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American Power Conversion XS 450 -48 manual

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Table of contents for the manual

  • Page 1

    Magnum XS 450 -48 Vdc Power System User’s Manual[...]

  • Page 2

    Magnum XS 450 Power System –48 VDC User’s Manual Page ii Table of Contents 1 SAFETY FIRST! ................. ............... .................... ................ ................... ................ .......... 1 1.1. W ARNING S YMBOLS ............................ .................... ................ ................... .................. 1 1.[...]

  • Page 3

    Magnum XS 450 Power System –48 VDC User’s Manual Page iii Relay Output Connections ............................. ................ ................ ................... ................ 27 External Alar m Input Connections ..................... ................ ................... ................ ............ 28 4 COMMISSIONING .................[...]

  • Page 4

    Magnum XS 450 Power System –48 VDC User’s Manual Page iv System Temperature Test ......................... ................ .................... ............... ................ .... 38 Battery Current Test ....... ................... ................ ................ ................... ................ ............ 38 Battery Temperature Test[...]

  • Page 5

    Magnum XS 450 Power System –48 VDC User’s Manual Page v Revision History Revisi on Da te By Descri pti on 990-1557 Revision 1 20 Oct, 2003 JPF Initial Re lease 990-1557 A Revision 2 30 MAR 2004 BET Update to inclu de Battery Cabinet Table of Figures FIGURE 2.1-1 MAGNUM XS 450 POWER PLANT .........................................................[...]

  • Page 6

    Magnum XS 450 Power System –48 VDC User’s Manual Page 1 1 Safety First! It is very import ant to follow all safety p rocedures when unpacking, installing and operating any sort of power equipment. 1.1. Warnin g Symbols CAUTI ON : An indicatio n that special care is required to prevent injury, equipment damage or misuse WARNING : An indication o[...]

  • Page 7

    Magnum XS 450 Power System –48 VDC User’s Manual Page 2 2 Introduction 2.1. General Informatio n DC Power Plants fr om APC have unique features tha t make them easy to install, maintain , and upgrade. The rectifier units are mo dular and truly “hot-pluggabl e” into the shelf assembly witho ut any separate ac wiring. The she lf assemblies ar[...]

  • Page 8

    Magnum XS 450 Power System –48 VDC User’s Manual Page 3 Figure 2.1-2 Power System Block Diagram[...]

  • Page 9

    Magnum XS 450 Power System –48 VDC User’s Manual Page 4 How to Use This Manual Each section of this manu al can be re ad in any order and should provide a compl ete explanation of the subject described by the title. However, the sequence of the sections is designed to provide a typical step-by-step p rocess for successful use of the equipment. [...]

  • Page 10

    Magnum XS 450 Power System –48 VDC User’s Manual Page 5 3 Installation 3.1. Unpacking Equipment Remove equipment from packing material and inspect for shipp ing damage or miss ing items. It is important to report damage or m aterial shortages to the shippin g carrier while a rep resen tative is o n site . If concealed damage or material shortag[...]

  • Page 11

    Magnum XS 450 Power System –48 VDC User’s Manual Page 6 Figure 3.2-1 Door Clearance Dimensions[...]

  • Page 12

    Magnum XS 450 Power System –48 VDC User’s Manual Page 7 Mounting The unit is self-s upporting, but designed to be bolted to the floor of the housing structure. Figure 3.2-2 shows the f ootprint of the box frame and the mounting p oints with dimensions. Systems with multiple box frames are bolted toge ther with each frame touching, side by side.[...]

  • Page 13

    Magnum XS 450 Power System –48 VDC User’s Manual Page 8 3.3. AC Power Connections WARNING : Ensure that all of the external dc and ac circuit break ers are in the OFF position prior to connectin g service to the power plant. Confirm that all voltages have been removed includin g any battery sources before proceeding . The Magnum XS 450 Power Sy[...]

  • Page 14

    Magnum XS 450 Power System –48 VDC User’s Manual Page 9 powered from the terminal bl ock labeled L2. The rig ht rectifier in each shelf is powered from the ter min al bl ock la bele d L3. AC Line 1 AC Line 2 AC Line 3 AC Neutral Earth Ground DC AC DC AC DC AC DC AC DC AC DC AC DC AC DC AC DC AC L1 L2 L3 Neut. E Figure 3.3-1 AC Kit with Three Ph[...]

  • Page 15

    Magnum XS 450 Power System –48 VDC User’s Manual Page 10 Neutral Input Wire Size (AWG) Wire Size (mm 2 ) Max Torque (in-lb) Max Torque (N-m) 350 kcmil – 2 Cu 185 – 35 Cu 275 31.75 L1, L2, and L3 Input Wire Size (AWG) Wire Size (mm 2 ) Max Torque (in-lb) Max Torque (N-m) 2/0 – 6 Cu 70-16 Cu 125 13.5 Earth Grou nd Input Wire Size (AWG) Wire[...]

  • Page 16

    Magnum XS 450 Power System –48 VDC User’s Manual Page 11 AC Line 1 AC Neutral 1 AC Line 2 AC Neutral 2 AC Line 3 AC Neutral 3 AC Line 4 AC Neutral 4 AC Line 5 AC Neutral 5 AC Line 6 AC Neutral 6 AC Line 7 AC Neutral 7 AC Line 8 AC Neutral 8 AC Line 9 AC Neutral 9 DC AC DC AC DC AC DC AC DC AC DC AC DC AC DC AC DC AC Earth Ground L N L N L N L N[...]

  • Page 17

    Magnum XS 450 Power System –48 VDC User’s Manual Page 12 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 b ack of each rect ifier slot. All switches ON will give an address of zero (rectifier 1). Set switches per the following tabl[...]

  • Page 18

    Magnum XS 450 Power System –48 VDC User’s Manual Page 13 Rectifier Module Installation WARNING : Rectifier dc output circuits would be damaged if battery were installed incorrectly. Before rectifier install ation, ensure proper battery polarity. Rectifier modules are hot-swappable. The rectifier modules are generally shipped in separate contain[...]

  • Page 19

    Magnum XS 450 Power System –48 VDC User’s Manual Page 14 Merlin Gerin 28 Circuit Breaker Module Installation WARNING : Hazardous energy levels are present on bare conduc tors in the -48Vdc distribution connection ar ea of the plant. Accidental shor ting of distribution conductors can caus e arcing and high currents that can cause serious burns [...]

  • Page 20

    Magnum XS 450 Power System –48 VDC User’s Manual Page 15 Merlin Gerin 12 Circuit Breaker Module Installation WARNING : Hazardous energy levels are present on bare conduc tors in the -48Vdc distribution connection ar ea of the plant. Accidental shor ting of distribution conductors can caus e arcing and high currents that can cause serious burns [...]

  • Page 21

    Magnum XS 450 Power System –48 VDC User’s Manual Page 16 Figure 3.5-2 12 Circuit Breake rs Module CIRCUIT BREAKER R ATING ORDERING NUMBER Merlin Gerin C60HC 4 A 0M-3318 Merlin Gerin C 60HC 10 A 0M-3314 Merlin Gerin C 60HC 20 A 0M-3315 Merlin Gerin C6 0HC 32A 0M-3316 Merlin Gerin C6 0HC 40A 0M-3317 Merlin Gerin C6 0HC 50A 0M-3319 Merlin Gerin C6[...]

  • Page 22

    Magnum XS 450 Power System –48 VDC User’s Manual Page 17 dc bus. Use M8 hardware to secure the buses together. Use M5 har dware to secure the front lip to the powe r system frame. Use M6 ha rdware to secure the rear of the module to the power system frame. Figure 3.5-3 NH2 Fuse Module Connect t he LVD pow er wiring to the po wer bus observ ing [...]

  • Page 23

    Magnum XS 450 Power System –48 VDC User’s Manual Page 18 Hooking the lo ad cables to a module us ed as a battery retu rn will cause erroneous batt ery curren t reading s. 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 c arry t[...]

  • Page 24

    Magnum XS 450 Power System –48 VDC User’s Manual Page 19 Installing circuit breakers in a 28 Circuit Breaker Mo dule on the DIN rail Figure 3.7-2 Merlin Gerin 28 CB Module Insta llation Detail Install the Merlin Gerin Circuit Breaker (CB) to the mounting DIN Rail on the 0M-2186 or 0M- 2579 circuit br eaker module wit h the DIN r ail lock positi[...]

  • Page 25

    Magnum XS 450 Power System –48 VDC User’s Manual Page 20 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 r[...]

  • Page 26

    Magnum XS 450 Power System –48 VDC User’s Manual Page 21 Figure 3.7-4 CB Alarm Interface Board (28 circuit breaker module) Figure 3.7-5 CB Alarm Expansion Board (12 circuit breaker module)[...]

  • Page 27

    Magnum XS 450 Power System –48 VDC User’s Manual Page 22 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. Figure 3.7-6 NH2 Fuse Connections DC Load Return Module Installation The modules that are attached to th e Return bus are designed to pr ovide a [...]

  • Page 28

    Magnum XS 450 Power System –48 VDC User’s Manual Page 23 Figure 3.7-7 Large Load a nd Small Load Return Module DC Lo ad Re turn cabl e con nec tio ns The battery return module has a shunt ins talled and t he load return modules do not. The small return has 40 pairs of M5 threade d holes on 1.59 cm (5/8 in.) centers. One set of M8 threaded holes[...]

  • Page 29

    Magnum XS 450 Power System –48 VDC User’s Manual Page 24 Connect t he LVD pow er wiring to the po wer bus observ ing proper polarity. Connect the LVD control cable to the customer interface bus. The alarm signal of each i ndividual Batt ery Disconnect Swit ch is connec ted to the blade terminals of the switch (C and N/C). The other end of the a[...]

  • Page 30

    Magnum XS 450 Power System –48 VDC User’s Manual Page 25 Battery Return Module Insta llation The battery return mo dule is typically installed in the top return modul e 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. Positi[...]

  • Page 31

    Magnum XS 450 Power System –48 VDC User’s Manual Page 26 positioning the probe o n the selected battery cell. Rem ove the adhesive prote ction strip from the probe body and press the adhesiv e side of the probe on the batt ery cell cover. Figure 3.8-3 Ty pical location of Battery Temperature Probe 3.9 DC System Grounding The Positive connection[...]

  • Page 32

    Magnum XS 450 Power System –48 VDC User’s Manual Page 27 is possible by DB-9 cable on t he Console Port of the module and v ia RJ-45 (Ethernet) cable on the 10/100 Base-T port on the Network Ma nagement Card. “Smart” Cable DB9 Connection The DB9 co nnector on the to p left hand si de of the u nit uses the special RS-23 2 cable (APC part num[...]

  • Page 33

    Magnum XS 450 Power System –48 VDC User’s Manual Page 28 External Alarm Input Connections Four external alarm inputs with assignable priority l evels are available. These a larm inputs respond to external dry contact closures between nor mally open (N/O) and common ( C) or contact openings between normally cl osed (N/C) and C. External Alarm So[...]

  • Page 34

    Magnum XS 450 Power System –48 VDC User’s Manual Page 29 4 Commissioning 4.1 Pre-Commissioning Inspection Environment 1. Ensure the dc system environment is suitable for operation. 2. Ensure that there is sufficient clearance around the system for service. 3. Ensure that there is no si gn of d amage to the d c system. 4. Disable installed alarm[...]

  • Page 35

    Magnum XS 450 Power System –48 VDC User’s Manual Page 30 10. Che ck th e tor que of all batt ery i nter - ce ll connector in accordance with the battery manufacturer’s specificati ons. 4.2 Commissioning Initial Set-up 1. Remove all rectifiers. 2. Disconnect battery by removing a link i n each string or opening th e battery disconnects. 3. Che[...]

  • Page 36

    Magnum XS 450 Power System –48 VDC User’s Manual Page 31 1. Monitor battery current an d verify that it is +/- 0.1 A. 2. Set battery maximum recharge setting by determi ning the entire battery string capacity and dividing by 10 hours. This setting will recharge the battery in 10 hours. 3. Enter this value in th e Max Batt Rech screen. 4. Monito[...]

  • Page 37

    Magnum XS 450 Power System –48 VDC User’s Manual Page 32 3. Verify that the system voltage is above the float voltage if the battery tempe rature is below 25 degrees C and below the float voltage if the battery temperature is above 25 degree s C. 4.3 Final Inspe ction: 1. Verify that the interio r and exterior of the system is clean and free fr[...]

  • Page 38

    Magnum XS 450 Power System –48 VDC User’s Manual Page 33 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 rectifi er modules. If installed with an interna l battery string, it will supply backup power as well. T he controller will monitor and co[...]

  • Page 39

    Magnum XS 450 Power System –48 VDC User’s Manual Page 34 5.3 DC Distr ibutio n DC Distribution Module The main function of the dc distribution module is to provide a means of connect ing and protecting cables that will be con nected to powe r dc loads. The dc distribution m odules also interface with the main controller to monitor the status of[...]

  • Page 40

    Magnum XS 450 Power System –48 VDC User’s Manual Page 35 5.5 C ustomer Interface Board Alarm Outputs (Output Relay s) There are eight a larm output relays desi gnated Relay 1 through Relay 6, Minor, and Maj or, respectively. These alarms reside on the controller and are connected to the external monitoring system via the customer i nterface boa[...]

  • Page 41

    Magnum XS 450 Power System –48 VDC User’s Manual Page 36 6 Preventive Maintenance Preventive Maintenance is typically perfor med on a quarterly basis. 6.1 Equipment 1. 4 Digit Voltmeter. 2. Clamp-on ampere meter. 3. Standard In sulated tools. 6.2 I nspecti on Environmental Ins pection 1. Ensure the dc system environment is suitable for operatio[...]

  • Page 42

    Magnum XS 450 Power System –48 VDC User’s Manual Page 37 2. Check the mechanical integr ity of the battery framing, racking, or cabinet. Tighten wher e nec essa ry. 3. If there is a battery disconnect device fitted, ens ure that it is properly connected and protected. 4. Check the general appeara nce and cleanliness of the battery. Clean if nec[...]

  • Page 43

    Magnum XS 450 Power System –48 VDC User’s Manual Page 38 5. After the fan has completely stopped spinnin g, insert a plastic pen or plastic screwdriver into t he fan blade of one of the rectifiers a nd reinsert both rectifier s 6. Verify that you get the fan f ail alarm on controller and the customer remote alarm panel. 7. Remove the fan fail d[...]

  • Page 44

    Magnum XS 450 Power System –48 VDC User’s Manual Page 39 Battery Preventive Mainten ance Procedure The purpose of the preventive ma intenance is to ensure that the battery is in good, worki ng condition. The observations, measureme nts, and tests performed are designed to determi ne the “state of health” of the battery. It will also allow f[...]

  • Page 45

    Magnum XS 450 Power System –48 VDC User’s Manual Page 40 7 Specifications The overall system specifications can vary, depe nding upon the number of rectifier modules. Note that some sp ecification it ems are provid ed on a “per r ectifier” basi s and must be combined or totaled for a give system configuration. 7.1 AC Input DCPM2 8HN54SH0 Re[...]

  • Page 46

    Magnum XS 450 Power System –48 VDC User’s Manual Page 41 7.4 Compliance Safety IEC 60950, 3 rd Edition CE Marked to Low Volt age Directive (EN60950, 3 rd Edition) EMC FCC Part 15 Class A EN55022 Class A , EN5502 4 EN61000 -3-2, EN610 00-3-3[...]

  • Page 47

    Magnum XS 450 Power System –48 VDC User’s Manual Page 42 8 APC W orldwide Customer Support Customer Support for this or any other APC product is available at no charg e. You can contact APC Customer Support in any of the followi ng ways: • Use an APC web page to fin d answers to freque ntly asked questions (FAQs), to access documents in the A[...]

  • Page 48

    Magnum XS 450 Power System –48 VDC User’s Manual Page 43 9 Limited Product W arranty The limit ed warra nty provi ded by Americ an Pow er Conversi on Corporat ion ("APC") in this St atement of Li mited Fact ory Warr ant y applies only to Pro ducts Bu yer purchase s for you r commerci al or indu strial use in the or dinar y course of B[...]