS ASSOCIATED WITH THE POWER SYSTEM AS DETAILED IN PARA 2. 1.2.4 CAUTION - BEFORE INSTALLING RECTIFIERS (POWER SUPPLIES) INTO AN UNPOPULATED SYSTEM SEE INSTALLATION INSTRUCTIONS IN SECTION 4. 1.
1.4 Inspection upon Receipt of Goods 1.4.1 General APC has taken precautions in packing the power equipment for shipment to ensure its safe arrival; however, the entire shipment including any boxes or crates should be inspected upon receipt for evidence of damage that may have occurred during transit. 1.4.
1.5 APC Worldwide Customer Support Customer support for this or any other American Power Conversion (APC) product is available at no charge in any of the following ways: l Visit the APC web site to find answers to frequently asked questions (FAQs), to access documents in the APC Knowledge Base, and to submit customer support requests. http://www.apc.com (Corporate Headquarters) Connect by links to APC web pages for specific countries and regions, each of which provides customer support information.
1.6 Warranty Information 1.6.1 Limited Warranty American Power Conversion (APC) warrants the DC Series MX06 60A Shelf to be free from defects in materials and workmanship for a period of two years from the date of purchase. It’s obligation under this warranty is limited to repairing or replacing, at it’s own sole option, any such defective products. This warranty does not apply to equipment that has been damaged by accident, negligence, or misapplication or has been altered or modified in any way.
2 Product Overview and Technical Description 2.1 Specification 2.1.1 Rectifier Parameter (per rectifier) 1TWF0500H54** Approved Input Rating I/p Operating Range RMS Input Current “ “ “ Approved Input Frequency range Turn-on Surge Turn-on Time Internal Fuse Power Factor Output Voltage (Nominal) O/p Current (Rated) 115V or 230Vac 103.5V to 264V 6.5A max @115V 3.
2.1.3 System Output Output Voltage Nominal Voltage Adjustment Range Current Rating Temperature Coefficient Current Limit Reverse Quiescent Current Regulation Over voltage 2.1.4 Environmental Temperature Range Humidity 2.1.5 54.5Vdc 44 V – 57 V 63 A @ 230Vac, 54 A @ 115Vac, 42A @ 100Vac -76mV/°C ±10% (over range 0°C - 50°C) 100% - 110% of Rated Current Less than 100mA, Typically 50mA 250mV max for any line or load condition 59.5V ± 0.
2.3 Alarms + Customer Inputs To monitor the system status a selection of alarm outputs are available. Each rectifier has 4 front panel LED’s giving a visual notification of a system fault. There is also a range of open collector transistor alarm outputs and a set of form C relay contacts that can be accessed at the rear of the shelf. Below is a list of the available alarms along with their function and pin number. 2.3.
2.3.2 Individual Rectifier Alarms In addition to the system alarms and inputs, six alarm connectors are mounted on the backplane board. Each one of these connectors offers six alarms/inputs for a particular rectifier. This means the end user can, if required, monitor each rectifier fitted separately as well as the system as a whole.
2.4 System Set-up options 2.4.1 Current Limit Programming The system output current limit can be set to either the standard “High” (100%) level or “Low” (70%) level by using SK30. For “High” current limit level link pins 1 and 2 For “Low” current limit level link pins 2 and 3 Selecting “Low” current limit level will program down each rectifiers current limit level to roughly 70% of the default level. (See section 2.1.1 for default levels). System is set to “High” current limit as standard. 2.4.
2.4.3 Temperature Compensation Temperature compensation / Fixed output voltage selection (SK1) For “Fixed Output Voltage” SK1-1 to SK1-2 will be linked. (default setting) For “Temp Comp” remove above mentioned link and fit supplied thermistor kit to SK1. Temperature compensation uses the thermistor to monitor battery temperature and automatically adjusts the output voltage of the system. This ensures the charging voltage stays within the battery manufacturers recommended limits.
2.5 Mechanical 2.5.1 Dimensions Dimension Length 2.5.2 A 482.6mm (19in) B 132.5mm (5.22in, 3U) C 283.6mm (11.17in) D 82.5mm (3.25in) E 138.5mm (5.45in) F 438.2mm (17.25in) Weight Item Measured Empty Shelf Single Rectifier Full System Weight (Kg) 5.2 1.75 15.70 Weight (lbs) 11.5 3.85 34.
2.5.3 Mounting Options The DC MX06 60A Shelf has 3 positions for mounting ears. If mounting ears were ordered with the system they will be fitted in the front position as standard. The 2 alternative mounting positions are shown below. The end user can simply unscrew the ears and re-fit in the desired position. Ensure all screws are re-tightened sufficiently.
3 System Configuration The MX06 60A shelf is designed to meet a range of customer requirements/applications. A number of options are available including alternative input supply configurations, 19 and 23 inch mounting versions and temperature probes etc. Contact APC for details.
4 Installation Procedure 4.1 AC Primary Input 4.1.1 Single Phase, Single Feed To connect the input supply to the DC MX06 60A Shelf proceed as follows: • The AC input current to the system should be limited by an appropriate device in the event of a short circuit as defined in EN60950 to protect the internal wiring of the end use equipment. Maximum input current is 39A at 115Vac and 22A at 230Vac, the device should be rated accordingly.
4.1.2 Single Phase, AB Feed To connect the input supply to the DC MX06 60A Shelf proceed as follows: • The AC input current to the system should be limited by an appropriate device in the event of a short circuit as defined in EN60950 to protect the internal wiring of the end use equipment. Maximum input current is 20A per feed at 115Vac and 11A per feed at 230Vac, the device(s) should be rated accordingly.
4.1.3 3 Phase Star Supply The DC MX06 60A Shelf can be used on any of the following supplies: 415V, 400V, 380V or 208V phase to phase. The maximum input current is 39A on a 208Vac phase to phase supply and 22A on a 380Vac, 400Vac or 415Vac supply. Choose AC Input cabling rated accordingly and colour coded as required for country/state concerned.
4.1.4 3 Phase Delta Supply Warning! The DC MX06 60A Shelf can only be used on a 208Vac phase to phase supply. In a delta connection system each rectifier input is connected directly across two phases. Due to the maximum voltage rating of the rectifiers being 264Vac this is the maximum phase-tophase voltage that can be applied. The maximum input current per phase on a 208Vac supply is 12.5A. Choose AC Input cabling rated accordingly.
4.2 System Output Connection The DC MX06 60A Shelf has an output voltage of 54.5Vdc nominal. In standard configuration the positive output is connected to earth. This means the output is –54.5Vdc with respect to earth. The picture directly below shows the output bus-bars and the connection points where output cables should be connected. The bus-bar inserts are M6 threaded therefore output cables should be crimped with M6 crimps.
4.3 System Earth 4.3.1 Output Earth The DC MX06 60A Shelf has its output earthed as default. The output is earthed by a bus-bar, which connects the relevant output bus-bar to the main earth stud. The earth link can be removed to leave the output floating but the user must then earth the output at some other point in the system. The default configurations are as follows: Positive earth configuration Default config for MX06 60A (54V) systems 4.3.
4.4 Routing Of Cables 4.4.1 Input cables One or more of the top 4 knockouts (top left and right hand side knockouts and 2 actually in the rear cover) must be used for entry of the input AC cable. This is essential if the input cabling used is not double insulated and recommended as this optimises the EMC performance by ensuring the AC Input cables are as far away from the output wiring as possible.
Fit Cable clips in positions shown 4.4.2 Output Cables The output cables may be of quite large diameter and therefore it may be necessary to use two knockout holes instead of one. The bottom two left hand side knockouts should be used to keep the output cables physically as far from the input cables as possible to optimise EMC performance.
5 Commissioning the System 5.1 General All site preparation and equipment installation in the previous chapters must be completed before commissioning. • Ensure that the ac power source isolator is switched OFF. • Switch any external battery circuit breakers to the OFF position. 5.2 Powering up the DC MX06 60A Shelf • Switch on the external ac power supply to the DC MX06 60A Shelf. • Check the Rectifier module LED’s: • If Rectifiers fitted have 4 LED’s.
6 Manual Handling Procedure 6.1 General 6.1.1 Items within the sub-system present a hazard due to mass. A fully configured system fitted with 6 rectifiers weighs almost 16Kg (35lbs). 6.1.2 The Manual Handling of Loads Regulations, 1993 require that all persons working on the equipment are familiar with the Regulations, that they take care to minimise risk of injury to themselves and others, that they are properly trained, and that the correct equipment is used. Safety shoes are to be worn. 6.1.
7 Fault Finding / Symptoms The power system is designed for maximum reliability and therefore faults during normal operation are unlikely. If faulty operation does occur the source of the failure can usually be readily determined by inspection of the LED’s and or the system alarms. 7.1 Warnings POTENTIALLY LETHAL VOLTAGES AND SOURCES OF HIGH ENERGY ARE PRESENT WITHIN THE POWER SYSTEM. EXTREME CAUTION MUST BE OBSERVED AT ALL TIMES.
8 Service, Accessories & Spares 8.1 Rectifier replacement If a faulty rectifier is to be replaced simply unscrew the two front panel fixings on the rectifier front panel and withdraw the rectifier from the shelf. A replacement rectifier can then be inserted directly into the shelf and will start-up automatically. Note – The rectifiers are “hot plugable” and therefore can be replaced without turning the system off. 8.
