Milpower Source M359-1 UNINTERRUPTIBLE POWER SUPPLY SINGLE PHASE 2.0KW/2.2KVA MADE IN THE U.S.A USER’S MANUAL Milpower Source Milpower Source West Coast Sales Office 7 Field Lane Belmont, NH 03220 Phone: (603) 267-7355 www.milpower.com E-mail: sales@mps.com Dave Hall 1498 Linda Vista Ave. Pasadena, CA 91103 Phone: 626-304-9620 Fax: 626-796-1415 E-mail: dmhall@pacbell.
Table of Contents Para Description Page Important Safety Instructions General Description Intended Application Functional Overview Electrical Installation Instructions Front Panel Description Front panel: Main Components Front Panel: Indicators and Controls Rear Panel Description Operating the M359 General Modes of Operation UPS Mode Off State By-Pass Mode Stand-By Mode UPS Test Mode Local Control (Using the Front panel Switches) PWR ON/OFF Switch INPUT UPS/BY-PSS Switch OUTPUT UPS/BY-PSS Switch Remote C
IMPORTANT SAFETY INSTRUCTIONS The M359 and its Battery Pack should not be tampered with by unauthorized personnel. Tampering with the M359 or its Battery Pack, or using them in any other way but their intended application, may result in a severe safety hazard. Disconnecting the input connector does not turn off the UPS. The unit should only be plugged into an approved, double-pole circuit breaker electrical outlet, rated between 32Amp (min) to 46Amp (max).
1. General Description 1.1. Intended Applications The M359 is a high quality, rugged, 2.0kW/2.2kVA, 19” rack-mounted, Uninterruptible Power Supply (UPS). It fully complies with all the requirements of MIL-STD-1399 (Section 300) and is specifically designed to meet the harsh military shipboard environment. The high reliability and ruggedness of the M359 make it an excellent choice not only for military shipboard applications, but for critical shore-based applications as well. 1.2.
batteries. Please check your local regulations before disposal. The Battery Charger is a voltage-regulated and current-limited DC to DC converter. It is powered from the 270VDC output of the AC-to-DC LID Converter and provides temperature-compensated float charge to the Battery Pack. This charging method preserves the batteries and provides the longest batteries-life possible. The DC-to-AC Inverter generates clean sine-shape 115VAC voltage from the 270VDC output of the AC-to-DC LID Converter.
AC INPUT 115 VAC RFI FILTER & VARISTOR ISOLATION TRANSFORMER RFI FILTER & VARISTOR Power Conditioner 2 Pole Input Relay 24VDC to Relays Control 2 Pole By-pass Relay AC-DC CONVERTER 270 VDC DC-AC INVERTER 2 Pole Output Relay 24VDC Back-up AC OUTPUT 115VAC RELAYS’ CONTROL BATTERY CHARGER REMOTE CNTL SWITCHES From Front-panel Switches 132 VDC RS-232 BATTERY PACK CONTROL & MONITOR DRY CONTACTS ETHERNET SNMP (Optional) Figure 1: M359 Block Diagram MPS Doc: M359_USER_MANUAL REV J Oct 23, 2014
2. Electrical Installation Instructions Before installing the unit, please read carefully the Safety Instructions at the beginning of this manual. Make sure that all the switches on the M359 front panel are in the OFF position. Verify that the Plug-in Battery Pack is properly installed and secured (see Paragraph 6.3). Verify that the electrical outlet that is powering the UPS is 115Vac/60Hz, protected by a double-pole circuit breaker (or fuses) rated to between 32 to 46Amp.
Phase 1 Input PWR 115VAC Input PWR from Ship, via a double-pole protected outlet. Phase 2 Input PWR C B J1 UPS Input Connector MS3102A-20-19P Chassis Ground A 115VAC Out (Hot) 115VAC Clean PWR to Equipment 115VAC Out (Neutral) Chassis Ground C B J2 UPS Output Connector MS3102A-20-19S A Grounding Bolt Chassis GND on Rear Panel Safety Ground Notes: 1) Use AWG #10 (or #8) Wires. 2) Pin B of J2 (Output Neutral) is grounded inside the UPS by a removable jumper.
3. Front Panel Description 3.1. Front Panel: Main Components (Figure 3) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Visual Indicators and Controls (for detailed view see Figure 4) Power On/Off Switch. Air filter captive screw. Removable air filter (Air Inlet). Serial Number and Date Code of Battery Pack. Plug-in, hot-swap Battery Pack. Input UPS/By-Pass Select switch. Output UPS/By-Pass Select switch. Air filter captive screw. Air filter captive screw. Battery Pack handle.
3.2. Front Panel: Indicators and Controls (Figure 4) 13. LOAD LEVEL Bar Graph (marked in %, 100% = 2,000W). 14. LOW BATT Warning LED (blinking yellow). 15. ALARM OFF Push-button. Note: In M359-1 of REV-C (or higher) this button is used also to manually set the Batt Charge Level to 100%. 16. ON BATT Warning LED (blinking yellow). 17. INPUT FAIL LED (red). 18. OUTPUT STDBY LED (yellow). 19. OUTPUT FAIL LED (red). 20. INPUT OK LED (green). 21. OUTPUT OK LED (green). 22. O. LOAD Shutdown LED (red). 23. O.
4. Rear Panel Description (Figure 5) 30. 31. 32. 33. 34. 35. 36. 37. 38. Left side Bushing (mating pins are supplied with the unit). Cooling fan (air outlet). Dry Contacts Connector J3 (see Paragraph 7.2 for pin-out description). Remote ON/OFF connector J4 (see Paragraph 7.4 for pin-out description). RS-232 Connector J5 (see Paragraph 7.3 for pin-out description). Right side Bushing (mating pins are supplied with the unit). Right-side GND Connection (threaded hole, .190, UNF-32, 1.
5. Operating the M359 5.1. General The UPS will not turn-on with Battery power alone. Therefore, to enable a UPS turn-on, AC Input must be presented at the UPS Input connector J1 and the Input UPS/By-Pass switch must be in the UPS position. If the Remote Switches function is not used, please verify that a mating connector is plugged into J4 (on the rear panel of the Unit) and that it has two jumpers: one between Pin 8 to Pin 4 and the other between Pin 5 to Pin 6.
5.2.2. Off State. When the M359 is OFF, the Input, the By-pass and the Output relays (see Figure 1) are not energized and are in the position shown on Figure 1. In this mode all of the UPS circuits are off and no power is presented on the AC Output connector J2. Please note that since the Input relay is located on the secondary side of the Isolation Transformer (see Figure 1), the Power Conditioner’s Input is always connected to the AC input on J1.
battery (thus simulating an AC input failure). In this mode, the INPUT FAIL red LED (17) should be on, the ON BATT yellow LED (16) should blink, the OUTPUT OK green LED (21) should remain on, and the Bar-graphs should indicate the Load and Battery charge level. 5.3. Local Control (Using the Front Panel switches). If the M359 is controlled from its front panel switches, the remote ON/OFF switch should be in the On position and the remote UPS/BY-PASS selector in the UPS position.
5.4. Remote Control (Using the Remote Switches). In order to control the M359 by the remote switches (via the connector J4 on the rear panel), the three front panel switches (2, 7 and 8) should be in the upper position. The recommended connection of the remote switches is described in Para. 7.4 and Figure 10. 5.4.1. Remote PWR ON/OFF Switch. When in the Off position (down) this switch turns off the M359 (regardless of anything else).
(external or internal to the M359) the OUTPUT FAIL red LED will be on. When in the By-Pass mode, all LED’s are off. 5.5.3. ON BATT Warning LED (16) When the M359 is operating in the UPS Mode and the AC Input fails, the UPS will use the Battery power as its primary source. In this state, the ON BATT Warning yellow LED (16) will start blinking, warning the user that the UPS is working on Battery power. 5.5.4.
5.5.11. BATT CHARGE [%] Bar-Graph (29). The Battery Charge Bar Graph indicates the charge level of the battery. 100% signifies that the battery is fully charged and will support 5 minutes at 2KW, 50% signifies 2.5 minutes at 2KW. Lower loads will result in longer hold-up time. When the Battery Charger is charging the Battery, the uppermost active segment of the Battery Charge Bar Graph will blink. 5.6.
5.7. UPS Response to Overload Condition The M359 has two distinct overload protection functions. The first is the linear (continuous) current limiting of the output current and other is an overload protection that shuts down the UPS Output if the output power (in watts) is exceeded. In case of a shutdown due to an overload, the green OUTPUT OK LED (21) will turn off and the red OUTPUT FAIL LED (19) and the red O. LOAD SHUTDOWN LED will both be On. 5.7.1.
Output Voltage (100V/Div) Output Current (25Amp/Div) ~700mS Figure 6: Output Short Circuit Shutdown +45mp -45Amp Figure 7: Output Short Circuit Current Waveform MPS Doc: M359_USER_MANUAL REV J Oct 23, 2014 Page 19 of 30
Output Voltage (100V/Div) Output Current (50Amp/Div) 3 Seconds Figure 8: Overload (3KW) Shutdown 5.8. UPS Response to Overtemperature Condition When the internal hot-spot temperature of the UPS exceeds a preset level (+940C), the yellow O. TEMP Warning LED (23) will start blinking and an audible alarm will sound at one second intervals, 50% duty cycle. Three minutes after the O. TEMP Warning LED starts blinking (and if the temperature does not drop), the UPS will shut itself off.
6. Maintaining the M359 6.1. Battery Test To test the Battery, press momentarily on the BATT TEST Push-button (26). Battery Test may be invoked only when all the following conditions are true: the UPS is running on AC input power, the Battery Charge level is above 85% and the load level is above 35%. If Battery Test is denied due to low charge level ( when the BATT TEST Pushbutton is pressed) the BATT CHARGE Level Bar Graph will blink once.
6.2.3. Charge-discharge Cycles The number of times and the depth of battery discharges (during AC Input failure) affects the service life of the battery. If the battery is allowed to discharge only to 50% of its charge, the number of charge-discharge cycles (before it fails) will be three times the number of cycles had it been allowed to reach 30% charge. Limiting the operating time on battery power, to the minimum required by the system to perform an orderly shutdown, will prolong Battery life. 6.3.
6.4. Air Filter Maintenance The Air Filter (4) should be monitored periodically for cleanness. Dust and dirt accumulation can interfere with the cooling air-flow and may result in over temperature condition. To clean the filter: 1) Open the three captive screws (3, 9 and 10) holding the Air Filter. 2) Remove the Air Filter Assembly (as is, no need for further disassembly). 3) Wash the assembly with warm water and detergent. 4) Using dry air, remove water residue and dry the filter.
Connector J3 Pin Assignment PIN 1 2 3 4 5 6 7 8 9 I/O O O I O O O O DESCRIPTION Fault Detect Signal Low Fault Detect Signal High Remote Shutdown Not Battery Operation System Common Ground N.C. Battery Voltage Low UPS On Input Power Loss, Battery operation NOTES (1) (1) (2) (3) (4) (5) (3) Notes: 1. Pin 1 will be shorted to pin 2 when any one of the following conditions occurs: an Over Temperature Condition, a Battery Failure, a Charger Failure, an Internal UPS Controller Failure. 2.
7.3. RS-232 Serial Interface The RS-232 serial communication interface is available through connector J5 (34), a D-Type 9S connector, located on the back panel of the UPS. This port is a DTE. Note: When the Optional Ethernet SNMP Agent is installed, this connector serves as RS-232 Console Interface and has different pin assignments (see the SNMP User’s Manual). The RS-232 interface allows control and monitoring of the UPS by a host computer through the serial RS-232 communication link.
The remote switches should be rated to 28Vac, 0.25AMP. Note: To control the UPS by the remote switches, leave all the front panel switches in the upper position. Turn the UPS On/Off by connecting/disconnecting Pin 8 to the Common. Select the operation mode (UPS or By-Pass) by toggling the Common between Pin 6 and 7. (See Figure 9 below).
8. Specification INPUT Voltage Range 0 - 155VAC In Accordance with MIL-STD-1399 (Navy) Switchover Voltage <102VAC, below this voltage the M359 may switch to Battery power. (Note: MIL-STD-1399 worst-case min. steady state voltage is 107VAC.) Frequency 48-64 Hz Power Factor Spikes 200 joules clamping device I.A.W. MIL-STD-1399 (Navy) Isolation Input is galvanically isolated from output and chassis (> 1 M at 600VDC). Total capacitance between input and chassis is less than 0.02uf per line.
ENVIRONMENT INDICATIONS & CONTROS Temperature Non operating: -40 to +72C (Note 3) Operating: 0 to + 52C (Note 2) Humidity Up to 95%, non-condensing. Altitude Operating: Up to 10,000 feet. Non-operating: (Air transport) 40,000 feet. Orientation May be installed at any orientation. Mechanical Shock When packed, withstands the free fall drop and edgewise drop IAW Methods 5007.1 and 5008.1 of Federal Test Method standard 101C.
INTERFACE Discrete interface Four dry contacts indicating the following conditions: "UPS ON" (Output OK) "Battery Voltage Low" "Input Power Loss" (Battery Operation) "Fault Detect" A "Shutdown" input (via opto-isolator) for remote shutdown of the UPS during AC input fail. When the AC input recovers the UPS will automatically turn ON. Serial Interface RS-232 Serial port (EIA-RS-232).
9. How to Order Order P/N: M359-1 -0 -0 -0 -0 Optional Special Hardware Basic Part Number Special Options -0 None (STD.) -1 Input Current Limited to 20Amp (MPS Doc: M359-1-1-X_SP) -2 Includes -1 above (20Amp Input Limit) and CRES top and bottom covers (instead of Al covers) -0 (STD.) None -1 With Mating Power Connectors set: MS3108R20-19S (Qty 1, 90 , AC Input Conn.) MS3108R20-19P (Qty 1, 90, AC Output Conn.) M85049/41-12A (Qty 2, Conn.
