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American Power Conversion DC Series manual

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Table of contents for the manual

  • Page 1

    User Manual 990-9178A DC MX06 40A She lf P age 1 of 44 18 th FEB 02 User Manual For DC Series MX06 40A Shelf[...]

  • Page 2

    User Manual 990-9178A DC MX06 40A She lf P age 2 of 44 18 th FEB 02 DC MX06 40A Shelf The MX06 40A Shelf is a 19” compatible modular power plant capable of supplying up to 42A at –48V DC (54V). The unit contains a controller that can config ure up to 4 x 10.5A rectif iers. Power distribution, Integ ral LVD contact and alarm signals are all incl[...]

  • Page 3

    User Manual 990-9178A DC MX06 40A She lf P age 3 of 44 18 th FEB 02 Contents SECTION DESCRIPTION PA GE 1 Genera l Informatio n 5 1.1 Introduct ion 5 1.2 Safet y Precautions 5,6 1.3 Types Of Hazard 6 1.4 Inspection Of Goods 7 1.5 APC W or ldwide customer support 8 1.6 W ar ranty Inf ormation 9 2 Product Overview + Technical Description 10 2.1 Specif[...]

  • Page 4

    User Manual 990-9178A DC MX06 40A She lf P age 4 of 44 18 th FEB 02 4 Install ation Procedure 24 4.1 AC Primary Supply 24 4.1.1 Single Phase 24,25 4.1.3 Single Phase AB Feed 26,27 4.1.4 3 Phase Star Supply 28,29 4.1.5 3 Phase Delta Supply 30,31 4.2 DC Distribution 32 4.2.1 10 GMT Fuses Rear Access 32 4.2.2 10 GMT Fuses F ront Access 33 4.2.3 4 Circ[...]

  • Page 5

    User Manual 990-9178A DC MX06 40A She lf P age 5 of 44 18 th FEB 02 1 General Information 1.1 Introduction DC Power Plants fr om APC have unique features that mak e them easy to install, maintain, and upgrade. The rec tifier units are m odular and truly “hot-pluggable” into the shelf assem bly without any separate ac wiring. All system settings[...]

  • Page 6

    User Manual 990-9178A DC MX06 40A She lf P age 6 of 44 18 th FEB 02 • CEC Code C22. 1-98 ( Canada ) • CONT ROL OF SUBSTANCES HAZARDOUS T O HEALTH (COSHH) REGS • MANUAL HANDLING REG ULATIO NS, 1993 (See Section 6) 1.2.3 BECOME FAMILIAR W I TH THE HAZARDS ASSO CIATED W I TH THE PO W ER SYSTEM AS DETAILED I N PARA 2. 1.2.4 C AUTION - B EFOR E IN[...]

  • Page 7

    User Manual 990-9178A DC MX06 40A She lf P age 7 of 44 18 th FEB 02 1.4 Inspecti on upon Receipt of Goods 1.4.1 General APC has taken precautions in pack ing the power equipment f or shipm ent to ensure its s afe arr ival; however, the entire shipm ent including any boxes or crates should be inspected upon receipt for evidence of dam age that m ay [...]

  • Page 8

    User Manual 990-9178A DC MX06 40A She lf P age 8 of 44 18 th FEB 02 1.5 A PC Worldw ide Customer Suppor t Custom er support f or this or any other Am erican Power Conversion ( APC) product is available at no charge in any of the following way s: l Visit the APC web site to find answers to f requently asked questions (FAQs) , to acces s documents in[...]

  • Page 9

    User Manual 990-9178A DC MX06 40A She lf P age 9 of 44 18 th FEB 02 1.6 Wa r ranty I nformation 1.6.1 Limited Warranty Amer ican Power Conversion (APC) warrants the DC MX06 40A Shelf to be free f rom defects in materials and workm anship f or a period of two y ears from the date of pur chase. It’s obligation under this warranty is limited to r ep[...]

  • Page 10

    User Manual 990-9178A DC MX06 40A She lf Page 10 of 44 18 th FEB 02 2 Product Overv iew and Technical Description 2.1 Specification 2.1.1 Rectifi er Parameter (per rectifi er) 1TWF0500H54** Approved Input Rating 115V or 230Vac I/p Operating Range 103.5V to 264V RMS Input Current “ “ “ 6.5A max @115V 3.6A max @230V Approved Input Frequenc y ra[...]

  • Page 11

    User Manual 990-9178A DC MX06 40A She lf Page 11 of 44 18 th FEB 02 2.1.3 System Output Output V oltage Nomina l 54.5Vdc V oltage Adjustment Range 44 V – 57 V (Below 42V LVD contact opens) Current Rat ing 42 A @ 230Vac, 36 A @ 115Vac, 28A @ 100Vac Temperature Coefficien t -76mV/°C ±10% (over r ange 0°C - 50°C) Current Limi t 100% - 110% of Ra[...]

  • Page 12

    User Manual 990-9178A DC MX06 40A She lf Page 12 of 44 18 th FEB 02 2.3 C ontro ller 2.3.1 A larm Card Layout Part Reference Function A djustment P1 Output Volt s Adjust Via Front Panel P2 LVD Disconnect Volts Adjust Factory Pre-set P3 Meter Current Calibr ation Factory Pre-set P4 Meter Reading Zero Adj ust Factory Pre-set P5 Meter Volts Calibratio[...]

  • Page 13

    User Manual 990-9178A DC MX06 40A She lf Page 13 of 44 18 th FEB 02 2.4 A larms 2.4.1 A vailabl e Alarms To monitor the system status a selection of alarm outputs are available. Dependant upon the rect ifiers fitted either 4 f ront panel LED’s or a s ingle LED give visual notification of a sy s tem f ault. There is also a range of open collector [...]

  • Page 14

    User Manual 990-9178A DC MX06 40A She lf Page 14 of 44 18 th FEB 02 2.4.2 Rear A ccess A larms To access the alar m outputs f irst ens ure batteries are disc onnected fr om the s y stem by setting battery connection switch to “OFF” via controller front panel (s ee section 2.3) and by turning the external battery break er of f. T he input mains [...]

  • Page 15

    User Manual 990-9178A DC MX06 40A She lf Page 15 of 44 18 th FEB 02 2.4.4 Major and Minor A larms In an MX06 40A Shelf , 9 of the available alarm s c an be set to show as a “Minor ” or “Maj or” alarm . As standard the alarm outputs ar e open collector tr ansistor outputs available from the connector s as detailed in the 2 previous sections.[...]

  • Page 16

    User Manual 990-9178A DC MX06 40A She lf Page 16 of 44 18 th FEB 02 2.5 Customer Inputs 2.5.1 Current Limit Programming Input Description Controller Ty pe Connector Current Limit Progra m Connect a DC voltage to this pin (r eferenced to signal com m on or –Ve output) to reduce the system output current lim it point. Current limit is progr amm ed [...]

  • Page 17

    User Manual 990-9178A DC MX06 40A She lf Page 17 of 44 18 th FEB 02 2.5.3 Battery T est Function Input Descript ion Location Battery Test Front panel m omentar y push button. Push and hold drops output volts to 45Vdc. T his is below battery float voltage and is used to chec k the batteries can supply the sy stem load. Push button m ounted on contro[...]

  • Page 18

    User Manual 990-9178A DC MX06 40A She lf Page 18 of 44 18 th FEB 02 2.5.5 Temperature Compensati on Input Descript ion Socket Pin Temp Compen sation T his func tion allows a temperatur e probe to be used to automatic ally adjust the output voltage of the sy stem . This ensures the c harging voltage stays within the battery manuf acturer s rec omm e[...]

  • Page 19

    User Manual 990-9178A DC MX06 40A She lf Page 19 of 44 18 th FEB 02 2.6 Mechanical 2.6.1 Dimensions Dimens ion A B C D E F Length 482.6mm (19in) 132.5mm (5.22in, 3U) 283.6mm (11.17in) 82.5mm (3.25in) 138.5mm (5.45in) 438.2mm (17.25in) 2.6.2 Weight Item M easured Sh elf + Dist + Contro ller Single Rectifier Full System W eight (Kg) 7.65 1.75 14.70 W[...]

  • Page 20

    User Manual 990-9178A DC MX06 40A She lf Page 20 of 44 18 th FEB 02 2.6.3 Mounting Opt ions The MX 06 40A Shelf has 3 positions for m ounting ears . If m ounting ears were ordered with the system they will be fitted in the front pos ition as standar d. The 2 alternative mounting positions are shown below. The end us er can sim ply unscrew the ears [...]

  • Page 21

    User Manual 990-9178A DC MX06 40A She lf Page 21 of 44 18 th FEB 02 2.7 Schematic 2.7.1 Positive Earth Configured[...]

  • Page 22

    User Manual 990-9178A DC MX06 40A She lf Page 22 of 44 18 th FEB 02 2.7.2 Negative Earth Configured[...]

  • Page 23

    User Manual 990-9178A DC MX06 40A She lf Page 23 of 44 18 th FEB 02 3 Sy stem Configura tion The MX06 40A shelf is des igned to m eet a wide range of cust omer r equirem ents/applications. A num ber of versions and options are available including various dis tribution ty pes, alternative input s upply configur ations, 19 and 23 inch m ounting versi[...]

  • Page 24

    User Manual 990-9178A DC MX06 40A She lf Page 24 of 44 18 th FEB 02 4 Installation Proced ure 4.1 A C Primary Supply 4.1.1 Single Phase The MX 06 40A Shelf can be used on a Single Phas e AC supply. The system can be connec ted to a 230V or 115V supply. Maxim um input c urrent is 26A at 115Vac and 15A at 230Vac. Choose AC Input cabling rated accordi[...]

  • Page 25

    User Manual 990-9178A DC MX06 40A She lf Page 25 of 44 18 th FEB 02 4.1.1.2 Front A ccess Connection To c onnect the input supply to the MX06 40A Shelf proceed as follows: • The s ame protec tion devices and cable par ameter s are required f or front acces s connection as explained f or “single- phase rear acc ess” pr eviously. • Ensure tha[...]

  • Page 26

    User Manual 990-9178A DC MX06 40A She lf Page 26 of 44 18 th FEB 02 4.1.2 Single Phase, AB Feed The MX06 40A Shelf c an be us ed on a Single Phas e AB Feed system. T his m eans that 2 separate supply ’s c an be us ed, each powering 2 of the 4 rec tifiers f itted. The s y stem can be connected to a 230V or 115V s upply . The max imum input current[...]

  • Page 27

    User Manual 990-9178A DC MX06 40A She lf Page 27 of 44 18 th FEB 02 4.1.2.2 Front A ccess Connection To c onnect the input supply to the MX06 40A Shelf proceed as follows: • Ensure that the AC supply intended for connec tion is isolated, loc ked off and under single operator contr ol. • The m ain circ uit board should have been conf igured for [...]

  • Page 28

    User Manual 990-9178A DC MX06 40A She lf Page 28 of 44 18 th FEB 02 4.1.3 3 Phase Star Supply The MX 06 40A Shelf can be used on any of the following supplies: 415V, 400V, 380V or 208V phase to phase. The max imum input current is 13A per phas e on a 208Vac phase to phase s upply and 7.2A per phase on a 380Vac, 400Vac or 415Vac supply. Choose AC In[...]

  • Page 29

    User Manual 990-9178A DC MX06 40A She lf Page 29 of 44 18 th FEB 02 4.1.3.2 Front access connection To c onnect the input supply to the MX06 40A Shelf proceed as follows: • The AC input c urrent to the system s hould also be lim ited by an appropriate device in the event of a shor t circuit as def ined in EN60950 to protec t the internal wiring o[...]

  • Page 30

    User Manual 990-9178A DC MX06 40A She lf Page 30 of 44 18 th FEB 02 4.1.4 3 Phase Delta Supply Warning! The MX06 40A Shelf can only be used on a 208Vac phase to phase supply. In a delta connection system each r ectifier input is connected direc tly acros s two phases. Due to the m axim um voltage r ating of the rectif iers being 264Vac this is the [...]

  • Page 31

    User Manual 990-9178A DC MX06 40A She lf Page 31 of 44 18 th FEB 02 4.1.4.2 Front access connection To c onnect the input supply to the MX06 40A Shelf proceed as follows: • The AC input c urrent to the system s hould also be lim ited by an appropriate device in the event of a shor t circuit as def ined in EN60950 to protec t the internal wiring o[...]

  • Page 32

    User Manual 990-9178A DC MX06 40A She lf Page 32 of 44 18 th FEB 02 4.2 DC Distri bution The MX06 40A Shelf has a DC distribution m odule fitted. T his m odule contains the c hosen distribution com ponents of either circuit breaker s or f uses. It als o contains an LVD contac t (controlled by the controller) and a current s hunt meas uring load cur[...]

  • Page 33

    User Manual 990-9178A DC MX06 40A She lf Page 33 of 44 18 th FEB 02 4.2.2 10 GMT Fuses Front A ccess To c onnect the cables to the system proceed as f ollows: • Cables should be rated to at least the sam e cur rent rating as the c orresponding output fuse and be colour coded as to meet all the loc al installation regulations • Remove the distri[...]

  • Page 34

    User Manual 990-9178A DC MX06 40A She lf Page 34 of 44 18 th FEB 02 4.2.3 4 Circuit Breakers Rear Access • Remove the rear c over to give acces s to the output term inals (s hown below ). • To connec t to the output term inals use M4 ring cr imps with cables rated to at least the sam e current rating as the c orresponding output break er and co[...]

  • Page 35

    User Manual 990-9178A DC MX06 40A She lf Page 35 of 44 18 th FEB 02 4.2.4 4 Circuit Breakers Front Access T o connect the cables to the sy stem proceed as follows: • To connec t to the output term inals use M4 ring cr imps with cables rated to at least the sam e current rating as the c orresponding output break er and colour coded as to m eet all[...]

  • Page 36

    User Manual 990-9178A DC MX06 40A She lf Page 36 of 44 18 th FEB 02 4.2.5 4 Cartridge Fuses Rear A ccess To c onnect the cables to the system follow the sam e procedure as for the “4 Cir cuit Break er Rear Acc ess” distribution m odule (sec tion 4.2.3). 4.2.6 4 Cartridge Fuses Front A ccess The ratings are the sam e as f or the rear acc ess ver[...]

  • Page 37

    User Manual 990-9178A DC MX06 40A She lf Page 37 of 44 18 th FEB 02 4.3 Routing Of Cabl es 4.3.1 Input cables One or m ore of the top 3 knock outs (top lef t hand side k nock out and 2 actually in the rear cover) m ust be used f or entr y of the input AC cable. This is essential if the input cabling used is not double ins ulated and recom m ended a[...]

  • Page 38

    User Manual 990-9178A DC MX06 40A She lf Page 38 of 44 18 th FEB 02 4.3.2 Output Cables The output c ables m ay be of quite large diam eter and theref ore it m ay be necessar y to use m ore than one knoc kout hole. T he right hand side k nockouts should be used to keep the output cables phy s ically as far from the input cables as possible to optim[...]

  • Page 39

    User Manual 990-9178A DC MX06 40A She lf Page 39 of 44 18 th FEB 02 4.4 External Battery Installation 4.4.1 Battery Back-up function Battery backup may be ac hieved by connecting 48V str ings of batteries onto the external battery terminals of the distribution module at the r ear of the system. T his battery string will be connected to the system b[...]

  • Page 40

    User Manual 990-9178A DC MX06 40A She lf Page 40 of 44 18 th FEB 02 4.4.4 Battery Connection Diagram 4.5 Sy stem Output Earthing The MX06 40A Shelf has its output earthed as default. T he output is earthed by the earth cable joining the earth stud to the output earthing bus -bar (as s hown in the above picture). The earth link can be rem oved to le[...]

  • Page 41

    User Manual 990-9178A DC MX06 40A She lf Page 41 of 44 18 th FEB 02 5 Co mmissioning the System 5.1 General All site preparation and equipm ent installation in the previous chapters m ust be com pleted before com m issioning. • Ensure that the AC power source is olator is switched O FF. • Switch all MX06 40A Shelf and any external battery circu[...]

  • Page 42

    User Manual 990-9178A DC MX06 40A She lf Page 42 of 44 18 th FEB 02 6 Manual Handling Proce dure 6.1 General 6.1.1 Items within the s ub-system present a hazard due to m ass. A fully configured s y stem fitted with 4 rectif iers weighs alm ost 15Kg. 6.1.2 The Manual Handling of Loads Regulations, 1993 requir e that all persons work ing on the equip[...]

  • Page 43

    User Manual 990-9178A DC MX06 40A She lf Page 43 of 44 18 th FEB 02 7 Fault Finding / Symptoms The sub-system is designed f or m axim um reliability and therefore faults during norm al operation are unlikely. If faulty operation does occ ur the sourc e of the failur e can usually be readily determ ined by inspection of the LED meter and the LED’s[...]

  • Page 44

    User Manual 990-9178A DC MX06 40A She lf Page 44 of 44 18 th FEB 02 8 Service, A ccessories & Spares 8.1 Rectifier replacement If a f aulty rectif ier is to be replac ed simply unscrew the two front panel fix ings on the rectif ier front panel and withdraw the rectifier f rom the shelf . A replacem ent rectif ier can then be ins erted directly [...]